EMAG NEWS 30 (EN)

NO30

SCHERER · KOEPFER · RICHARDON · ELDEC · LASER TEC · REINECKER · KARSTENS · KOPP · NAXOS-UNION · WEISS · SU · ECM

04

E lectric Motor

Complete-machining of stator housings for electric vehicles

Customers

02 06 Visit KORDEL Antriebstechnik GmbH & Interprecise Donath GmbH

WPG 7

12

22

EMAG SU

External cylindrical grinding Samputensili Machine Tools with EMAG Weiss joins the EMAG Group

EMAG VISITS:

KORDEL – HEADQUARTERED IN DÜLMEN NEAR MÜNSTER, GERMANY The creation of transmission solutions that can withstand demanding performance requirements – this is a perfect summary of the work that is done at Kordel, headquartered in Dülmen near Münster, Germany.

At Kordel, they develop and manufacture complete transmission systems that are used in industrial trucks, agricultural equipment, construction machinery, and more. To ensure that the solutions they produce can withstand rugged, and continuous use for a long period of time, while still efficiently transferring power, the Kordel team demands high-quality and precision from their production processes. For more than 20 years, those high quality solutions have included EMAG pick-up technology. Kordel has repeatedly invested in new machines from the south German machine manufacturer – most recently with the purchase of two VLC 200 GT turning and grinding centers.

The VLC 200 GT is used for the finish machining of a variety of bevel gears found in single-wheel transmission units.

“We have practically perfected the quality of a bevel gear using EMAG machines.”

Managing Director Johannes Kordel 2

KORDEL Long term partners (from left): Regional Sales Manager Florian Rose from EMAG, Kordel Managing Director Johannes Kordel, and Department Manager Stephan Lücke from Kordel.

The machine operator places parts in the drag rings located on the conveyor belt, and then removes parts when they are finished. Aside from that the machine operators autonomously.

FOCUSING ON MINIMAL TOLERANCES

T

he VLC 200 GT machines at Kordel are used exclusively to produce a variety of bevel gears, that when completed will become part of a single-wheel transmission unit for industrial trucks. These components are essential in the assembly of drive units that need to deliver an enormous amount of precision. The required tolerances in the finish machining cycle is minimal.

The basic principal is as simple as it is effective, and is based on complete machining the part in a single clamping operation.

After the hard turning process is performed, the residual oversize on a bevel gear is just a few hundredths of a millimeter.

The subsequent grinding of internal and external contours, using the two grinding spindles inside the VLC 200 GT, produce uniform surface quality, and ensures process stability. To hone in this process even further, the grinding wheel specifications can be customized to achieve your desired final quality - improving quality and decreasing costs. Costs will be minimized because the grinding wheel will wear more slowly due to the small amount of material being removed and will also need to be dressed less often. An integrated probe checks the diameter and length of the part after the process, and will correct them automatically if it is necessary.

Department Manager, Stephan Locke with one of the bevel gears he machined with the VLC 200 GT.

EMAG BLOG

A conversation with Kordel Managing Director, Johannes Kordel

A total of 17 EMAG machines in use This family-run company has an enormous manufacturing depth covering around 60,000 square meters of floor space! All the production stages for Kordel are performed under one roof, from blank to finished transmission, simplifying the quality assurance process. Since the beginning of the 2000’s, Kordel has invested significantly in the automation of its production technology. Today, it has more than 70 machines that load themselves, however, manual loading is also still used on occasion to allow small batch sizes to be produced more economically. On board from the very beginning – EMAG manufacturing solutions. In total, Kordel currently has 17 machines from the southern German machine manufacturer running on it floor – the oldest has been in use for more than 20 years! The most recent additions are two VLC 200 GT turning and grinding solutions.

So, why does Kordel continue to choose EMAG? “The value for the money that is delivered by a complete solution with integrated automation is the main reason for our decision,” says Managing Director, Johannes Kordel. “That impressed us 20 years ago, and is continuing to impress us today. We have also had a very good experience with these machines in terms of technology stability. There is absolutely no reason for us to move away from such an impress mechanical engineering partner.”

VLC 200 GT – Complete all the hard machining processes in a single clamping operation By combining the hard turning and grinding processes faster cycle times, higher machining quality and lower tool costs will be achieved.

