MANUFACTURING SOLUTIONS FOR MACHINING GEARS
Automatic raw part supply
Turning of the first side (OP 10)
Turning of the second side (OP 20)
MANUFACTURING SYSTEM FOR SPROCKET MACHINING From solid bulk material in the form of sawn parts to finished sprockets in less than 40 seconds – an excellent example of the performance of EMAG modular machines.
Complete process chain by EMAG With the VL 3 DUO vertical twin-spindle pick-up turning machine and the VL 4 H vertical gear hobbing machine, EMAG offers the perfect manufacturing system for the complete machining of gears. The machines are supplemented by the TrackMotion automation system which ensures smooth transport between the machines – including the turning of workpieces and placing them on stackable pallets.
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VL 3 DUO: HIGHLY PRODUCTIVE MANUFACTURING IN JUST 24.5 m² + Fast automation: Machining OP 10 + OP 20 incl. handling and + +
turning in only 23 sec. Minimum 15 sec. machining time with no machine downtime Up to 400 parts in parts storage area
TECHNICAL DATA Workpiece diameter / length Chip-to-chip time Spindle capacity (40% duty cycle) Torque (40% duty cycle)
150 / 110 mm 5 – 6 sec. 17.9 kW 144 Nm
CYCLE TIME 37 SEC.
Parts storage area for up to 400 workpieces including TrackMotion
VL 4 H: FASTEST PICK-UP GEAR HOBBING MACHINE IN THE WORLD + High-speed pick-up gear hobbing machine for milling chucked parts + + +
with a tailstock Excellent chip flow conditions ideal for high-performance dry gear hobbing Measuring probe for post-process measurement with optional process stabilization Tailstock ensures optimum stability and maximum tool service life
TECHNICAL DATA Module Workpiece diameter / length Max. angle of inclination Axial cutting distance, max.
4 200 / 350 mm +/- 35° 150 mm
MANUFACTURING SOLUTIONS FOR SPROCKETS I Manufacturing system for sprocket machining
Gear hobbing (OP 30)
VL 2 RC: EXCELLENT CHAMFERING RESULTS IN LINE CYCLE TIME + No moving around of parts, chamfering performed in the line + Separate and downstream chamfering and thus no machining +
time delays for gear hobbing Maximum reduction of secondary burrs and material bulging
TECHNICAL DATA Module, max. Max. workpiece diameter / length Max. feed force Ball screw spindle drive Main spindle max. speed
4 200 / 200 mm 5 kN 32 mm 6,000 rpm
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VL 3 DUO TWIN-SPINDLE TURNING MACHINE FOR THE HIGHLY EMAG has extended the product range of the extremely successful VL series in the form of the VL 3 DUO, a twin-spindle machine solution for the highly productive manufacturing of chucked parts with a diameter of up to 150 mm. The VL 3 DUO features popular technological developments from previous years (including pick-up automation, the TrackMotion automation system and the modular basic design of the machine) to create a highly productive manufacturing system that delivers maximum productivity, while minimizing its footprint.
Access to e-container and hydraulics OP 10 automation belt TrackMotion automation system
Spindle 1
Central machining area extraction unit OP 20 automation belt
Spindle 2
Parts storage facility
264 sq ft* MINIMUM FOOTPRINT
AUTOMATION INCLUDED
MEASURING – FULLY INTEGRATED IN THE PROCESS
On the VL 3 DUO machines, the working spindles are not only used to machine workpieces, but also to load and unload them. This saves money, space and unnecessary peripheral devices.
Optional measuring stations are available outside the machining area, installed between the machining area and the pick-up station. Measurement is performed during transportation to the loading / unloading station, thus saving time.
*Fully equipped machine including chip con
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Y PRODUCTIVE MANUFACTURING OF CHUCKED PARTS
The VL 3 DUO rates highly for heavy-duty machining due to its rigid machine. The machines high feed forces with a large cutting depth allow for a reduction in the machining time.
MACHINING AREA OF THE VL 3 DUO:
ap = 4.75 mm f = 0.4 mm/rev. vc = 250 m/min
Highly productive machining of chucked parts with a diameter of up to 150 mm and minimal space requirement.
TECHNICAL DATA Workpiece dia., max.
mm
150
Max. chuck diameter
mm
210
Workpiece length, max.
mm
110
Travel distance: X (machining stroke) / Y (optional) / Z
mm
505 / ±30 / 250
» Power rating, 40% / 100%
kW
17.9 / 15.5
» Torque, 40% / 100%
Nm
144 / 98
» Number of revolutions, max.
rpm
5,000
» Spindle flange to DIN 55026
Size mm
6 100
Qty m/min
12 60 / 30 / 30
inch
6
inch
8.5
inch inch
4.5
20 / ±1 / 10
Main spindles (x2)
High precision
Machine base made of MINERALIT® polymer concrete, machine weight 10,000 kg (22,046 lbs), size 45 linear roller guides and direct position measuring systems in all axes
Integrated automation
Pick-up working spindle for loading and unloading
» Spindle bearing dia., front Turrets (2x) » Turret tool positions Rapid-traverse rate X / Y / Z
hp
ft-lb rpm
inch
24 / 21
106 / 72
5,000
4
ipm 2,362 / 1,181 / 1,181
Unique machine concept
Two working spindles and two high-performance tool turrets with torque motor
Optimum accessibility
Short distance to the turrets and working spindle ensure optimum accessibility
Increased 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
MANUFACTURING SOLUTIONS FOR GEARS I Twin-spindle turning machine for the highly productive manufacturing of chucked parts
HIGH-PERFORMANCE TURNING WITH THE VL 3 DUO
Minimum floor space requirement
264 sq ft for the complete machine: VL 3 DUO + TrackMotion + parts storage area + chip conveyor
Machines shown in trade show format.
