EMCO lathe - MAXXTURN 65

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That’s E[M]CONOMy:

]

More value for money.

EMCO MAXXTURN 65 Universal turning center for complete machining of bar stock and chuck work

EMCO MAXXTURN 65 [ NEW] -

anuc 31iB F TFT color monitor USB interface and Ethernet ManualGuide i with 3D-Simulation

[ Control] -

Ergonomically placed 90° pivot 10.4� color monitor Sinumerik 840D-sl or Fanuc 31iB

[ Hydraulic unit ] -F ront-operated hydraulics

[ Work area] - Easily accessible workspace - Optimal chip flow - Guideways fully covered

[ Machine design ] -C ompact machine design, requiring a comparatively small amount of floor space Machine with optional equipment

The Maxxturn 65 is available in a new sheet metal design with a user-friendly textured finish, new colors, and the new Siemens control unit Sinumerik 840 D-sl. Rapid traverses have been increased by over 25% and the turret indexing time optimized in order to achieve reduced ancillary times, short cycle times and to increase productivity.

[ Workpieces ] [ Tool turret ] -1 2-position VDI30 (VDI40) quick-change system - Precise EMCO alignment system - 12 driven tool stations - Servo-controlled - Rigid tapping - Polygonal turning, gear-cutting­ operations, etc.

[ Y axis ] - Travel +/–40 mm (1.6”) - 90° implemented in the machine construction - Large distance between guide rails - Stable and compact construction without restrictions

Drive pulley (Aluminum)

Chain wheel adapter (Aluminum)

[ NEW ] - New sheet metal housing with a textured finish in new colors

Adjustor sleeve (Stainless steel)

[ Machinecover ] -

All-round protection from chips 100% coolant retention Large safety glass window in door Clear view of the work area Built-in buttons for operator convenience

Distributor (Steel)

[ Engineering ]

Highlights � Extreme machining precision � Siemens Sinumerik 840D-sl control unit, also

available with Fanuc 31iB control unit

� Highly stable Y axis with large travel � Very compact machine layout � Simple, dialog-supported programming � Made in the Heart of Europe

Tool turret. Fast 12-station servo tool turret for VDI30 or VDI40 tools. All stations can hold driven tools for drilling, milling and ­tapping. The operator is able to control the indexing speed with the override switch at any time.­

Tool measurement tracer. The measurement tracer mounted in the work area of the MAXXTURN work area makes it possible to measure the tools in the turret while in the machine. It can be swung in and out automatically using a button or an M function.

Part pick-up device. Finished parts are transported from the counter spindle to the finished parts holder with the part pick-up device. This proven EMCO concept with the pivoting pick-up tray ensures optimum accessibility to the work area, free chip flow, and the gentle removal of the finished parts.

Tailstock. In this model, the tailstock is mounted directly on the roller slides rather than on the counter spindle and can be automatically positioned within a range of 500 mm. The live centre is included directly in the machine taper mounting. This removes the need for an additional quill.

Y axis carriage. The 90° offset machine base with the broad-based, prestressed guide rails ensures short overhangs and top stability for complete machining.

Versions EMCO MAXXTURN 65 MT 65 with tailstock MT 65 M with tailstock, C axis, and driven tools MT 65 MY with tailstock, Y and C axes, and driven tools MT 65 SM with counter spindle, 2 C axes, and driven tools MT 65 SMY with counter spindle, Y axis, 2 C axes, and driven tools

100

10 M (S6-40 % D.C.)

50

M (S1-100 % D.C.)

5

0

0 0

1000

2000

3000

4000

M (Nm)

6000

Leistung und Momentenverlauf Werkzeugwender VDI30

Power n (rpm)

Leistung und Momentenverlauf HT 665 Hauptspindel

P (kW)

300

5000

30

P (S6-40 % D.C.)

M (Nm)

P (kW)

150 250

20

150

15

100

20

150

15

100

10

50

M (S1-100 % D.C.)