VLC 200 GT Chuck diameter

mm

210

Swing diameter

mm

270

Max. workpiece diameter

mm

160

Workpiece length, max.

mm

100

T ravel distance X (total stroke from pick-up to turret)/Z

mm

1.700/250

inch inch inch

inch inch

Shuttle automation for supply and removal of parts Probe External grinding spindle Rotating dressing roll Working spindle Internal grinding spindle 12-tool turret for (hard) turning tools (optional turret with driven tools) NC controller

8

11 6

4

67/10

3

EMAG SCHERER:

STATOR HOUSING MANUFACTURING SOLUTIONS FROM THE GLOBAL MARKET LEADER! The specialists at EMAG Scherer have developed a highly efficient solution for machining stator housings.

I

n two consecutive operations on a DUO machine, the roughing and dressing of the external geometry (OP 10), as well as, the roughing and dressing of the internal surface and connection surface are performed – including several drilling and milling processes (OP 20).

Included with this solution is an NC-controlled circular axis, which is installed between the two machining areas. By using this to correctly position and turn the parts between OP 10 and OP 20, part cycle times are dropped to just 130 seconds. Both of these operations take place simultaneously on two components, minimizing undesirable downtimes.

SINGLE SPINDLE OR DOUBLE SPINDLE – THE VDZ 420 AND VDZ 420 DS VERTICAL TURNING MACHINES The VDZ 420 single-spindle and VDZ 420 DS double-spindle CNC vertical turning machines are the latest innovations in synchronous drive technology. With a rating of 64.4 kW and a nominal torque of 820 Nm, these systems are impressing users with its machining performance. The sturdy machine base is made out of welded steel and filled with concrete, providing excellent damping qualities, ensuring the systems maximize efficiency and run smoothly.

4

SCHERER

EMAG

BENEFITS AT A GLANCE » For workpieces up to 400 mm in height and 550 mm in diameter

» For workpieces up to 280 mm in length (driven/ non-driven)

» NC 12-station VDI 50 tool turret installed » Modular machine concept allows for flexible machining » A variety of automation options are available for both large and small production runs

» Optional Y-axis with a travel distance of +140/-140 mm

TECHNICAL DATA WORKPIECES The finished workpiece has a four mm thick wall with tolerances of between 0.016 - 0.25 mm, and highly accurate roundness.

This piece also includes a variety of boreholes, grooves and nonrotationally symmetrical geometry, that made it a challenge to manufacture in the past – but we successfully accomplish with this system.

VDZ 420 Chuck diameter

mm

550

Drive rating (100% duty cycle)

kW

64.4

Torque (100% duty cycle)

Nm

820

1/min

3,500

X axis

mm

1,310

Y axis

mm

±140

Z axis

mm

450

Tool system

VDI

50

Max. speed

inch hp

ft-lb rpm

inch inch inch

21

86

605

3,500 51

±5

18

5

Maximize precision with teamwork (from left): Interprecise Managing Director: Christian Witte, EMAG Sales Engineer: Michael Gumbel, as well as, Daniel Braun and Adam Smuda from Interprecise.

Before and after: the bearing ring blanks first undergo soft machining, and later hard machining on the VL machine.

EMAG VISITS:

INTERPRECISE DONATH GmbH NEAR FÜRTH Without roller bearings, the production of many machines and transmissions would be impossible. With their ring-shaped design, roller bearings make rolling movements easier and reduce friction. However, the production of roller bearings is tricky, and requires precision down to the micrometer – a job perfect for Interprecise Donath GmbH near Fürth, Germany. The company has been manufacturing particularly challenging roller bearings, for example those in machine and transmission production, for over 30 years. All the planning, design and production work is performed in house, and since 2017, EMAG VL vertical turning machines have been a major part of that. With its integrated automation, this system has helped to increase productivity, while also guaranteeing required component quality in the soft and hard machining of parts such as bearing rings.

EMAG VIDEO Watch the video of our visit to Interprecise Donath GmbH

6

"Ultimately, we managed to significantly reduce cost per part, by around 15%."

Managing Director Christian Witte

INTERPRECISE

DONATH

VL Series A total of three VL 4 machines and one VL 6 are in operation at Interprecise.

For technical data on the VL series, see page 11.

EFFICIENTLY MANAGING GROWING ORDERS

I

nterprecise Managing Director, Christian Witte explains, “We specialize in short response times and providing complete support to our customers in this extremely challenging and technical industry” – an approach, which has allowed the company to experience continuous growth: its workforce has nearly tripled over 13 years.

