Both new and ongoing developments in the automotive industry tend to focus on increased component complexity. The best examples are lightweight construction, complex geometries and greater functional density. For the manufacturers of production systems in the machining sector, this creates new challenges regarding precision, productivity and, last but by no means least, process integrity. With its vertical concept, EMAG was able to score heavily, particularly in medium and large batch production. The VL 2 P and the VTC 100-4 are the machines with which EMAG has now rounded off their product range downwards.
The external dimensions alone indicate that, with the VL 2 P and the VTC 100-4 for small flange and shaft components, two very special products have hit the market. These machines are just 1,600 mm (VL 2 P) and 2,350 mm (VTC 100-4) wide – and with good reason: this way, it makes it easy to line up and connect a number of these vertical turning machines and not take up too much space. The space-saving process chain has thus become an automatic design concept in the construction of these machines. Operator access to the individual machines is another factor that closely follows this basic requirement. The user can operate all control units from the front, from where he also has easy access to the machining area. At the same time, all important peripherals can be easily reached from the back of the machine – another important point where the intention is to interlink the machines.
Productivity written large
The machine concept clearly favors productivity. The user is being given the opportunity to select the best solution, in the greatest detail, for his particular requirements. For flange machining, for instance, there is the VL 2 P two-spindle vertical turning machine with pendular technology, on which the tool turret swings from workspindle to workspindle in a pendular movement (the "P" stands for pendular). While one workpiece is loaded, another is being machined. This considerably reduces idle times. With cycle times of 20s, even the productivity rates of multi-spindle machines can thus be equalled. And for shaft machining, EMAG offers the VTC 100-4, a 4-axis vertical turning machine.
Even the smallest components can be machined
Both machines feature a 160mm chuck, which allows for the machining of even the smallest turned parts. The largest workpiece diameter is 100 mm on the VL 2 P and 63 mm on the VTC100-4. The maximum turning length of shafts is 400 mm, and the maximum length of chucked components 150 mm. Both machines also rely on the pick-up principle, where the machines quasi load themselves. On the VL 2 P chucker, this task is taken up by the main spindle, on the VTC 100-4 shaft machine by the two turrets.
Well equipped for any machining task
The 12-station tool turret used on both machines is well equipped for any machining task, whereby the VTC 100-4, as a 4-axis machine, features two turrets, of course. All turret stations can be equipped with driven tools with impressive speeds of 6,000 rpm and a torque rate of 22 Nm. On both machines, the interface is a BMT 55; but, on request, both machines can be equipped with a VDI 30 tooling system instead. This ensures that there are hardly any limits when the users choose the required tools. Similarly open and simple in design is the control system for the machines. The user interface remains the same, whatever the chosen CNC. For the machines of the VLxx and VTxx series, the user can choose between the 31i/32i from Fanuc (with integral PLC) and the Sinumerik 840D sl from Siemens (with integral PLC S7-300). This very much simplifies both training and commissioning of the machines.
The advantages of the VL 2 P in summary
• Cycle time-concurrent loading of the main spindles
• Extremely fast chip-to-chip times
• Damping and thermal stability through the machine base in MINERALIT® polymer concrete
• Standardized automation modules ensure great flexibility
• Ideal chip flow conditions, with the chips falling unhindered to the bottom
• The compact machine design provides for a small footprint
• The machining times of the two spindles can be of different length
The advantages of the VTC 100-4 in summary
• Integrated workhandling
• Raw-part and finished component storage sectors form an integral part of the machine
• Use as stand-alone machine or in production lines, as part of a manufacturing system
• The vertical design of the machine and the unhindered chip flow ensure there are no "birdsnest" chip formations
• Short setting and resetting times through easy access and great operator-friendliness
• Reduced investment in sensors owing to the fact that the machine axes are direct driven and modern control technology is used
• Small footprint owing to the compact, vertical design
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