EMAG VL se­ries of­fers mod­u­lar sys­tem for line pro­duc­tion

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The Ger­many-based EMAG Group cov­ers the en­tire spec­trum of machining pro­cesses in the met­al­work­ing in­dus­try. The com­pa­nies un­der the EMAG um­brella of­fer the lat­est tech­no­log­i­cal ad­vances to op­ti­mize a man­u­fac­tur­ing so­lu­tion for ev­ery cus­tomer’s re­quire­ment. Ac­tive in the au­to­mo­tive, oil field, power gen­er­a­tion, aero­space and large equip­ment in­dus­tries, EMAG is a trend­set­ter in the field of ver­ti­cal turn­ing cen­tres and mul­ti­func­tional pro­duc­tion machines. In In­dia EMAG has bases in Noida, Pune and Chen­nai.

The leader in in­verted ver­ti­cal pick-up lathes, EMAG has in­te­grated its pick-up prin­ci­ple into a wide ar­ray of tech­nol­ogy-spe­cific machines of­fer­ing world-class man­u­fac­tur­ing with a min­i­mal foot­print, short chip-to-chip times and top qual­ity.

Ver­ti­cal pro­duc­tion machines are EMAG’s ter­ri­tory. It all be­gan with the VSC se­ries, which laid the foun­da­tion for the suc­cess­ful ma­chine con­cept of the ver­ti­cal pick-up turn­ing cen­tre. This ma­chine con­cept runs through nearly the en­tire prod­uct range of the man­u­fac­turer, and it takes on its lat­est form in the VL se­ries.

VL machines are part of EMAG’s mod­u­lar stan­dard se­ries. As the term sug­gests, th­ese machines are built on a com­mon ma­chine base but al­low the use of an ex­tremely wide range of tech­nolo­gies, sim­i­lar to the mod­u­lar plat­form sys­tems seen in the au­to­mo­tive in­dus­try. There are now mod­u­lar machines avail­able for turn­ing, gear hob­bing, and cham­fer­ing pro­cesses; for grind­ing (chucked parts and shaft parts); for in­duc­tion hard­en­ing; and also in spe­cial de­signs for laser weld­ing or PECM tech­nol­ogy. Es­sen­tially, they are avail­able for vir­tu­ally all the tech­nolo­gies of­fered by the EMAG Group.

Au­to­ma­tion

The ma­chine base of th­ese mod­u­lar machines is made out of MINERALIT poly­mer con­crete. This ma­te­rial has ex­cep­tional vi­bra­tion damp­ing prop­er­ties, which is the ba­sis for the machines’ ex­cel­lent process qual­ity. The ma­chine base sup­ports a com­pound slide rest equipped with an X-axis and a Z-axis, which al­lows the work­ing spin­dle to move.

The work­ing spin­dle is the heart of the pick-up au­to­ma­tion sys­tem which is an es­sen­tial part of ev­ery mod­u­lar ma­chine. It in­cludes a parts stor­age unit in ev­ery ma­chine, from which the pick-up spin­dle loads and un­loads it­self in­de­pen­dently. This low­ers non-pro­duc­tive time to an ab­so­lute min­i­mum as there are only a few sec­onds be­tween the machining pro­cesses. An op­tional mea­sur­ing probe can be in­stalled di­rectly along­side the load­ing po­si­tion, al­low­ing time-op­ti­mized mea­sur­ing of the parts. The de­sign­ers have thought of ev­ery­thing to make th­ese machines as ef­fi­cient as pos­si­ble.

VL Se­ries

The ver­ti­cal pick-up turn­ing cen­tres of the VL se­ries were de­vel­oped par­tic­u­larly for the pro­duc­tion of pre­cise chucked

parts. There are now 5 ver­sions of the VL ma­chine to cover the widest pos­si­ble range of parts. The small­est ma­chine is the VL 2, de­signed for chucked parts with a di­am­e­ter of up to 100 mm. It is fol­lowed by the VL 4, VL 6, and VL 8 machines which al­low for an in­crease of 100 mm in di­am­e­ter with each model in­crease. Th­ese ad­di­tional mod­els al­low the VL se­ries to cover work­pieces up to 400 mm in di­am­e­ter. Each VL ma­chine is equipped with a tool tur­ret with up to 12 (driven) tools for the machining of chucked parts.