The year 2000 has special meaning to the employees of Interprecise, as it was the first year the specialists introduced the market to their own brand “iDC”, giving their own roller bearing quality a name. However, the success of this brand forced product planners at Interprecise to ask themselves a very important question about three years ago – how can we produce a growing number of different component versions and families, while still manufacturing them cost-effectively and without compromising on precision process reliability? The answer ultimately led them to the pick-up automation system used by EMAG’s vertical machines, as Witte describes, “I first looked at the solution because some of our customers were using it. It quickly became clear that the approach used by this machine, which loads itself using the working spindle allowing the process to operate semi-automatically, was perfect for what we wanted. The whole process allows us to increase productivity, even in small production runs, because one operator can easily run multiple machines. Ultimately, this means that we can produce more parts, without hiring additional people.” As a result, in 2017 Interprecise invested in its first two VL turning machines, followed about one year later by an additional VL 4 and VL 6 (for larger parts). The internal and external rings for the roller bearings undergo soft and hard turning on four EMAG machines, overall, they comprise of 50 different components that are turned on VL machines. The quantities for each batch fluctuates between fifty and five hundred parts, and approximately, three times per week the specialists reset their four pick-up turning machines.

What are your plans for the next few years?

A major advantage to these machines is the ability to run autonomously with an integrated circulating part conveyor and part storage area.

Focusing on flexibility: Approximately 50 different parts are manufactured on these EMAG machines.

EMAG BLOG We had a discussion with Interprecise Managing Director, Christian Witte, about market challenges and the benefits of pick-up technology.

We want to continue to grow, and we believe that we’ll have plenty of opportunities to do so because roller bearings are essential for so many applications. Industries such as aerospace, logistics, robotics, printing and packaging feature many machines that implement our technology. Roller bearings are even used in the movement of elements on solar panels and in agricultural machinery. Roller bearings are generally mounted on axle shafts, and used for guidance or load transfer purposes, reducing friction, and minimizing the energy consumption of the drive units. With this diversity and these benefits, we are immune from some of the economic development being experienced in a few of these industries. However, we do face some very fierce competition, making smart production solutions like the pick-up turning machines from EMAG essential.

7

PRODUCTION LINE:

MINIMIZING COSTS PER PART FOR BRAKE DISC PRODUCTION Quality, productivity and process reliability are principals that EMAG has used to build on decades of success in the production of brake discs.

With our VSC series pick-up turning machines, we have production solutions that can provide our customers with massive performance improvements in the production of brake discs, especially when combined with perfectly coordinated automation solutions.

PART HANDLING We can customize your production solution to fit any manufacturing scenario or specific requirements. We’ve seen and produced them all before, from manual loading to loading and unloading using a bin picking system.

MACHINING

OP 10

OP 20

The VSC series from EMAG is the perfect system for the complete machining of brake discs. All of the required machining technologies can be integrated onto this one machine model. When combined with pick-up automation, the VSC can deliver a manufacturing process that is both fast and precise. The DUO version of the VSC machines is perfect for this task, with two complete machining areas on a single machine body.

Turning of the first side

Turning of the second side

With this system, only two machines are required to perform the standard four machining operations: machine 1: OP 10 + OP 20, turn the two sides of the brake disc; machine 2: OP 30 + OP 40, drill and perform precision turning of the brake discs with with a straddle tool. If necessary, another machine can be integrated for perforating or groove milling on the friction ring surfaces of the brake discs.

REDUCE THE AMOUNT OF FINE DUST USING LASER COATED BRAKE DISCS EMAG LaserTec has developed a new technology for the laser coating of grey cast-based brake discs that makes it possible to decrease wear, minimizing the amount of fine dust emissions on the roads. The process involves welding a powder-based additional coating (typically made of tungsten carbide) onto the prepared friction ring surface using a laser.

The process, developed by EMAG LaserTec, has been optimized for use in mass production situations. For those customers that already have an existing EMAG manufacturing solution for brake discs, this product is very easy to integrate.

To learn more about this process and much more, use this QR code to subscribe to our newsletter.

8

PRODUCTION LINE

BRAKE DISC

LINE SOLUTION HIGHLIGHTS » Complete project management by EMAG Systems including the integration of third party machines

OP 30

OP 40

OP 50

Drilling + turning

Precision turning

Perforation / Groove milling

» Compact installation of the entire line thanks to the DUO machine concept

» Complete integration of all machining technologies in

VSC machines (turning, drilling, reaming, and grinding)

» Brake discs perforated bores can also be manufactured if required

» Grey cast, aluminium, and coated brake discs can be machined

BALANCING / MEASURING / MARKING If desired, EMAG can take over the planning for your entire production line, including the integration of third party machines (ex. measuring, balancing or marking). That way, you’ll have one contact for the complete system, even during production or for service issues.

