Lagermaschinen_Modular_GB

MODULAR SOLUTIONS

THE MOST VERSATILE STANDARD MACHINE ON THE MARKET

MACHINES IMMEDIATELY AVAILABLE

2

FLEXIBLE

Vertical turning machines for chucked parts with a maximum diameter of 400 mm (16 in)

10

FASTER

VT machines ensure quick machining processes for shafts

PICK-UP TURNING MACHINES FOR CHUCKED PARTS The vertical pick-up turning machines of the VL series are the perfect examples of the EMAG Group’s modular machine concept.

EMAG VIDEO

VL 8 machines in action

Machine body Z-axis X-axis Main spindle Measuring probe (optional)

Turret (optional Y-axis) “O” automation

X

Z

(Y) C

2

MINERALIT® polymer concrete machine base

Brake drum

Differential housing

Brake disk

MAXIMUM PRECISION – DIRECT

THE PATENTED EMAG TURRET

POSITION MEASURING SYSTEMS

0.3 SEC.

RAPID-TRAVERSE RATE, X-AXIS

TURRET SWIVELING TIME

60 m/min

» GLASS SCALES

» QUICK WITH NO WEAR

» STANDARD

» PRECISE

Fully encapsulated linear glass scales in all linear axes.

Glass scales on all EMAG machines come standard!

The EMAG turret is equipped with a direct drive (torque motor) for the swiveling.

Thermal stability ensured thanks to an ambient temperature controlled cooling system.

» FLEXIBLE

The turret has space for twelve tools (featuring either a VDI or BMT interface).

Driven tools can be used in all tool stations. The optionally available Y-axis ensures maximum flexibility.

3

VL SERIES

AVAILABLE:

SIEMENS 840D SL AT A GLANCE Vertical pick-up turning machines for the production of precision chucked parts – a variety of configurations available for parts ranging between 10 and 400 mm (0.4 and 16 in) in diameter.

» COMPLETE AUTOMATION

AUTOMATED PRODUCTION WITH VERTICAL PICK-UP TURNING MACHINES

Including standard raw and finished parts storage areas

» MINIMIZED FOOTPRINT

Thanks to a compact machine design

» SIMPLE HANDLING

All the service units are easy to reach

» DIRECT POSITION MEASURING

SYSTEMS Glass scales come standard in all axes

» EMAG TURRETS

With direct drive (torque motor)

» HIGH STRENGTH

Large working spindle bearing diameter + machine body made of MINERALIT®

VL 2 AND VL 4:

FOR SMALL AND MEDIUM-SIZED WORKPIECES

T

he VL 2 and VL 4 pick-up turning machines are ideal for the production of workpieces with a maximum diameter of 100/200 mm (4 - 8 in). The machines include integrated automation and a parts storage area that allow for autonomous operation - relieving the strain on production personnel. With these systems, the efficient mass production of various batch sizes is possible and thanks to their flexible clamping systems, they can also machine entire part families without any problem.

» MAXIMUM PERFORMANCE

Thanks to short distances between the machining area and pick-up automation system

» EASY ACCESSIBILITY AND SETTING Short distance to the turrets and working spindle ensure very good accessibility and easy setting

VL 2 AND VL 4:

MACHINES AVAILABLE ON SHORT NOTICE

4

Brake piston

Cylinder

Gear wheel

CVT pulley

VL 6 AND VL 8:

FOR LARGE WORKPIECES

I

f you want to efficiently machine large workpieces, or are striving to maximize your flexibility in production, look no further than the VL 6 and VL 8 pick-up turning machines. The integrated conveyor belt included on these systems makes loading heavy parts a breeze! The parts are simply placed on the conveyor belt by a crane, and the machine takes care of the rest!

TECHNICAL DATA Max. workpiece diameter

mm

VL 2 100

VL 4 200

VL 6 300

VL 8 400

Chuck diameter

mm

160

260

400

500

Max. workpiece length

mm

150

200

250

300

Travel distances, X/Y (optional)/Z

mm 650/± 50/375 760/± 30/415 900/± 30/495 1,110/± 30 /595

inch inch inch

4 6 6

8

10 8

12

16

10

16

20 12

inch

26 /± 2/15

30/± 1/16

35 /± 1/19

44 / ± 1/23

» Power rating, 40%/100%

kW

15.7/13.9

22.7/18

41.4/28

47.6/34.5

» Torque, 40%/100%

Nm

77/59

256/202

491/340

780/600

» Max. speed

rpm

6,000

4,500

3,100

2,850

» Turret tool positions

Qty

12

12

12

12

» Revolutions of driven tools

rpm

6,000

6,000

6,000

6,000

» Torque of driven tools at 30%/100% duty cycle

Nm

27/15

27/15

27/15

48/30

Main spindle hp

ft-lb

21/19

57/44

30/24

189/149

56/38

362/251

64/46

575/443

Turret

ft-lb

20/11

20/11

20/11

35/22

5

VL 1 TWIN:

T

HIGH SPEED LINEAR MOTOR

ROBOT CELL ENSURES MAXIMUM PRODUCTIVITY

he VL 1 TWIN with its two main spindles is already a powerful machine for the production of components up to 75 mm (3 in) in diameter, so when you connect it to an equally powerful automation system output is maximized!