15

2000

3000

5

4000

5000

0 0

6000

1000

2000

3000

4000

5000

3 2

P (S6-25%D.C.)

1

0

M (S1-100 % D.C.) 0

0 1000

4

5

5

0 0

M (S6-40 % D.C.)

5

10

10

50

6,7 6

20 P (S1-100 % D.C.)

M (S6-40 % D.C.)

P [kW] M (S6-25%D.C.)

25

200

P (S1-100 % D.C.) 200

M [Nm]

25

P (S6-40 % D.C.)

25

6000

0 0

7000

1000

2000

3000

4000

Motor characteristics for counter spindle

Motor characteristics for main spindle M (Nm)

5000

n [rpm]

n (rpm)

n (rpm)

Tool turret motor characteristics for driven tools

P (kW)

150

25

P (S6-40 % D.C.) 200

20 P (S1-100 % D.C.)

150

15

100

10

[ Spindle motor ] 50

M (S6-40 % D.C.)

5

M (S1-100 % D.C.)

0

0

Water-cooled hollow spindle motor for the main and counter spindles

0

1000

2000

3000

4000

5000

6000

7000

n (rpm)

[ Tool turret ]

[ Y axis ]

12-position tool changer VDI 30 (VDI 40) radial for up to 12 driven tools

Y axis integrated into the machine as an extremely stiff element

[ Guide rails] Wide-set guide rails for high stability, including on the counter spindle

[ Roller guides ]

[ Ball screws ]

Linear, preloaded roller guides in all axes for high rapid-motion speeds

Ball screws in all axes make high feed forces possible

[ Machine base ] Extremely low torsion, steel/welded machine base

Work area

Installation plan

Specifications in millimeters

Individual automation Tailor-made solutions. Unmanned or minimally staffed manufacturing is the task - and EMCO has numerous tailored ways of providing it. For preshaped blanks and parts with larger diameters than the spindle clearance, EMCO offers a high-performance loading system for fully automatic loading and unloading. This has been conceived as one unit with the machine and impresses with uninterrupted operation and very short loading times. It is activated using the control unit. For producing serial workpieces from bar stock, there is a short-bar loader and a 3-meter bar loader.

Workpiece magazine Pallet attachments for all raw parts enable the positioned loading of parts into the machine and raise the number of loadable parts for unmanned production. Changeover times are reduced or eliminated thanks to the perfect adjustment to the customer’s parts.

12-position pallet fixture for oriented pick-up of diecast connector parts

9-position pallet fixture for oriented pick-up of die-cast threaded connections

20 pallets on the magazine table with customerspecific fixtures

Customizing options: The MAXXTURN Gantry loader is a universal loading and unloading device for preformed raw parts of all kinds.

EMCO Automation can equip it according to your individual needs with numerous gripper and handling systems. How we do it: we standardize the components and customize the solution. The goal: a custom tailored machine for the same price as a standard unit.

2 x 3 jaw double-gripper head

4 x 3 jaw gripper head

Shaft gripper head

[ Emco Top Load 10-65 ]

Short and to the point In view of the ever-increasing pressure on floorspace for machines, EMCO has developed the most compact short loader on the market: the EMCO LM1200.

Finished part conveyor The finished-part pick-up device puts the parts on an accumulating conveyor. A discontinuous belt ensures that the often very complex parts do not fall onto each other.

Unloading through the counter spindle Long, slender workpieces can be removed from the machine through the counter spindle.

Long parts can be stored in different ways. Finished pieces can simply be rolled onto an inclined surface or stored in a lateral magazine using a discontinuous belt.

EMCO tool break monitoring The tool status is monitored by evaluating the load on the various axis drive motors. Excessive loads point to wear or broken tools. Too little load indicates a tool is missing.

Band filter with high-pressure coolant pumps A coolant pressure of 25/40/60 or 80 bar can be set as needed. This enables coolant-fed drilling and milling tools to be used to their best advantage.

