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VL -Series: Modular Manufacturing Solutions
VL -Series: Modular Manufacturing Solutions
Versatility, reliability, precision and efficiency are all elements of an ideal manufacturing process. The new VL-Series of machines from EMAG offers these with the added benefits of a small footprint and our signature integrated, self-loading automation. With a best in class life cycle ownership, the high performance of the EMAG VL-Series offers machining solutions for chucked components ranging from 20 to 400 mm in diameter.
The VL Platform includes the VL 2 Modular Standard Machine, VL 2 with the additional option of a Y-axis, and VLC 100-P featuring a double spindle arrangement for chip-to-chip times of less than one second. To ensure your needs are met, the platform has widened its range of applications to include turning, hard turning, ID grinding, OD grinding, and hobbing of both gears and shafts, all capable of being integrated into existing production, or combined to create new, complete manufacturing lines.
For more information on the entire VL-Series, please see our E-book here.
Manufacturing Systems for Precision Metal Components
EMAG equipment covers the entire spectrum of machining processes in the metalworking industry, offering the latest technological advances in turning, drilling, milling, grinding, gear cutting, electro-chemical machining, preheating and joining, induction hardening and laser welding. Active in the automotive, oil field, power generation aerospace and large equipment industries, EMAG is a trendsetter in the field of vertical turning centers, multi-spindle machining centers and multi-functional production machines. The German based company is an important partner in the realization of complete manufacturing lines with turn-key solutions and has recently launched its modular series of machines for both stand-alone and integrated manufacturing solutions.
Drivers are already used to the sixth gear and the development continues. There are plans afoot for an automatic gearbox for a 9-gear transmission system, since it allows the car to be driven at optimal speeds for longer intervals, thus saving fuel. With continuing pressure to optimize, high volume gear production must become faster and cheaper and the EMAG Group has demonstrated their solution to this challenge: the VLC 200 H Vertical Hobbing Machine that adds a new dimension to productivity levels.
According to the German Federal Statistical Office, the German transmission sector generated a combined turnover of over 17 billion EURO last year alone, with a continuing upward trend. Consistently increasing production volume keeps the industry firmly in the mind of production planners, especially those in the automotive industry, where demand rises for faster, more efficient production. Yet they want guarantees that quality is maintained despite an increasingly demanding component. This comes as no surprise, considering transmission technology accounts for a large percentage of research costs in the automotive industry according to experts.
The modular platform in action
KOEPFER, a subsidiary of EMAG, is no stranger to this dynamic. Not just a supplier of machines for the high-quality gear production, KOEPFER is also a competent partner for anything to do with the gear. For decades now they have invested heavily in industry developments. A product of close collaboration within the EMAG Group, the VLC 200 H is the latest result of these efforts. The VLC 200 H vertical hobber is the first KOEPFER machine based on the new modular standards of EMAG, bearing the name of the new standard machine platform that represents a new generation of machine tools for use in a range of greatly varying applications. This “modular approach“ is of great advantage when it comes to establishing a highly efficient production system for the transmission industry, as it allows for the individual processes used in the soft machining of a gear, from turning of the raw part to hobbing and deburring, to be combined with perfection and without any great outlay for automation. “The machines are easy to interlink, as they are perfectly coordinated and work at the same transfer height,” explains Jörg Lohmann of KOEPFER.
Short cycle times
A closer look at the VLC 200 H hobbing machine reveals a technology that offers the user great economic advantages, even in its stand-alone version. The machine features high-performance drives offering top main spindle and hobbing speeds. Gears of a maximum diameter of 200 mm and module 4 can be dry-milled at greatly shortened cycle times. Removal of the hot chips generated by the process is of no concern on vertical machines, as they fall unhindered into the chip conveyor below. The typical EMAG pick-up design principle also minimizes idle times. The main spindle removes the raw-part from the conveyor belt, transfers it to the tailstock – where it is firmly supported during machining by a tailstock flange – and removes it from the machining area after completion of the hobbing cycle. This integrated automation concept with short travels not only makes for efficient speeds, but also guarantees a high degree of machine availability.
The VLC 200 H also guarantees exceptional and consistent component quality. This it owes, in part, to the vibration-resistant polymer concrete MINERALIT® machine base. An optional measuring probe can be integrated into the machining area and used for either positioning tasks or the measuring of finish-machined components. “It even allows us to carry out adjustments in the machining process. In fact, the whole machine provides added value with its integrated production process quality control,” Lohmann states.