The VL 1 TWIN has two main spindles in one machining area that can simultaneously machine two identical workpieces with a cycle time of under 15 seconds for two components (a cam for example). However, the loading and unloading of the components could become a bottleneck. To solve this, EMAG has developed a powerful robot cell for the VL 1 TWIN. This automation system can be included in any production environment and takes up a very small amount of space.

EMAG VIDEO

SIMULTANEOUS

MACHINING FOR HIGHLY PRODUCTIVE

MANUFACTURING

VL 1 TWIN with robot cell

Measuring station

Gear wheel Robot Main spindles 1 and 2

Cam

Parts storage area

Planetary gear

6

Brake piston

HIGHLIGHTS

» MAXIMUM PRECISION VL 1 TWIN highlights

VL 1 TWIN

EMAG VIDEO

Machine base made of MINERALIT® with optimal vibration-damping properties, size 45 linear roller guides as well as direct position measuring system in the X-axis.

» INTEGRATED AUTOMATION

Two pick-up working spindles for loading and unloading.

“Automation ready”: Linking using the EMAG TrackMotion automation system.

» UNIQUE TWIN CONCEPT

Simultaneous machining of two identical workpieces reduces the cost per part.

Independent correction of diameter and length (X/Z direction) of the two components.

» OPTIMAL DYNAMICS

Linear drive in the X-axis for maximum dynamics, minimal wear and maximum positioning accuracy.

TECHNICAL DATA

Automation included

Max. workpiece diameter

mm

75

Chuck diameter

mm

140

Swing diameter

mm

160

Max. workpiece length

mm

75

kg

1

Travel distances, X/Z

mm

605/200

Main spindle » Power rating, 40%/100% duty cycle » Torque, 40%/100% duty cycle

kW

13/11.7

Nm

113/88

rpm m/min

6,000 60/30

Workpiece weight

» Max. speed Rapid-traverse rate, X/Z Tool stations CNC controller

inch inch inch inch lb

inch

hp

ft-lb

ipm

3 6 6 3 2

24 / 8

17/16

Fully integrated measuring system

83/65

2,362/1,181

2 x 4 – VDI30/BMT45 Fanuc 31i

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VL 3 DUO TWIN-SPINDLE TURNING MACHINE For the highly productive manufacturing of chucked parts with a maximum diameter of 150 mm (6 in) NOW INCLUDING A HIGH-PERFORMANCE

TURRET

EMAG VIDEO

VL 3 DUO in operation

THE VL 3 DUO NOW INCLUDES A HIGHPERFORMANCE TURRET FOR IMPROVED PRODUCTION CAPACITY + Frequency-controlled synchronous motor with direction detection and power amplifier (installed in the control cabinet)

VL 3 DUO: 3 STOCK MACHINES AVAILABLE NOW

+ The “turn-milling drive” control option is already included + Each turret position can be fitted with a Lifetool and is internally cooled + Max. speed: 9,600 rpm rather than 6,000 rpm in the standard version + Max. power at 3,000 rpm + Torque at 40% duty cycle: 44 Nm (32 ft-lb) rather than 24 Nm (18 ft-lb) 45 40 35 30 25 20 15 10 5

30

20 15 10

Number of revolutions (rpm)

5,500

5,000

4,500

4,000

3,500

3,000

2,500

2,000

1,500

1,000

5

Torque (Nm) 40% duty cycle 100% duty cycle

8

Power [kW]

25

500

Torque (Nm)

+ Power at 40% duty cycle: 13.8 kW (19 hp) rather than 7.5 kW (10 hp)

Power [kW] 40% duty cycle 100 % duty cycle

AVAILABLE:

SIEMENS 840D SL

* Fully equippe

VL 3 DUO

MACHINE STRUCTURE 1

Spindle 1

2

Spindle 2

3

OP 10 automation belt

4

OP 20 automation belt

5

TrackMotion automation system

6

Parts storage area

7

Access to e-container and hydraulics

8

Central machining area extraction unit

7

8

5

4

3

1

2

6

TECHNICAL DATA

CVT pulley

Sprocket

Gear wheel Maximum precision

Machine base made of MINERALIT® polymer concrete Machine weight 10,000 kg (22,050 lb), size 45 linear roller guides and direct position measuring systems in all axes

Integrated automation

Pick-up working spindle for loading and unloading

Unique machine concept

Two working spindles and two high-performance tool turrets with torque motor

High performance turret

Each machining area features a tool turret with 12 tool positions

Optimum accessibility

Short distance to the turrets and working spindle ensure optimum accessibility

Maximum flexibility

Parts storage area for up to 400 workpieces and TrackMotion automation system for high-speed part transport between the parts storage area and machining areas as well as for turning the workpieces

