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
7
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
9
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
11
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
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 7711-29 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 UK Ltd. Chestnut House Kingswood Business Park Holyhead Road Albrighton Wolverhampton WV7 3AU Great Britain Phone: +44 1902 37609-0 Fax: +44 1902 37609-1 E-Mail: info@uk.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
EMAG (Chongqing) Machinery Co., Ltd. No. 10th Lailong Road Yongchuan District 402160 Chongqing China Phone: +86 23 49783399 Fax: +86 23 49783388 E-Mail: info@emag-china.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 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
Salach Austraße 24 73084 Salach Germany Phone: +49 7162 17-0 Fax: +49 7162 17-4027 E-Mail: info@salach.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 Leipzig Pittlerstraße 26 04159 Leipzig Germany Phone: +49 341 4666-0 Fax: +49 341 4666-2114 E-Mail: info@leipzig.emag.com Munich Zamdorferstraße 100 81677 München Germany Phone: +49 89 99886-250 Fax: +49 89 99886-160 E-Mail: info@muenchen.emag.com Austria Glaneckerweg 1 5400 Hallein Austria Phone: +43 6245 76023-0 Fax: +43 6245 76023-20 E-Mail: info@austria.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 Hungary Gerenda 10 1163 Budapest Hungary Phone: +36 30 9362-416 E-Mail: lbujaki@emag.com Czech Republic Lolkova 766 103 00 Praha 10 – Kolovraty Czech Republic Phone: +420 731 476070 E-Mail: mdelis@emag.com Poland ul. Krzycka 71A / 6 53-020 Wrocław Poland Phone: +48 728 389 989 E-Mail: info@poland.emag.com 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
www.emag.com