Turn-key
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[ EMCO Automation ]
The EMCO swing loader. The integrated solution. Tailor-made solutions. What would highly flexible universal lathes be without the features afforded by modern automation technology? EMCO has a range of bespoke solutions for unmanned or minimally staffed manufacturing. For pre-formed blanks and parts with a diameter larger than the spindle capacity, we offer an integrated swing loader for fully automatic loading. This has been conceived to work together with the machine as one harmonious unit and is characterized by uninterrupted operation and very short loading times. It is activated using the control unit.
[ Chain feeding system] [ Swing loader]
Gear wheel (Hard machining/steel)
[ Finished parts conveyor]
Ball stud (Steel)
Connector housing (Aluminum)
Maximum output minimum space. The EMCO swing loader is a universal loading device for all types of preformed blanks. It can be highly customized in line with individual customer requirements. Numerous gripper and handling systems are available. How we do it: We standardize the components and customize the solution. This results in a custom-tailored machine for the same price as a standard unit.
[ Chain feeding system]
[ Swing loader] [ Finished parts conveyor]
Feeding systems for blanks Feed systems specific to particular blanks allow preformed workpieces to be loaded into the main spindle in the correct orientation, which enables economical unmanned operation.
Chain feeding system for oriented loading of blanks with a large storage capacity.
Multiple infeed chutes for rotationally-symmetrical blanks; the length of the blanks determines the number of infeed chutes.
Chain feeding system with V-supports for preformed shaft parts of various shapes
Multiple infeed chutes for loading rotationally symmetrical blanks. A sensor monitors the availability of blank parts for each infeed chute.
Shaft gripper for automatically loading pre-formed shafts
Fully automatic shaft loading. Feed-in via a chain feeding system. Removal via the finished parts collection device.
Customization: A wide range of gripper and handling systems are available.
2-finger gripper with 180째 rotary module for loading vertically fed blanks
2-finger toggle lever gripper for loading shaft parts
Parallel grippers with 180째 turning module for loading shaft parts (1st and 2nd clamping cycle)
The EMCO gantry loader. The universal solution. The perfect combination. Decades of experience, constant innovation and ongoing refinement have made the EMCO gantry loader one of the fastest and most flexible handling systems on the market. The machine and gantry are constructed by EMCO to match each other perfectly. This results in precise, rapid integration of all units and uninterrupted processes. Our gantry enables the automatic loading of both preformed flanged parts and shaft parts. Manufacturing time can also be reduced significantly through the use of additional features such as a measurement station, marking station, filtering tank, or even mounting assemblies – a sure-fire route to economical manufacturing, even in high-wage countries.
[ Gantry loader]
[ Pallet magazine (20 station)]
Water fitting (Brass)
Sprocket wheel adapter (Aluminum)
Sprocket wheel (Steel)
The gantry loader offers maximum flexibility. Tailor-made solutions. EMCO has a range of bespoke solutions for unmanned or minimally staffed manufacturing. For preshaped blanks and parts with diameters larger than the spindle clearance, EMCO offers a high-performance loading gantry for fully automated loading and unloading. Designed as a compact unit, the machine and gantry loader guarantee uninterrupted operation and very short loading times. It is activated using the control unit. A short-bar loader and a 3-meter bar loader can be used to produce serial workpieces from bar stock.
Profile: EMCO gantry loaders significantly reduce the time required for manufacturing processes and enable a large increase in efficiency. They are optimally aligned to the individual machine, resulting in an integrated, highly productive system.