LASER COATING PROCESS Laser beam

EMAG VIDEO Application coating Melt pool

For more on this topic, check out our webinar focused on brake disc production:

Connection zone Heat influence zone

Brake disc

9

TRUCK BRAKE DRUMS:

COMPACT SOLUTION FOR MANUFACTURING TRUCK BRAKE DRUMS

W

ith their large machining areas, powerful driven spindles and option for live tooling, VL series modular machines can even successfully manufacture truck brake drums. This compact solution benefits from short transportation distances, and complete automation from the blank to the finished part.

ALL FROM A SINGLE SOURCE! Machines, robotic material handling, automation, peripherals, clamping equipment, tools, and technology support.

OP 20 I 1 x VL 8 Soft turning After turning the part, the screw ring for the brake drum is machined. This includes the drilling of the screw holes with a live tool turret.

OP 10 I 2 x VL 8 Soft turning The large machining area of the VL 8 enables all the turning work, both internal and external, on the first side of the brake drum to be completed. Two machines are used here to improve the cycle time.

CYCLE TIME 109 SEC.

WORKPIECES 10

Differential housing

Flange

Sprocket

Wheel hub

Gear wheel

VL 8

MODULAR MACHINES FROM EMAG – FROM SMALL TO LARGE PRODUCTION RUNS

» Consistent vertical model product families with a modular design

» Perfect for mass production – from small to large production runs

» Every machine features the full range of automation and handling technologies

» Simple, automated linking of multiple machines available » Automated systems make it possible for operators to run multiple machines, simultaneously

Machine body Z-axis X-axis

AUTOMATION

Spindle

Robot track system

Measuring system (optional)

This extremely flexible automation system performs all of the part handling work for this production line. This includes unloading blanks from pallets, feeding the machines, and stacking finished brake drums onto pallets.

Turret (optional Y-axis) Automation

THE BENEFITS

» High strength: large spindle bearing diameter + MINERALIT® machine body

» Complete automation: Including raw and finished parts storage areas

» Simple handling: All the service units are easy to reach » Minimized footprint thanks to compact machine design » Maximum performance due to short distances between the machining area and pick-up automation system

TECHNICAL DATA OP 30 I BALANCING Balancing system Finally, the brake drums are balanced on an EMAG system designed for this application.

EMAG VIDEO Check out this animation to see brake drum machining process in action.

Workpiece diameter, max.

Chuck diameter

VL 2

VL 4

VL 6

VL 8

mm

100

200

300

400

mm

160

260

400

500

inch

inch

4

7

8

10

12

16

16

20

Workpiece length, 150 200 250 300 mm inch 6 8 10 12 max.

Travel distances mm 700/±50/375 740/±30/400880/±30/480995/±30/580 inch 28/±2/15 29/±1/16 35/±1/19 39/±1/23 X/Y (optional)/Z Revolutions of 6,000 6,000 6,000 6,000 1/min rpm 6,000 6,000 6,000 6,000 driven tools Torque of driven Nm 27/15 27/15 27/15 48/30 tools 30%/100% ft-lb 20/11 20/11 20/11 35/22 duty cycle Rapid-traverse 60/30/30 60/15/30 60/15/30 60/15/30 m/min ipm 2,363/1,181/1,181 2,363/591/1,181 2,363/591/1,181 2,363/591/1,181 rate X/Y/Z Main spindle » Power rating kW 18.1/13.9 25/18 39/28 44/34.5 40%/100% hp 24/19 34/24 52/38 59/46 duty cycle » Torque 77/59 280/202 460/340 775/600 Nm 40%/100% ft-lb 57/44 207/149 339/251 572/443 duty cycle 1/min 6,000 4,500 3,100 2,850 » Speed, max. rpm

6,000

4,500

3,100

2,850

11

WPG 7:

COMPACT UNIVERSAL EXTERNAL CYLINDRICAL GRINDING MACHINE FOR WORKPIECES UP TO 250 MM IN LENGTH Highly productive, flexible and with an extremely small footprint – the new WPG 7 CNC external cylindrical grinding machine delivers significant performance improvements for the machining of small and medium-sized workpieces.

P

erfect your grinding process with this innovative new solution from EMAG Weiss! Extremely efficient in the production of small and medium sized workpieces, the WPG 7 can produce parts up to 250 mm in length and 200 mm in diameter.

Rigid machine design, dynamic axes, a powerful grinding wheel drive unit and an extremely small footprint are just a few features of the WPG 7 that contribute to the systems efficiency. This complete system only requires four sq meters (43 sq feet) of floor space!

