VERTICAL TWIN-SPINDLE MACHINES MODULAR SOLUTIONS
VL 1 TWIN – HIGHLY PRODUCTIVE SIMULTANEOUS M Twin-spindle turning center for the highly productive manufacturing of workpieces up to 3 inches in diameter The VL 1 TWIN has two main spindles in one machining area which can simultaneously machine two identical workpieces. This method allows for a massive increase in output quantities and lowers cost per piece. The diameter and length of both components can be corrected independently of one another using both spindles. In addition, the machine has a direct position measuring system and a linear motor in the X-axis to ensure the highest machining quality and maximum productivity.
TECHNICAL DATA Max. workpiece diameter
mm
75
Chuck diameter
mm
140
Swing diameter
mm
160
Workpiece length, max.
mm
75
kg
1
X-axis / Z-axis travel
mm
605 / 200
Main spindle »» Power rating, 40% / 100% duty cycle
kW
13 / 11.7
»» Torque, 40% / 100% duty cycle
Nm
113 / 88
»» Max. number of revolutions
rpm
Workpiece weight
Rapid-traverse rate, X / Z Tool stations
2
CNC controller
inch inch inch inch lb
inch
hp
ft-lb rpm
m/min
ipm
3 6
Planetary Gear
7
Workpiece dia: 38 mm / 1.5 in Material: 20CrMoH
3
Sleeve
Workpiece dia: 51 mm / 2 in Material: 21NiCrMo2
2
17 / 16
83 / 65
6,000 6,000
60 / 30
2,400 / 1,200
2 x 4 – VDI30 / BMT45 Fanuc 31i with Manual Guide i
16 SEC.
12 SEC.
24 / 8
Flange Workpiece dia: 52 mm / 2 in Material: CrNi1810
26 SEC.
VL 1 TWIN Workpieces Cycle Time*
Cam
Workpiece dia: 42 mm / 1.5 in Material: 100Cr6
9 SEC.
MACHINING SIMULTANEOUS MACHINING
HIGHLIGHTS ++ High Precision
Machine base made of MINERALIT® polymer concrete with optimal vibration-damping properties, size 45 linear roller guides and direct position measuring systems in the X-axis for optimal positioning, repetition and long-term accuracy.
++ Integrated Automation
Two pick-up working spindles for loading and unloading. Machines are automation ready making it possible to link with other EMAG machines/ technologies (ex. gear hobbing).
++ Unique TWIN Concept
Simultaneous machining of two identical workpieces possible, doubling the output and reducing the cost per piece. Diameter and length (X/Z direction) of both components can be corrected independently of one another using the two spindles.
++ Optimal Dynamics
Linear drive in the X-axis for maximum dynamism (21 mph acceleration), minimal wear and maximum positioning accuracy.
AUTOMATION INCLUDED
Linking two VL 1 TWIN machines including parts storage area and TrackMotion automation system Access to e-container and hydraulics
Number of spindles
Machine 1 (OP 10 / OP 10)
Access to e-container and hydraulics
TrackMotion automation system
Number of spindles
Machine 2 (OP 20 / OP 20)
* Cycle time of 9 sec., for example, for a machining time of 18 sec. (2 spindles)
Parts storage area
On the VL 1 TWIN 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.
FULLY INTEGRATED MEASURING SYSTEM
Measuring systems installed between the machining area and the pick-up station are available as an option. To save time, these measurements are performed during the parts’ movement to and from the loading/ unloading station.
3
VL 3 DUO – TWIN-SPINDLE TURNING MACHINE FOR THE HIGHLY PRODUCTIVE MANUFACTURING O EMAG has extended the VL Series product range with the VL 3 DUO, a twin-spindle machine solution for the highly productive manufacturing of chucked parts up to 6 inches in diameter. The VL 3 DUO integrates all of the most recent EMAG technological developments (including self-loading spindle, TrackMotion automation system and the modular design of the machine) to create a highly productive manufacturing system that delivers maximum productivity with a minimum footprint.
Access to E-Container and Hydraulics OP 10 NC Shuttle TrackMotion Automation System
Spindle 1
Central Machining Area Extraction Unit OP 20 NC Shuttle
Spindle 2
Parts Storage Area
NOW AVAILABLE
SIEMENS 840D SL
HIGH PERFORMANCE TURNING WITH THE VL 3 DUO The VL 3 DUO is perfect for heavy-duty machining thanks to its rigid machine design. High feed forces with a large cutting depth allows for the reduction of machining time. Standard spindle: ap =
4.75 mm
f =
0.4 mm/rev
vc =
250 m/min
0.2 in
0.02 in/rev
1,000 in/min
High torque spindle:
4
ap =
8.5 mm
f =
0.4 mm/rev
vc =
250 m/min
0.3 in
0.02 in/rev
1,000 in/min
* Fully equipped machine, including chip conveyo
OF CHUCKED PARTS
NEW!
