EMCO automation - the swing loader - the integrated solutionEmco automation

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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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