If desired, this robust machine is also extremely accessible and can be retooled very quickly to preform additional machining functions.

EASY Touchscreen HMI

INTELLIGENT G and M code support

TRANSPARENT Diagnostics

» Windows-based control interface » USB and Ethernet connections » Simple entry of technology values in the

» Functions and cycles clearly displayed » Extensive help, including documentation,

» SPS status clearly displayed » Drive diagnostics on the HMI » Trace record and parameter box diagnostics » Optional BDE/MDE interface

relevant cycle

» Graphic display of technology inputs

WORKPIECES 12

available in the machine control

WPG 7

EMAG WEISS

F RO M 7 G WP IS S E W G EM A S a ve

! space

TECHNICAL DATA Center height

mm

100 (125)

Distance between centers

mm

280

mm

390

in in

4 (5)

11

Longitudinal axis (Z) » Longitudinal travel » Feed speed » Table adjustment

in

m/min

15

15

ipm

591

°

8

mm

190

m/min

10

Lateral axis (X) » Lateral travel » Feed speed

in

8

ipm

394

» Grinding wheel diameter

mm

400 (500)

» Max. grinding wheel width

mm

80

» Grinding wheel bore

mm

127 (203)

» Grinding wheel peripheral surface speed

m/s

Grinding headstock in in in

ips

16 (20) 3

5 (8)

50

1,968

Workpiece headstock W20

» Mounting cone » Speed

(W25 or MK4, MK 5)

m/s ips

0 to 2,000 0 to 78,740

13

ANOMALIES:

ANOMALY DETECTION WITH MACHINE LEARNING

Visual perception is one of the most important tools we have to guide us through our environment. This also applies to the complex world of data.

W

e humans find it significantly easier to record and analyze data if it is presented to us using graphics, rather then,, for example, list-based or tabular form. In other words, the simple visualization of complex data, e.g., machine data, delivers added value.

When visualizations are combined with machine learning algorithms, used to analyze data and detect anomalies, a powerful tool for improving production processes is created. With the EDNA solution from EMAG, you get all of that and more!

EDNA: 4 LIFELINE DATA APPS EDNA data apps calculate production KPI’s throughout the production process, based on current machine data.

“OEE can be increased by simply adding a visualization of machine parameters.

The addition of tools for the automatic detection of anomalies brings this to a completely new level. ” Peter Strohm, Team UX 14

PART QUANTITY FORECAST

MULTI-DEVICE VIEW

CYCLE TIME MONITOR

SMART TOOL CHANGE

OEE MONITOR

CUSTOMIZED DASHBOARDS

ANOMALIES HIGH FREQUENCY DATA ANALYSIS MAKES REAL TIME ANOMALY DETECTION POSSIBLE: Our newly developed interface enables machine data to be requested and saved, even in millisecond cycles.

The base for this project is the new EDNA IoT solution for networking, operating, and analyzing machines. It essentially includes an industrial powered PC, known as the EDNA IoT core that records, aggregates, and analyzes data. This in-process measurement data, which we can then supply to our EDNA software system (EDNA Cortex), can be used to create completely new ways to monitor your production process.

TYPES OF KPI ANOMALIES A typical scenario in KPI-controlled anomaly detection, already implemented by EMAG, is the monitoring of standard production data and KPI’s to identify problems and systematic improvement opportunities in the production process. When combined with the EDNA apps, both current and long-term production trends and anomalies can be identified.

ONE-OFF SYSTEM-RELATED EVENTS ex., changing machine parameters, adjusting automation systems, etc.

EMAG VIDEO

KPI

KPI

SPONTANEOUS EVENTS ex., tool breakages and machine failures

All these values can be classified by EDNA using a“desired-actual analysis”: If a discrepancy occurs, the system can discharge the potentially nonconforming parts or notify the user early, for example in the form of a visual notification.

Everything found here, and more is available in our webinar on anomalies.

time

SYSTEMATIC DEVELOPMENTS ex., cumulative problems in the automation process

KPI

KPI

REPETITIVE SYSTEMIC EVENTS ex., scheduled maintenance, shift changes, breaks, etc.

time

time

time

15

VSC 400 CM / VSC 500 CM:

MACHINE CONCEPTS FOR THE FLEXIBLE MACHINING OF PIPE ENDS AND COUPLINGS VSC 400 CM / VSC 500 CM – vertical production centers

T

he VSC 400 CM, VSC 400 DUO CM and VSC 500 CM vertical production centers were designed for the complete machining of couplings with all types of threads used in the OCTG market. With its diameter capability ranging from 2 3/8” to 9 3/8”, the VSC CM series covers a very wide variety of parts in coupling production, making it extremely versatile.