Gripper heads
Pallet attachments
2x3-jaw double-gripper head
4x3 jaw gripper head
Shaft gripper head
4-station pallet attachment for valve caps
6-station pallet attachment for articulated brackets
20-station pallet magazine with customer-specific pallets
20-station pallet magazine with customer-specific pallets
Technical data Traverse speed
Workpiece dimensions for 4 x 3 jaw gripper
Horizontal
120 m/min
Max. diameter
120 mm
Vertical
60 m/min
Max. length
100 mm
Max. weight
5 kg
Workpiece dimensions for 2 x 3 jaw gripper
Workpiece dimensions for 2 x 2 jaw gripper
Max. diameter
220 mm
Max. diameter
100 mm
Max. length
100 mm
Max. length
300 mm
Max. weight
10 kg
Max. weight
10 kg
Everything from a single source. The EMCO loading gantry solution provides maximum flexibility in terms of weight and machine size. It allows the integration of various automated systems such as a shaft conveyor, circulating magazine, robot, or measurement station. This enables various combinations of minimally staffed complete solutions to be implemented in line with customer requirements.
[ Control] [ Gantry axes ] -
Robust mechanism Safety brake Central lubrication system Optional: H-loader, machine connection
- Ergonomically placed and pivotable - Multi-channel for machining and parts handling - Siemens 840D-sl incl. ShopTurn - Color LCD monitor - USB interface - Ethernet connection
[ Tool turret] - 12-position VDI 40 - 12 tool adapters with coolant feed (block tool) - Synchronized thread cutting and polygonal turning as standard
[ Blank conveyor / finished parts conveyor] - Shaft conveyor (shown) - Circulating magazine
[ Gantry ]
[ Hydraulic unit]
-
- Ergonomic operation - Automatic pressure monitoring - Compact and low-maintenance
Electric shaft gripper Adjustable gripping force Position monitoring via NC axis No compressed air required
Drive shaft (Steel/C45)
Gantry loader offers maximum flexibility: For Maxxturn 95 and 110, Hyperturn 110 The benefits ■ ■ ■ ■
Large number of individual applications For fully automated loading and unloading Complete solution for uninterrupted operation Short loading times
[ Y axis] - Travel +80/-60 mm - 90° implemented in the machine construction - Large distance between guide rails - Stable and compact construction
[ Chip conveyor] -
Slat band conveyor Ejection height 1200 mm 350-liter coolant volume Included in the basic model
Technical data: Traverse speed Horizontal
80 m/min
Vertical
40 m/min
Application example: Maxxturn 95 Workpiece dimensions for flanged parts
Workpiece dimensions for shaft parts
Max. diameter
250 mm
Max. diameter
180 mm
Max. length
100 mm
Max. length
800 mm
Max. weight
25 kg
Max. weight
150 kg
Flexible and change-over friendly auto EMCO Vertical Turn machines. The user saves costs and programming time involved with automation equipment thanks to the integrated pick-up system that loads the chuck with parts up to a diameter of 160 mm. Short cycle times and the ample parts storage guarantee short chip-to-chip times of up to 5.5 s for two-track loading. The various flexible feeding systems facilitate the integration into production lines: pallet, drag frame or chain conveyor belts.
The benefits ■ Flexible automation: for both heavy and light parts, ample and low parts storage ■ Individual customer requests, such as pallets, drag frames, conveyor belts, and the integration of feed systems can be implemented easily
■ Short travels allow short loading times
omation solutions for Perfect Automation and integration are parts of the performance offered by the new vertical lathe VT 400 (for chuck parts with up to 400 mm clamping diameters). The automation concept enables customer-specific solutions. Since the pick-up system removes the need for additional loading systems for workpieces, machine linkage and technical adaptation are easily made to fit any customer’s individual needs.
■ Quick loading through direct pick-up for high productivity ■ Simple automation solutions for maximum flexibility ■ Small footprint of machine and automation ■ Access to automation: easy to change over and maintain
The EMCO Compact Loads. Perfect teamwork. Low price. Strong performance. "Design to cost" was the primary aim when developing the EMCO E-series. These loaders intentionally do not include a dedicated control unit and are instead controlled directly by the machine control system. This results in an unbeatably low price for the entire package - including parts catchers, alarm lamp, and interface. Of course, we also provide tailored bar loader packages for our EMCOTURN E25, E45 and E65. The technology. The loaders in our E-series can be used immediately as a "plug-and-play" solution. Their extremely small footprint enables processes to be automated even if space is tight. All loaders offer comprehensive cycle support and are perfectly aligned to the spindle lengths in the individual machines. Changing over to different bar diameters requires only minimum effort and the loaders can also be used to load individual workpieces.