Production system flexibility
Designed on the basis of a modular platform, production planners have a choice where this automated high-efficiency package is to be integrated into a manufacturing system.. They can choose directional component flow, recirculating automation or the “chaku-chaku” principle. A processing concept, meticulously planned by EMAG experts, ensures the lowest cycle times: after turning of the raw parts on an EMAG VL 2 the gear cutting process is carried out on the VLC 200 H, with the final deburring and single-sided chamfering process following on the VLC 100 D. All these machines are designed on the “modular standard” basis from EMAG. The gearing is generated in a single cut and followed only by chamfering, in comparison to alternative production solutions that rely on a second cut after chamfering. Cycle times for the machining of gears will drop dramatically with modular EMAG solutions and KOEPFER technology.
Mr. Lohmann considers the market opportunities for the VLC 200 H from KOEPFER as positive: “When it comes to optimizing large-volume gear production or developing processes, we offer a highly efficient solution with integrated automation that can be configured a number of different ways. It should signal a new, interesting approach to production planners.”
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Five axes + turret with up to 12 tools + automation + optional changer OP10/OP20
The VL 2 P is a two-spindle vertical turning machine with pendulum technology for parts that have a diameter of up to 100 mm. The working spindles on the VL 2 P are mounted on the left and right of the machine body and complete the Z movement. The tool turret is located at the front and moves in the X-axis.
The main focus during the design of the VL 2 P was on reducing idle times. Non-productive times in the machine due to loading and unloading have been almost completely eliminated. The machine is ideal for workpieces with short machining times since the ratio of machining time to idle time is vital for the economy of the process.
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April 2014 Product Spotlight: Turning
Click through this month’s product slideshow featuring lathes and turning centers.
Vertical Turning Machine Integrates Automation Features
Emag’s VL 8 pick-up turning center is capable of turning larger workpieces ranging to 400 mm in diameter, such as components for powertrains of semi-trucks, excavators and buses.
Vertical Hobber Enables High-Volume Gear Production
The VLC 200 H vertical hobber from Emag is designed for flexible, high-volume gear production as part of a modular system.
An Electrochemical Option for Blisks, Blades
This machining platform offers the non-contact electrochemical/precision electrochemical processes for five-axis milling of turbine engine blades and blisks.
Emag Adds Staff
Two new employees will provide sales leadership in their respective markets.
Solid-State Welding Machines Use Less Energy
The ELC series of solid-state welding machines from EMAG is capable of creating a carefully dosed amount of energy emitted by the laser beam on the welding point to minimize warping.
Emag Supports Michigan Manufacturing Education
The company is participating in two training initiatives.
Vertical Pick-Up Lathe for Small Components
Emag will display its VL 2 vertical pick-up turning machine for small chuck components ranging to 100 mm in diameter and measuring as long as 150 mm.
Vertical Turning Machine Provides Four-Axis Machining
Emag’s VT 2-4 vertical turning machine is capable of machining shafts as long as 400 mm and ranging to 63 mm in diameter.
ECM System Designed for High-Precision Applications
Emag offers the Comfort Standard (CS) electro-chemical machining (ECM) system.
Machine Combines Hard Turning, Grinding
Emag’s VLC 250 DS combines vertical hard turning and finish grinding in one setup on a single machine.
Four-Axis Vertical Turning Center for Shaft Production
Emag’s VTC 100-4 four-axis vertical turning machine is designed for the production of shafts ranging to 400 mm in length and 63 mm in diameter.
A Preview of Houstex 2013
This slideshow provides a sneak peek at some of the technologies that will be on display at Houstex 2013.
Turning Machines for Threading Applications in the Oil and Gas Industry
Emag’s USC turning machines are designed for pipe thread applications in the oil and gas industries.
Vertical Pick-Up Turning Machine for Large Parts
Workpieces as large as 100 mm in diameter can be completely machined on Emag’s VL 2 P, a two-spindle vertical turning machine.
Grinding Center Can Accommodate Two Spindles
Emag’s VLC 100 G vertical grinding center is designed for small chucked components with a maximum diameter of 100 mm.
Video: Two-Spindle Inverted Vertical Turning
See how Emag's vertical turning center reduces "nebenzeit."
Suffering from Nebenzeit?
“Nebenzeit” is German for non-productive time.
Automatic loading and unloading is a central design principle of the vertical turret lathe.
Turning and Grinding Combined
The VSC 400 DDS vertical grinding and turning center from Emag accommodates complex parts with diameters as large as 400 mm