Thanks to the modular machine design, these systems can be tailored for individual machining tasks, aiding in flexibility, efficiency and quality. The proven pick-up process that automates the loading and unloading of the machine, as well as the dynamic axes, ensure minimized idle times.

THE USC 21 SERIES The USC 21 machine concept was specifically designed for the production of pipe fittings. The machine design beautifully combines all of the features responsible for quality, durability, and maximizing productivity, with a level of versatility that covers all applications for both standard and premium thread qualities.

With the option of five different spindle sizes, the pipe diameter capabilities for this machine range from 2 3/8” to 20”, allowing these pipes to be machined with the best possible technologies and customized conditions.

WORKPIECES 16

D BR AN !

NE W

VSC

500 CM

CONTACTLESS MEASUREMENT OF THREAD GEOMETRIES IN THE MANUFACTURING PROCESS Measuring for quality assurance in an oil field requires a lot of time and money. So, switching from a manual to fully automated measuring process is a logical next step. The contactless Pipe and Coupling Thread Inspection System (TIS) developed by EMAG, allows pipe and coupling thread geometries to be measured with absolutely no contact for the very first time!

TIS BENEFITS

» Significantly shorter measuring times » Consistently high measuring accuracy » Reduction in the number of required inspection personnel » Minimization of cost and waste » Automatic transfer of all measuring results to the tracking system

» Available as a single machine or integrated into the manufacturing process

Contactless measurement of pipe and coupling thread geometries.

Automated coupling production – the VSC machines are loaded using the pick-up station.

17

ELDEC TUBE LINE:

LONGITUDINAL SEAM WELDING USING SDF® TECHNOLOGY Working with the Technical University of Chemnitz, EMAG eldec has developed a new method for the longitudinal welding of steel pipes.

F

esign · 3D Ma

D 3D

» HPTS

EMAG eldec Intuitive Interface

t

HIGH PRECISION TOOL SYSTEM

ec

18

n

Coil Con n

EMAG eldec eQC is a package of modules that build on and complement one another. When combined, they guarantee users a fully monitored process and, if applicable, the ability to use process and generator data with industry 4.0 solutions.

ng · 3D Q turi Co

· 3D

» EMAG ELDEC eQC

ac uf

l tro

n

or this process, we use the new EMAG eldec Tube Line generators, as either a high frequency energy source or with innovative SDF® technology. Our patented SDF® technology stands for “Simultaneous Dual Frequency”, and is new in longitudinal pipe welding. With this technology, two frequencies are simultaneously superimposed, and the higher frequency will modulate on the lower one. This creates a “mixed frequency,” which can be almost infinitely adjusted by altering the frequency proportions, even while the process is being performed. With this process, the welding technology can be customized for a wide range of tube types, including plated and high strength tubes.

By combining inductors designed using 3D CAD systems and modeled with FEM, with inductors manufactured using 3D SLM, 3D quality control and 3D Coil Connect inductor mounting, set-up and tooling times are decreased significantly in the new HPTS (High Precision Tool System).

» EEI²

New multi-touch display with intuitive control interface and smartphone look & feel.

ELDEC

TUBE-Line

TUBE-Line

SDF®

HF

Rating

225 – 2000 kW

100 – 1500 kW

Frequency

12/140 – 350 kHz

12/140 – 350 kHz

100/140 – 400 kHz

100/140 – 400 kHz

(in progress)

(in progress)

Process reliability /

HPTS (High Precision Tool System)

HPTS (High Precision Tool System)

QS / I4.0

eQC (eldec Quality Control)

eQC (eldec Quality Control)

Operation / HMI

EEI² (EMAG eldec Intuitive Interface)

EEI² (EMAG eldec Intuitive Interface)

Other properties

“Single cabinet” generators with:

ECO LINE EEI² Simple, intuitive control of the heating process, similar to a smartphone. More information is available here:

» IGBT transistors » Profibus/Profinet interface » Temperature/pyrometer control » Available with or without hose package » Tailored cooling systems available on request

19

NEW TECHNOLOGY SITE:

HEUBACH WILL BECOME A MULTITECHNOLOGY SITE EMAG LaserTec and EMAG ECM are combining to create a new facility for non-machining technologies.