The benefits ■ Smaller footprint ■ Easy to use ■ Short feed times ■ Fast, straightforward changeover ■ Option to load individual workpieces ■ Central diameter adjustment ■ Ergonomic EMCO design
The EMCOTURN E65 with EMCO COMPACT LOAD E65 A clever "plug-and-play" solution with comprehensive cycle support
The EMCOTURN E25 with EMCO COMPACT LOAD E25 25 The most compact machine design for fully automatic processing of bar material up to ø 25 (51) mm.
Technical data
COMPACT LOAD E25
COMPACT LOAD E45/E65
Bar diameter
Ø 25 (51) mm
Ø 8 – 65 mm
Max. bar length
800 mm
1100 mm
Min. bar length
100 mm
150 mm
Material support
approx. 550 mm
approx. 550 mm
Feed rate
0 – 60 m/min
0 – 60 m/min
Bar change time
approx. 10 sec.
approx. 12 sec.
Dimensions (L x W)
1200 x 1100 mm
1700 x 1100 mm
Weight
approx. 330 kg
approx. 535 kg
The EMCO short bar loaders. Universal, high-performance. Short and to the point. Faced by ever-increasing pressure on floorspace for machines, EMCO has developed the most compact short loaders on the market: The EMCO LM800 and EMCO LM1200/1500 are the perfect solution for automatic feeding and loading of cut-to-length bars. The key advantages are a small footprint and rapid loading times resulting from shorter strokes. The technology. The loaders in our LM series can be used immediately as a "plug-and-play" solution. Their extremely small footprint enables processes to be automated even if space is tight. In contrast to the EMCO COMPACT LOADs, the loaders in the LM series are fitted with their own control units, which also enables the loaders to be used together with other machines. The controls are perfectly coordinated with the machine interfaces, which are identical on all three models. All loaders offer comprehensive cycle support and are optimally aligned to the spindle lengths in the individual machines. Changing over to different bar diameters requires only minimum effort and the loaders can also be used to load individual workpieces.
EMCO LM800 For use with MAXXTURN 25/45.
EMCO LM1200 Compatible with the machines EMCOTURN E65-BB, MAXXTURN 65, HYPERTURN 45, HYPERTURN 65.
Infeed of profile bar stock using a chain feeding system (option)
The benefits ■ Smaller footprint ■ Easy to use ■ Short feed times ■ Fast, straightforward changeover ■ Option to load individual workpieces ■ Central diameter adjustment ■ Dedicated control ■ Ergonomic EMCO design
Technical data
LM800
LM1200
LM1500
Bar diameter
Ø 6 – 52 mm
Ø 8 – 65 mm
Ø 16 – 95 mm
Max. bar length
800 mm
1200 mm
1500 mm
Min. bar length
100 mm
150 mm
150 mm
Material support
approx. 550 mm
approx. 550 mm
approx. 550 mm
Feed rate
0 – 60 m/min
0 – 60 m/min
0 – 60 m/min
Bar change time
approx. 10 sec.
approx. 12 sec.
approx. 14 sec.
Dimensions (L x W)
1200 x 1100 mm
1700 x 1100 mm
2000 x 1100 mm
Weight
approx. 330 kg
approx. 535 kg
approx. 550 kg
EMCO TOP LOAD. The premium class. Quality by the meter. The EMCO TOP LOAD series was designed to automatically load 3-meter long bar stock into EMCO machines. Loaders are available for diameters of 4 - 25 mm, 8 - 42 mm, and 10 - 65 mm. The oil-coolant-fed loading channel, lined with plastic shells, reduces vibrations to a minimum, even at high speeds. Bar stock is fed in via a servo motor which controls both the speed and feed force. A patented guidance system with several guide rests guarantees optimum feed quality. Time-consuming conversions and channel changes are a thing of the past. The bar loader can be switched from one diameter to another within one or two minutes.
