Reasons to Replace Your Existing Electromagnetic Chuck Controllers

With the market for new chuck controllers dwindling, many manufacturers are left without support on their electromagnetic chuck controllers. This is causing many manufacturers to be left with aged equipment, which can introduce unseen production issues, larger overhead when doing repairs, and the threat of purchasing new equipment that is not locally supported.

Arter CNC Model E with Magna-Lock USA chuck

Mattison Surface Grinder with Magna-Lock USA Chuck

Whether operating a new CNC machine or a manual machine, cycle times are everything.

The number one unseen issue when working with older equipment is the long-term drop in efficiency, and it is no different with chuck controllers. Demagnetizing a chuck isn't a simple on-off. The controller has to send a series of reversing pulses that step down to zero and pull the residual magnetism low enough for the part to let go, and that cycle is only as good as the electronics behind it. The capacitors, rectifiers, and switching parts inside an older controller wear out over years of heat and use, and as they weaken the demag cycle gets less effective. More residual magnetism is left behind, so parts hang on longer or the operator ends up running the cycle twice to hit Gauss specifications on their parts.

For example, an additional 45-second delay in demagnetization when milling, surface grinding, or planing adds up over the course of 8-hour shifts. On a single machine running one shift, multiplying your machine rate by those 45-second delays can cost roughly $8,000 per year. Across a floor of several machines, or a second shift, that quietly climbs into the tens of thousands of dollars per year or more, depending on other factors. This issue is also a gradual change over time to the point that it will seem normal to operators.

Want to plug in your own numbers to see your cost savings? Scroll down and use our calculator...

How to Test Your Controller

The key is consistency, because residual magnetism depends as much on the workpiece as it does on the controller.

1. Use the same part every time. Pick one representative workpiece and material. Hardened steel holds far more residual magnetism than mild steel, so swapping parts will throw off your numbers.

2. Run a normal cycle. Magnetize, hold, then run a full release/demag cycle exactly as your operators would.

3. Time the release. Note how long it takes from starting the demag cycle until the part lifts off cleanly by hand with no drag.

4. Check the residual with a Gauss meter. Right after the cycle, measure residual magnetism on the part and on the chuck face, and write the reading down.

5. Compare it to a baseline. Check against the controller's original spec, a new unit, or your own past readings. Longer release times, parts that drag or need a second cycle, and residual readings that keep creeping up are all signs the demag circuit is weakening.

6. Log it over time. The drift is gradual, so a single reading tells you little — a trend tells you everything. Re-run the test every few months and keep the numbers.

7. NOTE: we use 45 seconds of total demag time as a baseline of a new controller with slow demag cycling, results vary based on size of controller, chuck, etc.

If the release stays quick and the residual stays low, great - you have a well-functioning controller. But if release times are climbing or the residual won't come down, the demag circuit is likely degrading, and that is the hidden cost showing up in real numbers. That is the point to have the unit evaluated by your maintenance teams annually.

Recent OEM Closures

The recent closures of Magna-Flux International and Electro-Matic's chuck control division have also left thousands of manufacturers with obsolete units. True OEM support is no longer available for these units, and most maintenance teams are searching high and low to "make it work" with second-hand parts. The cost of the search, downtime waiting for parts, installation, and subsequent hope it works for a bit longer can add up behind the scenes. Replacing your obsolete chuck controller with a model that is new, and serviceable by an OEM, can provide thousands of dollars of cost savings, if not more.

Magna-Flux International Chuck Control

Electro-Matic Chuck Control

Electro-Matic Chuck Control

Magna-Flux International and Electro-Matic's discontinuation of support for their chuck controllers has left thousands of manufacturers without invaluable support for their operations.

North American Support

Local support doesn't always truly provide value until you need it. But when you do need it, it is a valuable thing to have. With such a global market in today's manufacturing world, many companies act as sales offices in North America, only selling product but not being able to support it after the sale. Many times, units have to be sent overseas to evaluate the product before even finding if the problem is fixable. Add in the time to get through customs twice, and this becomes a major issue for potential downtime that must be a consideration when choosing a new chuck controller.

Partnering with us at Magna-Lock USA, we provide the product, the price, the people, and the support of a true partner in production.

To wrap up, electromagnetic chuck controllers are becoming a high demand item with OEMs that have recently closed their doors. Older units prove to be more difficult to keep running at top performance and create more cost in attempting to service the unit. When considering how to replace the unit, an issue North American manufacturers face is having no localized support with a long-term partner.

If you find yourself in this situation, we encourage you to reach out to our team and plan out a good time to replace your outdated units. We provide flexible terms and are supported out of our Rockford, IL facility with people who know these controllers and how to service them.

NOTE: Numbers are only estimates and may vary based on real-life results. We use 45 seconds as a baseline for new controllers with the demag cycle set to slow. New controllers vary in demag cycle time based on individual circumstances. Numbers are only to be used a baseline and reference point.

Obsidian Manufacturing Industries, Inc. is a Rockford, IL, manufacturing company and is the OEM for Magna-Lock USA workholding, MagnaLift & Power-Grip lift magnets, and Arter Precision Grinding Machines, as well as providing surface grinding services. They are located at 5015 28th Ave. in Rockford, IL, with a phone number of 815-962-8700. Check out more at obsidianmfg.com/brands