Quality components

[Machine bases and slides] When matching components, we place great value on high stability, good damping characteristics, and a thermoneutral design. We achieve high stability through a shorter force flow, thermal stability through symmetry, and dampening through the materials and interfaces selected.

www.emco-magdeburg.de

[Tool turret]

[Clamping cylinder / chuck] Hydraulically activated clamping cylinders and chucks guarantee the precise, safe clamping of work pieces.

Programmable sensors are used for stroke monitoring. There is no need for time-consuming adjustments of contactless limit switches.

[Tool holder] Innovative, fully developed tool holder systems form the basis for costeffective machining. High changeover accuracy and stability result in short setup and cycle times.

Rapid-indexing turrets with adjustable swivel speeds and milling drives represent the current state of the art. The backlash-free milling drive is not only ideal for milling and drilling, but also for rigid tapping, hobbing, and polygonal turning.

www.roehm.biz

www.wto.de

www.sauter-feinmechanik.com

[Chip conveyor]

[Coolant pumps]

Slat band conveyors allow for flexible implementation and the safe removal of chips. A monitored overload clutch prevents damage from improper use.

Low-maintenance immersion pumps for pressures of up to 25 bar and flow rates of up to 1500 l/min provide optimum conditions for machining and enable reliable chip transportation.

www.knollmb.de

www.grundfos.at

[Headstocks] The design and manufacture of headstocks are two of EMCO‘s core competencies. During engineering, the focus is on precision, robustness, high rigidity, precise rotational characteristics, and a long service life.

www.emco-magdeburg.de

[Hydraulic systems] Compact dimensions, quiet operation, and high energy efficiency - just some of the advantages of the hydraulic assemblies used by EMCO. Monitored pressure switches prevent the need for time-consuming manual pressure adjustments.

[Ball screws and roller guides] Highly precise and generously dimensioned guide rails and ball screws with optimal pretensioning form the basis for the machining of precision parts.

www.hawe.de www.boschrexroth.com

Minimum use of resources for maximum profit.

E[M]COLOGY Designed for Efficiency

At EMCO, we take a consistent, responsible approach to the use of resources in machine tools in order to safeguard long-term investments. From the development of our machines through to their construction and manufacture, we place a strong focus on the sensible and sparing use of raw materials and energy.

This enables us to achieve parallel savings in two areas: 1. Reduction in the basic power consumption of machine tools, e.g. assemblies are switched on and off as required and the installed connected loads are kept to a minimum.

2. Reduction in variable consumption: This can be seen in the lighter axes, energy recovery system, increased rate of good parts, and the shorter process chain enabled by complete machining.

Through these measures, which are constantly being refined and further optimized, EMCO truly demonstrates that its slogan of „Designed for your Profit“ is not just an empty promise: EMCO products help save the environment and provide intelligent customer savings without compromising on quality and flexibility.

[Regenerative drive system]

[Compact hydraulics unit with pressure accumulator]

[Roller guides]

Kinetic energy is converted into electrical energy and fed back into the grid.

Savings of up to 10%

Thanks to its accumulator charging system, the pump only runs when required. If the pressure accumulator is full, the pump switches over to closed loop circulation.

Savings of up to 90%

Extremely low friction losses thanks to rolling friction.

Highly dynamic performance with minimal lubricant consumption.

Savings of up to 50%

10

90

50

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%

[Structurally optimized mechanics]

[Highly efficient motors]

[Synchronized chip conveyor]

FEM analysis is used to optimize the relevant components in terms of their rigidity while simultaneously reducing their weight.

Savings of up to 10%

The use of energy-efficient motors (IE2) in the coolant preparation area guarantee highly cost-effective operation.

Savings of up to 10%

Programmable interval times enable optimal use of the chip conveyor independently of of the machining process.

Savings of up to 95%

10

10

95

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%

[Intelligent standby concepts]

[Virtual machine]

[Intelligent energy management]

Reduced consumption by automatically switching off ancillary units and machine space/screen illumination after a defined period of inactivity on the control panel.