EMCO TOP LOAD 10-65/3300 in the MULTI-LEVEL version. Multiple material supports enable even longer unmanned operation.
EMCO TOP LOAD 8-42/3200 in the SINGLE LEVEL version. Pieces of bar stock are laid on a slanted feed track (350 mm) and fall into the guide channel one by one.
EMCO TOP LOAD 4-25/3300 in the SINGLE LEVEL version. Pieces of bar stock are laid on a slanted feed track (350 mm) and fall into the guide channel one by one.
[ Technology]
The benefits ■ Optimized length through use of a releasable feeder ■ Programmable diameter adjustment on the control panel ■ Servo-controlled feed motor (programmable) ■ Oddments ejected to the front or rear ■ Longitudinal sliding unit (approx. 800 mm) ■ Quick-change systems result in lower changeover effort ■ Extremely short setup time of just 1 to 2 minutes ■ No changeover sets required thanks to the patented guidance system
■ Includes installation accessories
Standard guide rests (8-42 and 10-65) Integrated and automatic travelling guide rests center the bar stock at several points and enable to material to be fed through in the optimal manner. A patented system with great results: High rotational speeds, economical cutting data, and excellent productivity.
Standard guide rest (4-25) When machining smaller items of bar stock, the integrated guide rest ensures improved centering and reduces vibrations.
Accessories The feed grippers are placed in the loader to match the bar width. A quick-change system ensures that the system can be changed over quickly and without the need for tools. Steel feed gripper for
Steel-Vulkollan feed grip-
Taper adapter for
ejection of oddments
per is milled according to
forward ejection of
to the rear.
the bar diameter (1 item
oddments (basic confi-
provided in the basic
guration)
configuration)
Technical data
TOP LOAD 4-25/3300
TOP LOAD 8-42/3200
TOP LOAD 10-65/3300
Bar diameter
Ø 4 – 25 mm
Ø 8 – 42 mm
Ø 10 – 65 mm
Max. bar length
3300 mm
3200 mm
3300 mm
Min. bar length
1500 mm
1500 mm
1500 mm
Material support
approx. 350 mm
approx. 200 mm
approx. 350 mm
Feed rate
0 – 100 m/min
0 – 30 m/min
0 – 30 m/min
Bar change time
approx. 30 sec.
approx. 70 sec.
approx. 75 sec.
Dimensions (L x W)
4390 x 867 mm
4310 x 790 mm
4410 x 1090 mm
Weight
approx. 1100 kg
approx. 1200 kg
approx. 2200 kg
Unloading through the counter spindle The length of the workpieces determines the distance between the centers on the lathe. The "unloading through the counter spindle" option enables long workpieces to be manufactured using compact machines with short dimensions. Machined parts, whether round or contoured, are transported onward easily through the counter spindle. Long parts are stored on a sloping surface or on a chain feeding system. This enables the extremely efficient manufacturing of typical shaft parts such as piston rods, cylinder tubes, drills, drive shafts, shock absorbers, and many more. On machines without counter spindles, long workpieces may also be unloaded using modified tailstock slides.
MAXXTURN 45 with unloading through the counter spindle Workpieces measuring up to 1,000 mm in length and up to a maximum of 32 mm in diameter may be unloaded through the counter spindle. Short parts measuring up to 120 mm in length are unloaded through the parts catcher. This system may also be installed on the HYPERTURN 45 (up to ø 45 mm).
MAXXTURN 65 with unloading through the counter spindle Workpieces measuring up to 1200 mm in length and up to a maximum of 54 mm in diameter may be unloaded through the counter spindle. Short parts measuring up to 175 mm in length are unloaded through the parts catcher. This system can also be installed on the HYPERTURN 665.