Minimum floor space requirement

24.5 m (264 sq ft) for the entire machine: VL 3 DUO + TrackMotion + parts storage area + chip conveyor 2

Machines shown in trade show format.

ed machine, including chip conveyor, TrackMotion and parts storage area for up to 400 workpieces (depending on the workpiece geometry)

Max. workpiece diameter

mm

150

Chuck diameter

mm

210

Max. workpiece length Travel distance, X (machining stroke)/Y (optional)/Z Main spindle

mm

110

inch inch inch

6 8 4

mm 505/±30/250 inch

20/±1/10

» Power rating, 40%/100% duty cycle

kW

17.9/15.5

» Torque, 40%/100% duty cycle

Nm

144/98

» Max. speed » Spindle flange to DIN 55026

rpm Size mm

5,000 6 100

» Power rating, 40%/100% duty cycle

kW

31.5/28.1

» Torque, 40%/100% duty cycle

Nm

255/192

rpm

5,000

» Spindle bearing dia., front

hp

ft-lb

inch

24/21

106/72

4

High-performance spindle (optional)

» Max. speed Turret

hp

ft-lb

42/38

188/142

» Power rating, 40%/100% duty cycle

kW

7.5/2.8

» Torque, 40%/100% duty cycle

Nm

24/15

» Max. speed

rpm

6,000

Turret tool positions

Qty

12

» Power rating, 40%/100% duty cycle

kW

13.8/10.4

» Torque, 40%/100% duty cycle

Nm

44/33.1

rpm m/min

9,600 60/30/30

hp

ft-lb

10 / 4

18/11

High-performance turret (optional)

» Max. speed Rapid-traverse rate, X/Y/Z

hp

ft-lb

ipm

19/14

32/24

2,362/1,181/1,181

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WORKPIECE

CHANGEOVER TIME

VT SERIES

AT A GLANCE

VT 2 AND VT 4:

EMAG’s VT machines are vertical shaft turning systems with four axes that can quickly machine workpieces from two sides. The VT 2 can produce shafts up to 400 mm (16 in) in length, while the VT 4 can reach 630 mm (25 in) in length.

MAXIMUM PERFORMANCE IN SHAFT PRODUCTION

W

hen it comes to producing a high quantity of shafts, fast manufacturing processes are crucial. In order to achieve this, the loading and unloading of the machine must be done very quickly. The VT 2 and VT 4 machines guarantee maximum performance with their four axes, short travel distances and powerful main spindles.

» Two tool turrets, each with eleven tool positions

» Simultaneous loading and

The benefits of this machine platform are obvious when the machine is required to produce high part volumes. Since this platform can machine the workpieces from two sides, the production time is dramatically reduced allowing more parts to be machined, quicker. The two tool turrets, each with eleven tool stations that can be equipped with turning or driven tools, also guarantee the machines flexibility.

unloading

» Integrated automation » Optimum accessibility TECHNICAL DATA Chuck diameter

mm

VT 2 160

VT 4 250

Swing diameter

mm

210

270

Max. workpiece length

mm

400

630

Main spindle » Power rating, 40%/100% » Torque, 40%/100% » Max. speed

inch inch inch

6 8

16

11

25

24/19

43/35

Nm

142/90

246/200

rpm

6,000

4,500

ft-lb

105/66

All technical data is available at: www.emag.com » Machines

10

10

kW 17.9/14.1 32.4/26.4 hp

6 SEC.

181/148

Max. workpiece diameter: 100 mm (4 in) Max. workpiece length: 400 mm (16 in)

Max. workpiece diameter: 200 mm (8 in) Max. workpiece length: 630 mm (25 in)

4 MACHINES AVAILABLE IMMEDIATELY

Rotor shaft

Rotor shaft

Transmission shaft

Bell housing

Turret 1 Working spindle with C-axis Turret 2 Tailstock Automation

THREE KEY SUCESS FACTORS

VT 2 / VT 4

VT 2 AND VT 4:

» REDUCED MACHINING TIMES thanks to four-axis machining

» SHORTER IDLE TIMES »

thanks to simultaneous loading and unloading of components HIGHLY PRODUCTIVE SHAFT MANUFACTURING thanks to integrated automation

EMAG VIDEO

AVAILABLE WITH

SIEMENS 840D SL

VT 2 in operation

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GO LIVE!

VISIT EMAG VIRTUALLY AND IN THE REAL WORLD. In addition to our wide range of information online, get more detailed information about our product offerings by visiting our showrooms in Germany, China and the USA. Contact us today to schedule an appointment to visit!

MARKET COMPANIES

EMAG SALACH GMBH

EUROPE

AMERICA

ASIA

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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

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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 7711-29 E-Mail: info.france@emag.com

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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

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