Savings of up to 50%

Significant reduction in the setup and running-in times on the machine through the use of highly developed simulation and programming software.

Savings of up to 85%

Intuitive data entry screens for activating the individual energy-saving functions.

Savings of up to 70%

50

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%

85

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%

70

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100%

[ Technical Data]

Work area Swing over bed Swing over slide Distance between centers on tailstock version Main spindle / counter spindle distance Maximum turning diameter Maximum part length Maximum bar diameter Travel Travel in X / Z Travel in Y

Main spindle Speed range Maximum drive power Max. torque on the spindle Spindle nose DIN 55026 Spindle bearing (inner diameter at front) Spindle bore hole Counter spindle Speed range Maximum drive performance Max. torque on the spindle Spindle nose DIN 55026 Spindle bearing (inside diameter at front) Spindle bore hole C axes Round axis resolution Rapid motion speed Tailstock Tailstock travel Maximum thrust Maximum travel speed Tailstock bore taper

610 mm (24”) 360 mm (14.2”) 682 mm (26.9”) 840 mm (33.1”) 500 mm (19.7”) 550 mm (21.6”) 65 (76) mm (2.6 (3)”) 260 / 610 mm (10.2 / 24”) 80 (+ / –40) mm (3.1 (+ / –1.6)”) 0 – 5000 (0 – 4000) rpm 29 kW (38.9 hp) 250 Nm (184.25 ft·lbs) KK 6 (KK 8) 105 mm (4.1”) 73 (86) mm (2.9 (3.4”) 0 – 7000 rpm 22 kW (29.5 hp) 130 Nm (95.8 ft·lbs) KK 6 85 mm (3.3”) 53 mm (2.1”) 0.001° 1000 rpm 500 mm (19.7”) 8000 N (1798.4 lbs) app. 20 m/min (787.4 ipm) MT 4

Tool turret Number of tool positions (all driven) 12 VDI shaft (DIN 69880) 30 mm (40 mm) (1.2 (1.6)”) Tool cross-section for square tools 20 x 20 (25 x 25) mm

(0.8 x 0.8 (1 x 1)”) Shaft diameter for boring bars 32 mm (1.3”) Tool indexing time 0.7 sec.

Driven tools DIN 5480 Speed range 0 – 5000 rpm Maximum torque 25 Nm (18.4 ft·lbs) Maximum drive power 6.7 kW (9 hp) Feed drives Rapid motion speed X / Y / Z 30 / 15 / 40 m/min

(1181.1 / 590.6 / 1574.8 ipm) Feed force in the X / Y axes 5000 / 7000 / 7000 N (1124 / 1573.6 / 1573.6 lbs) Feed force in the Z2 axis (counter spindle) 8000 N (1798.4 lbs) Positioning scatter Ps VDI 3441 in X / Y / Z 3,5 / 3,5 / 4 µm

(0.00014 / 0.00014 / 0.00016“) Coolant system Tank volume 230 liters (50 gal) Pump power (optional) 0.57 (2.2) kW

(0.76 (2.95) hp) Power consumption Connected load 38 kVA Compressed air 6 bar (87 PSI) Dimensions and weight Height of spindle center above floor 1150 mm (45.3”) Machine height 2050 mm (80.7”) Machine footprint L x D 3320 x 2070 mm

(130.7 x 81.5”) Total weight approx. 5700 kg

(12566.2 lb) Safety devices CE compliant

ZERTIFIZIERT EN ISO 9001 ZERTIFIKAT NR. 20 100 20419

TÜV AUSTRIA CERT GMBH

www.emco-world.com

EMCO MAIER Ges.m.b.H. Salzburger Str. 80 . 5400 Hallein-Taxach . Austria Phone +43 6245 891-0 . Fax +43 6245 86965 . info@emco.at

EN4357 . 07/14 . Technical modifications reserved. Errors and omissions excepted.

Emco MAXXTURN 65