HIGH TORQUE SPINDLE WITH 32 KW CAPACITY
VL 3 DUO FOR DEMANDING TURNING WORK
++ Working spindle with 5,000 rpm / 32 kW / 255 Nm at 40% duty cycle
++ Sturdy mechanical design – spindle bearing, front:
100 mm (4 in) in diameter, spindle flange to DIN 55026, size 6
++ Motor spindle with DirectDrive for minimum run-up times, maximum true running and diameter tolerances
MACHINING AREA OF THE VL 3 DUO:
++ Maximum torque over large range of speeds – baseline spindle speed: 1,408 rpm (at 100% duty cycle)
Highly productive machining for chucked parts with a diameter of up to 6 inches.
++ Water-cooled motor spindle for maximum thermal stability
50 45 40
255 196 175 150 125 100 75 50
25 20 15 10
25
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
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
Minimum Floor Space Required
24.5 m (264 ft ) for the complete machine: VL 3 DUO + TrackMotion + parts storage area + chip conveyor 2
2
Machines shown in trade show format.
or, TrackMotion and parts storage area for up to 400 workpieces (depending on the workpiece geometry)
Torque (Nm) 40% duty cycle 100% duty cycle
Power [kW] 40% duty cycle 100% duty cycle
Number of revolutions (rpm)
TECHNICAL DATA
5,400
4,800
4,200
3,600
3,000
2,400
1,213 1,408 1,800
5 600
Precise Machining
Machine base made of MINERALIT® polymer concrete Machine weight 10,000 kg (11-tons), size 45 linear roller guides and direct position measuring systems in all axes
Power [kW]
35 30
6,000
Torque (Nm)
225
Max. workpiece diameter
mm
150
Max. chuck diameter
mm
210
Workpiece length, max.
mm
110
Travel distance: X (machining stroke) / Y (optional) / Z Main spindles (2x) – Standard
mm
505 / ±30 / 250
»»Power rating, 40% / 100% duty cycle
kW
18 / 15
»»Torque, 40% / 100% duty cycle
Nm
144 / 98
»»Max. number of revolutions
rpm
5,000
»»Spindle flange to DIN 55026
Size mm
»»Spindle bearing dia., front High torque spindle (option)
inch
inch inch
inch
hp
ft-lb rpm
inch
6 9
5
20 / ±1 / 10
24 / 21
106 / 72
5,000
6 100 4
»»Power rating, 40% / 100% duty cycle
kW
32 / 29
»»Torque, 40% / 100% duty cycle
Nm
255 / 196
»»Max. number of revolutions
rpm
5,000
Turrets (2x) »»Turret tool positions Rapid-traverse rate X / Y / Z
hp
ft-lb rpm
Qty m/min
44 / 39
188 / 145 5,000
12 60 / 30 / 30
ipm 2,362 / 1,181 / 1,181
5
VL 5 DUO – TWIN SPINDLE TURNING MACHINE FOR COMPONENTS UP TO 250 MM (10 IN) Two separate machining areas provide maximum production flexibility Whether it is a “one-machine solution” for OP 10 and OP 20 or a TWIN turning machine for OP 10 and OP 10 – the VL 5 DUO can be configured to fit a variety of manufacturing scenarios.
Machines shown in trade show format.
The machining areas on this system mirror one another, and each is equipped with its own working spindle which, with a rating of up to 34.1 kW (46 hp) and a torque of up to 593 Nm (437 ft-lb) with a duty cycle of 40%, has plenty of power to achieve high speed, precision machining. A twelve position tool turret is also available in each machining area (VDI 40 or BMT 55 interface), with either turning or driven tools and a Y-axis.