This tur­ret is ex­cep­tion­ally dy­namic; its very fast in­dex­ing cuts non-pro­duc­tive time to a min­i­mum, which in turn re­duces cycle times. The machines can also be equipped with a Y-axis in the tur­ret for the machining of com­plex shapes. This greatly ex­pands the num­ber of pos­si­ble ap­pli­ca­tions of the machines. The fifth ma­chine in the set is the VL 3 DUO with dual spin­dle.

VL 3 DUO

The VL 3 DUO is the first du­al­spin­dle ma­chine in the VL se­ries. Its parts ca­pac­ity places it be­tween the VL 2 and VL 4, al­low­ing high-pro­duc­tiv­ity man­u­fac­tur­ing of chucked parts with a di­am­e­ter of up to 150 mm. It is no co­in­ci­dence that the ma­jor­ity of trans­mis­sion gear­wheels fall into this size cat­e­gory. Ev­ery as­pect of the VL 3 DUO has been de­signed for high-vol­ume pro­duc­tion, which makes it the ideal so­lu­tion for the machining of gear blanks that have to be churned out by the mil­lions.

The VL 3 DUO is pure per­for­mance. In­clud­ing the parts stor­age unit, the VL 3 DUO has a foot­print of no more than 13 square me­ters. That space houses the au­to­ma­tion sys­tem, the parts stor­age unit, and 2 com­plete machining ar­eas, each with its own work­ing spin­dle and its own 12-sta­tion tool tur­ret. This ma­chine is ideal for pro­duc­tion in 2 clamp­ing op­er­a­tions – machining both sides of a work­piece in OP 10 and OP 20, re­spec­tively. Of course, the part needs to be flipped over be­tween the 2 op­er­a­tions. With the Track­Mo­tion au­to­ma­tion sys­tem, EMAG has found an in­ge­nious so­lu­tion for this prob­lem.

Track­Mo­tion

The Track­Mo­tion au­to­ma­tion sys­tem has been spe­cially de­signed for mod­u­lar machines and dras­ti­cally sim­pli­fies the con­nect­ing of mul­ti­ple machines. The ex­am­ple of the VL 3 DUO makes this very clear. The Track­Mo­tion au­to­ma­tion sys­tem is made up of 2 com­po­nents: a track, which is a kind of rail routed be­hind the work area of the machines, and the Tran­sLift, a grip­per sys­tem that runs along on that rail.

This NC grip­per, which is pro­grammed di­rectly through the ma­chine’s con­trol, pro­vides the trans­porta­tion of parts be­tween the machines, as well as to and from the stor­age unit for raw and fin­ished parts. The grip­per has a Z-axis so it can also store the parts three-di­men­sion­ally, on top of each other, in stack­ers. This al­lows a huge num­ber of parts to be stored in a very small space. The grip­per also func­tions as a flipover unit, turn­ing the Track­Mo­tion into a gen­uine all-pur­pose so­lu­tion for the au­to­ma­tion of mod­u­lar machines.

Mod­ern Man­u­fac­tur­ing

EMAG’s VL se­ries of ver­ti­cal pick-up turn­ing cen­tres of­fer a whole range of machines where every­body can find the per­fect tool for their ap­pli­ca­tion. Whether as stand­alone machines, or linked with other mod­u­lar machines, the VL se­ries prom­ises the sta­teof-the-art pro­duc­tion of chucked parts with top of the line qual­ity, at rock-bot­tom unit cost.

The VL 3 DUO comes with the com­bi­na­tion with the parts stor­age unit and the Track­Mo­tion au­to­ma­tion sys­tem.

The Track­Mo­tion au­to­ma­tion sys­tem doesn’t just trans­port the parts but also acts as a flip-over unit be­tween op­er­a­tions.

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