L ASER WELDING

M

THERMAL JOINING

anagement has been discussing the idea of relocating and merging these two companies to a single facility, and the benefits of this co-location, for a while now. One of the main benefits is the available space provided by the Heubach location. For the past couple of years, production at EMAG ECM in Gaildorf has been constrained by capacity limitations, and the industrial estate in Heubach provides the perfect opportunity for expansion. The second major benefit is that the EMAG Group already owns the facility in Heubach, and was simply renting the building in Gaildorf. With renting, the process of making any modification’s or adaptations to the facility is tricky. By owning the property at Heubach, we have the option to make a wide range of necessary infrastructure and assembly changes specifically for the building and customization of EMAG machines.

20

LASER COATING

TECHNOLOGY SITE LASER CLEANING

ECM/PECM

3 QUESTIONS FOR: Franz Groß, Sales Manager EMAG ECM

» What are the primary benefits of relocation for

EMAG ECM? Merging the two sites will lead to significant reductions in costs. Warehousing and logistics, IT, dining facilities and facilities management are all functions that the two companies will now share, and that includes the costs incurred by them. Preliminary estimates are projecting that these savings will be approximately six figures every year.

» What benefits does this co-location provide

customers?

Customers will now be able to meet contacts from both companies, at one site.

The new application center will also provide new opportunities for ECM customers.

» What are the benefits for machine production at

the Heubach site?

Merging our two companies will allow us to invest more into the Heubach site. In the near future, we are planning to build a temperature-controlled precision manufacturing area for the 5-axis production of machine parts and tools. This will result in major benefits for our equipment, and tool production for our customers.

21

EMAG SAMPUTENSILI (EMAG SU):

SAMPUTENSILI MACHINE TOOLS BECOMES PART OF THE EMAG GROUP With EMAG SU the EMAG Group has expanded its range of technologies to include shaving, gear shaping, profile milling, gear generating and profile grinding.

T

hese new technologies are a perfect addition to EMAG’s existing gear cutting portfolio, which includes gear hobbing, chamfering, and deburring. Ultimately, however, the whole EMAG machine production division will benefit from this investment as it will enable new, holistic manufacturing solutions to be built.

These extend from initial turning and gear cutting for a blank to induction hardening and hard machining, to final gear flank grinding – of which, the last two feature Samputensili technology.

» GENERATING GRINDING MACHINES

The G Series has been specially developed for short cycle times and premium quality in the mass production of gear wheels with an external diameter of up to 450 mm and shafts with a length of up to 550 mm. The machine also has two working spindles which almost completely eliminate down times during the manufacturing process.

» PROFILE GRINDING MACHINES

EMAG SU supplies a wide range of profile grinding machines, such as the G 500 H. This is ideal for the throughfeed grinding of straight and angled external gearing, threads, spline shafts, rotors, and screw-type workpieces with diameters of up to 500 mm and a length of up to 2,150 mm. Straight and angled internal gearing can also be ground as an option.

WORKPIECES 22

Threads

Drive shafts

Straight & angled internal gearing

SAMPUTENSILI

EMAG

ABOUT THE COMPANY Samputensili has been developing and manufacturing a wide range of machine tools at its main site in Bentivoglio near Bologna for around 50 years – most recently independently under the name Samputensili Machine Tools. Its focus is on the coarse and final machining of gear wheels, shafts, worm gears, rotors, and other helical workpieces for use in mechanical engineering, aerospace, and the automotive and robot industry.

Samputensili gives its customers a lead over their rivals with its extraordinarily innovative solutions, e.g., for generating grinding, shaving, and shaping, and ensures they have a rapid return on their investment. High tech features such as direct linear drive units, energy saving concepts, parallel processes, and integrated measuring and dressing units confirm the high standards demanded by the company. Samputensili also continuously invests in research and development in order to continue to produce the most efficient and environmentally friendly machines possible.

» SHAVING MACHINES

EMAG SU also develops shaving machines such as the RASO 400. With its large, open “C” design, this machine can shave gear wheels in to a wide range of sizes, even large gear wheels and long shafts.

A range of automation options and additional units are available, including chamfering/deburring units, oil separation, labeling, etc.