TECHNICAL DATA Max. workpiece diameter
250 mm
Chuck diameter
315 mm
»»Power rating, 40% / 100%
Swing diameter
340 mm
»»Torque 40% / 100%
593 / 501 Nm
Max. workpiece length
175 mm
»»Max. speed
4,500 rpm 60 / 30 m/min
Workpiece weight Travel distances, X / Y (optional) / Z CNC controller
6
10 in
12 in
13 in 7 in
40 kg
88 lbs
750 / ±30 / 350 mm
30 in / 1 in / 14 in
Fanuc 31i with Manual Guide i
Main spindle
Rapid-traverse rate, X / Z Tool stations
34.1 / 28.9 kW 46 / 38 hp
437 / 370 ft-lb
197 / 98 ft/min
2x12 – VDI40 / BMT 55
POWERFUL! 34 KW / 46 HP
HIGHLIGHTS ++ Maximum precision
Machine base made of MINERALIT® polymer concrete with optimal vibration-damping properties, size 45 linear roller guides, and a direct position measuring system in the X-axis for the highest positioning accuracy, repeat accuracy and long-term accuracy
++ Highly productive DUO concept
Machining OP 10 and OP 20, or simultaneous machining in OP 10 and OP 10 of two identical workpieces is possible
++ Main spindle
with 34.1 kW (46 hp), 593 Nm (437 ft-lb) at 40% duty cycle
++ Motor spindle
with DirectDrive for minimum run times, maximum true running and diameter tolerances
++ Maximum torque
covering large range of speeds – baseline working spindle speed: 550 rpm
++ Water-cooled motor spindle 750
50
675
45
593 501 450 375
40 35 30 25 20 15
300 225
10
150
5
Speed (1/min) Drehzahl (1/min)
5.000 5.000
4.500 4.500
4.000 4.000
3.500 3.500
3.000 3.000
2.500 2.500
550 550 Drehmoment Torque (Nm) (Nm) 40 % ED 40% 100 % ED 100%
1.000 1.000 1.500 2.000 2.000
75
Ring gear
Leistung (kW) Power (kW)
Drehmoment (Nm) Torque (Nm)
for maximum thermal stability
Leistung Power (kW) (kW) 40 % ED 40% 100 % ED 100%
Differential housing Workpiece Ø: 165 mm / 6in Material: GGG60
Workpiece Ø: 230 mm / 9 in Material: 20MnCr4
64 SEC. Car wheel hub
100 SEC. Annulus gear
VL 5 DUO
Workpiece Ø: 136 mm / 5 in Material: C55
Workpiece Ø: 135 mm / 5 in Material: 27MnVs6
workpieces Cycle time
86 SEC.
40 SEC.
TRACKMOTION AUTOMATION SYSTEM The VL 5 DUO and the TrackMotion automation system are perfectly fit for one another. The TrackMotion system performs the loading and unloading process, transports the parts and turns the parts between operations.
FULLY INTEGRATED MEASURING Gear wheel
CVT part Workpiece Ø: 163 mm / 6 in Material: 15 CrMo5
145 SEC.
80 SEC.
Workpiece Ø: 220 mm / 9 in Material: 20 NiMoCr65
A measuring station is available as an option for each machining area. The measuring station is installed between the machining area and the pick-up stations.
7
TRACKMOTION AUTOMATION SYSTEM – TRANSPOR RAILS AUTOMATION EXAMPLE: SOFT MACHINING OF GEARS (COMPLETE LINE)
Parts storage area for up to 400 workpieces, including TrackMotion
Turning of first and second side (OP 10/OP 20)
AUTOMATION EXAMPLE: SOFT TURNING OF PULLEYS FOR CVT TRANSMISSIONS
AUTOMATION EXAMPLE: SOFT TURNING OF SPROCKETS (COMPLETE LINE)
Turning of the first side (OP 10)
8
Turning of the second side (OP 20)
93 SECOND CYCLE TIME
RTING PARTS AS IF THEY WERE ON
28 SECOND CYCLE TIME
2
Gear hobbing (OP 30)
3
1
++ TrackMotion automation system, consisting of 1 Track Roller deburring (OP 40)
2 Lift and turn-over unit (TransLift) 3 E-container
++ Completely modular system (ex. adaptable in length)
Turning of both sides (OP 10 and OP 20)
++ TransLift lift and turn-over unit ++ Adaptable to a wide variety of components (chucked and shaft parts)
37 SECOND CYCLE TIME
++ Replaces belts, pick-and-place units and changers ++ Z-stroke of up to 650Â mm (26 in) is possible
Parts storage area for up to 400 workpieces, including TrackMotion
++ Raw and finished parts storage area can be adapted to a wide variety of components (chucked and shaft parts)
++ The use of stacker pallets enables the storage of up Gear hobbing (OP 30)
Roller deburring (OP 40)
to 400 raw and finished parts.
9
Turning
Milling
Grinding
Gear Hobbing
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