Machine layout MAXXTURN 45 and HYPERTURN 45 with unloading via the counter spindle
1955
1234
0
2141
1710
377
Details in millimeters
0
1918
4493
0
[ Installation plans] Machine layout MAXXTURN 45 with swing loader 2861 7
n120
8
1200
1171
0
0
4282
3382
11
3018
2587
0
937
1958 1852 1653
3285 3203
4
5
16
17
18
21
2385 2244
3
1745 1541 21
929 2
1
22
4282
2991 3179
2587
1480
632
0
0 20
14
13
23
22
23
23 A7124622 F1Z2003 21 A7126120 A7126019 A7126018 A7126017 A7126016 A7126015 A7126014 A7126013 A7126012 A7126011 A7101310 9 8 215276 7 R7Z030 6 A707434 5 A711934 R2Y6410 3 S4Y6000 2 S4Y6200 1 S4Z3000 Pos. Zeichn.Nr. Z
15 13
15 3
Machine layout HYPERTURN 45 with swing loader
Details in millimeters
[ Installation plans] Machine layout MAXXTURN 65 with gantry loader 3779
2524 2231
1800 installation space for chip conveyor
1650 1197
1085
0
0
970
620
3759 3572 2945
3759
2115 1874 1234 983 12,5
D
roh
F
3,2
F
F
schruppen
0,8
F Name
0
Gezeichnet Norm gepr.
7893
6094
5539
4633 4944
1650
1252
0
Nr.
Änderung
Datum
Oberflächenschutz :
Maßstab
Untolerierte Maße nach DIN / ISO
1:30
2768mK / 6930 / 8570BF 79 Unterstrichene Maße nicht maßstäbl. gez.
Für diese Zeichnung
_
Name
Änd.Nr.
schlichten
Prototyp
0,4
feinschlichten
Geprüft
hoellbam
schleifen
Datum 19.11.2010
ZV: Datumsstempel / Unterschrift
Rohteil-Nr:
Werkstoff:
Masse:
_
Teil-Benennung:
Zeichnungs Nr.:
_ _ Blatt:
Machine layout HYPERTURN 65 - POWERMILL with gantry loader
Details in millimeters
[ Installation plans] Machine layout MAXXTURN 95 with gantry loader 5545
2820 2400 2130 1135 750
12888
8888
8060
7460
3131
0
0
0 200
2400
6070
Machine layout MAXXTURN 110 with gantry loader 6115
3200 2780 2523
1260 750 0
0 431 664
3381
16140
10640
9850
9300
3202 3502
0
4590
Details in millimeters
[ Installation plans] Machine layout EMCO COMPACT LOAD E45/E65
Machine layout EMCO LM800
Machine layout EMCOTURN E25 with EMCO COMPACT LOAD
201 190
1198
1583 1420
1115 - 1160
163
1812 1130
1123
1323
1812
1200
250
545
1103
220
327,5 ~1080
383,5
2950 1684
Machine layout EMCO LM1200
Machine layout EMCO LM1500
1334
450 453
1334
645 1012
1040
210 10 5
Maschinenachse
352
1040
645 1012
262
331
348
40
546 - 832 235 418 594
546 - 832
304
500
964 - 1250
285 418 594
Maschinenachse
210 10 5
176
40
500
176
515 405
515 405
964 - 1250
1522
45,3
349
1266
715
1025
157
1705
2005
Details in millimeters
[ Installation plans]
1300-1650
900-1250
Machine layout EMCO TOP LOAD 4-25/3300
739
318.5
616
1767
726
4395
857
Machine layout EMCO TOP LOAD 8-42/3200
Multi-Level
950-1300
1293-1663
980-1350
227
700
3200
486
1340-1700
4386
362
540
426
547
354.5 987
523
980-1350
675.5
786
1652
786
1420-1790
Multi-Level
1420-1790
980-1350
Machine layout EMCO TOP LOAD 10-65/3300
510.5 523
929
4410 1156.5
Details in millimeters
EN4570 . 08/13 . Technical modifications reserved. Errors and omissions excepted.
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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