nveyor, TrackMotion and parts storage area for up to 400 workpieces (depending on the workpiece geometry)
Optimum accessibility also to the TrackMotion automation system
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VL 4 H MODULAR GEAR CUTTING MACHINE Integrating highly productive gear cutting – the VL 4 H gear hobbing machine. The VL 4 H features high-performance drives which can generate high torques and high speeds at the main spindle and milling tool. They guarantee productive manufacturing of gears with a diameter of up to 200 mm and module 4, and enable dry milling within a short machining time. The machine body made of MineralitŽ ensures low vibration machining of the workpieces, thus contributing to the excellent machining quality. The vertical design of the machine with pick-up spindle guarantees short idle times since it is only a matter of seconds between the finished part being deposited and the raw part being picked up and transported to the milling head. Furthermore, the pick-up automation system allows the use of a measuring probe, which is positioned outside the machining area where it is well protected from soiling.
Machine body Measuring system (optional)
Gear hobbing head Spindle Control system (Fanuc) Automation
PROBE TO MEASURE GEARS AND SENSOR SYSTEM FOR ALIGNING GEARS
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The VL 4 has a very compact design. This machine can be easily incorporated into a production line or chaku-chaku layout thanks to its integrated automation and small machine footprint.
+ High-speed pick-up gear hobbing machine for milling chucked parts with a tailstock
+ Excellent chip flow conditions ideal for high-performance dry gear hobbing
+ Probe to measure gears and sensor system for aligning
with boreholes or grooves, for example. Both the probe and sensor system are fitted outside the machining area and are thus optimally protected from chips and soiling
+ Easily incorporated into manufacturing systems + Integrated automation: no additional costs + Time-tested KOEPFER gear hobbing technology + Both Fanuc and Siemens (VLC 200 H) control systems can be used
TECHNICAL DATA Standard module, max.
4
Workpiece dia., max.
mm
200
Workpiece length, max.
mm
350
Axial cutting distance, max.
mm
150
X-axis travel (radial infeed)
mm
115
Z-axis travel (main spindle)
mm
400
inch inch inch inch
8
14 6
4.5
inch
15.5
» Power rating, 100% duty cycle
kW
22
» Torque (100% duty cycle)
Nm
140
» Full power at spindle speed of
rpm
1,500
» Number of revolutions, max.
rpm
2,000
» Tool diameter, max.
° mm
±35 100
» Tool length (gearing length), max.
mm
240
» Shift travel distance
mm
200
» RPM range, max.
rpm
4,000
» Motor capacity, 100% duty cycle
kW
28
» Torque (100% duty cycle)
Nm
140
MANUFACTURING SOLUTIONS FOR GEARS I Modular gear cutting machine for gear production
THE BENEFITS:
Main spindle
Gear hobbing head » Swivel angle, max.
hp
ft-lb rpm
rpm
inch inch inch
rpm hp
ft-lbh
30
103
1,500 2,000
4
9.5
8
4,000 38
103
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AUTOMATED MANUFACTURING – THE KEY TO REDUCING COSTS On the VL machines, the working spindle is not only used to machine workpieces, but also to load and unload them. Thanks to the carrier prisms, the change part costs for different components are extremely low. The carrier prisms are simply inserted into the revolving chain and the transport-related data are entered in the control unit.
THE TRACKMOTION AUTOMATION SYSTEM The TrackMotion system is an automation solution combining the previous concept of conveyor belts, pick-and-place units and changers in a single system. On the TrackMotion automation system, a TransLift unit runs on a rail system, the “track,” through the machines. The TransLift grips the parts at different heights, while also positioning and turning the workpiece over. The machines can be linked to each other very easily using TrackMotion. Another benefit is the speed of the TrackMotion system, this automation concept is very fast.
Linking two VL 2 turning machines to a VL 4 H gear hobbing machine using the EMAG TrackMotion automation system (shown without safety fences)
The raw parts are supplied by a parts storage facility. This has a storage capacity of up to 400 parts, depending on the geometry of the workpiece.
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From small to large with no retooling. The universal NC gripper ensures that the machine can be reset very quickly.
HARD MACHINING OF GEAR
When induction hardening gears on an EMAG eldec MIND 750 hardening machine, the priority is on the highest output possible with constant component quality. Depending on the type of workpiece, cycle times are between four and eight seconds. For this, the fully automated system is equipped with a sprinkler system with the same cycle times. Energy is supplied by an SDFÂŽ generator or a high-frequency generator. The sintered gears achieve the required hardness thanks to the highly precise transfer of energy during the induction hardening process and the subsequent annealing and cooling processes.
PRECISION FINISHING OF GEARS USING THE COMBINED PROCESSES OF HARD TURNING AND GRINDING Machines shown with optional decorative sheet metal cover kit
It’s easiest to see the quality that can be achieved with the VLC 100 GT by using a real life example. By observing the machining of gears, the benefits of combination machining quickly become clear. Once the machine has been automatically loaded by a pick-up spindle, the first machining operation is performed by the integrated internal grinding spindle. The gear borehole has only a small machining allowance and is finish-ground using CBN. The flat surfaces of the gear are machined by the tool block holders which are also located in the machining area. Machining using hard turning technology not only allows extremely short machining times, but also ensures that no reworking is necessary. The machining quality of the gear is then checked using the probe located between the machining area and the loading station.
MANUFACTURING SOLUTIONS FOR GEARS I Automated production I Hard machining of gears
INDUCTION HARDENING OF SINTERED GEARS ON THE MIND 750 HARDENING MACHINE
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Turning
Milling
Grinding
Gear Hobbing
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