Rotors

Gear wheels with straight and angled gearing

Spiral pumps

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Salach Austrasse 24 73084 Salach Germany Phone: +49 7162 17-0 Fax: +49 7162 17-4027 E-mail: info@salach.emag.com

Austria Glaneckerweg 1 5400 Hallein Austria Phone: +43 6245 76023-0 Fax: +43 6245 76023-20 E-mail: info@austria.emag.com

Frankfurt Martin-Behaim-Strasse 12 63263 Neu-Isenburg Germany Phone: +49 6102 88245-0 Fax: +49 6102 88245-412 E-mail: info@frankfurt.emag.com

Denmark Horsvangen 31 7120 Vejle Ø Denmark Phone: +45 75 854854 Fax: +45 75 816276 E-mail: info@daenemark.emag.com

Sweden Glasgatan 19B 73130 Köping Sweden Phone: +46 221 40305 E-mail: info@sweden.emag.com

Czech Republic Lolkova 766 103 00 Praha 10 – Kolovraty Czech Republic Phone: +420 731 476070 E-mail: mdelis@emag.com

Hungary Gerenda 10 1163 Budapest Hungary Phone: +36 30 9362-416 E-mail: lbujaki@emag.com

Poland ul. Krzycka 71A / 6 53-020 Wrocław Poland Phone: +48 728 389 989 E-mail: info@poland.emag.com

NEWS 30/04.2021 · © Copyright EMAG · Printed in Germany

EMAG Salach GmbH

Turkey Sanayi Cad. No.: 44 Nish İstanbul Sitesi D Blok D: 155 Yenibosna – Istanbul Turkey Phone: +90 532 694 54 44 E-mail: ckoc@emag.com

Markt Companies EUROPE

AMERICA

ASIA

EMAG MILANO S.r.l.

Via dei Mille 31 20098 San Giuliano Milanese (Mi) Italy Phone: +39 02 905942-1 Fax: +39 02 905942-24 E-mail: info.milano@emag.com

EMAG L.L.C. USA 38800 Grand River Avenue Farmington Hills, MI 48335 USA Phone: +1 248 477-7440 Fax: +1 248 477-7784 E-mail: info@usa.emag.com

EMAG MILANO S.r.l.

Succursale en France 5 Avenue de l'Europe 18150 La Guerche sur l'Aubois France Phone: +33 02 48 7711-00 Fax: +33 02 48 7111-29 E-mail: info.france@emag.com

EMAG MEXICO Maquinaria EMAG Mexico S de RL de CV Av. Hercules 301 Nave 1 Poligono Empresarial Santa Rosa 76220 Santa Rosa Jauregui, Querétaro Mexico Phone: +52 442 291 1552 E-mail: info.mexico@emag.com

EMAG (China) Machinery Co., Ltd. Sino-German Advanced Manufacturing Technology International Innovation park Building 2, No. 101, Chen Men Jing Road 215400 Taicang Jiangsu, China Phone: +86 512 5357-4098 Fax: +86 512 5357-5399 E-mail: info@emag-china.com

EMAG MILANO S.r.l.

Sucursal en España Pasaje Arrahona, n° 18 Polígono Industrial Santiga 08210 Barberà del Vallès (Barcelona) Spain Phone: +34 93 7195080 Fax: +34 93 7297107 E-mail: info.spain@emag.com

EMAG DO BRASIL Edifício Neo Corporate Offices, CJ 1503 Rua Enxovia, 472 04711-030 São Paulo SP Brazil Phone: +55 11 38370145 Fax: +55 11 38370145 E-mail: info@brasil.emag.com

EMAG (Chongqing) Intelligent Technical Co., Ltd Building 7, No. 24 Fangzheng Avenue Beibei District Chongqing 400714 China Phone: +86 23 49783399 Fax: +86 23 49783388 E-mail: info@emag-china.com Subject to technical changes. All machines are shown as they would be at a trade show and may deviate from standard appearance.

EMAG UK Ltd. Newport Road (Newport House) ST16 1DA Stafford Great Britain Phone: +44 1902 37609-0 E-mail: info@uk.emag.com

EMAG KOREA Ltd. Rm204, Biz center, SKn Technopark 124 Sagimakgol-ro, Sangdaewon-dong Jungwon-gu, Seongnam City Gyeonggi-do, 462-721 South Korea Phone: +82 31 776-4415 Fax: +82 31 776-4419 E-mail: info@korea.emag.com

TAKAMAZ EMAG Ltd. 1-8 Asahigaoka Hakusan-City Ishikawa Japan, 924-0004 Japan Phone: +81 76 274-1409 Fax: +81 76 274-8530 E-mail: info@takamaz.emag.com EMAG INDIA Pvt. Ltd. Technology Centre No. 17/G/46-3, Industrial Suburb 2nd Stage, Yeshwantpur Bengaluru – 560 022 India Phone: +91 80 50050163 E-mail: info@india.emag.com

EMAG OOO ul. Akademika Chelomeya 3/2 117630 Moscow Russia Phone: +7 495 287 0960 Fax: +7 495 287 0962 E-mail: info@russia.emag.com

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