Issuu

EMAG GROUP

Machine Tools and Manufacturing Systems

Turning Chucked Components

Turning Shafts

Milling

Gear Hobbing

Gear Grinding

Cylindrical Grinding

Out-of-round Grinding

ECM/PECM

Laser Processing

TECHNOLOGY. CONNECTED.

www.emag.com

EMAG GROUP At Home Around the World Based in the heart of Europe, EMAG has been a leading manufacturer of CNC machine tools since 1867. We offer processes for soft machining and hard machining – for metals and machinable materials. EMAG relies on proven machining processes such as turning, milling, and drilling – supplemented by a wide range of other machining technologies. The ideal manufacturing solution for virtually any application The EMAG Group is one of the few producers of manufacturing systems that covers the entire process chain, from soft to hard machining. With access to a very broad range of technologies (turning, drilling, milling, gear cutting, grinding, laser welding, ECM deburring, PECM machining, automation), EMAG implements complete process chains in producing transmission, engine, and chassis components, as well as in the non-automotive sector. In doing so, the long-established company from Salach, Germany draws on the comprehensive experience of all companies within the EMAG Group and offers its customers modular turnkey manufacturing solutions of the highest standard. As an OEM supplier, EMAG guarantees customers the fastest possible support. Upon request, we deliver a complete turnkey package: machine, tooling, workholding technology, cutting fluids, and a finished workpiece program. The customer receives a production-ready solution from a single source.

2,241 Total number of EMAG employees

Technology and manufacturing companies » EMAG Systems GmbH » EMAG Salach GmbH » EMAG KOEPFER GmbH » EMAG LaserTec GmbH » EMAG ECM GmbH » EMAG SU S.r.l. » EMAG Zerbst Maschinenfabrik GmbH » EMAG China Machinery Co., Ltd.

OUR LARGEST MARKET COMPANIES – GLOBAL SALES AND SERVICE:

EMAG Salach GmbH Spain Barcelona, responsible for the Spanish market EMAG Salach GmbH Salach, Germany, founded in 2014, responsible for the DACH markets as well as Central and Eastern Europe

21 14 Branches and

EMAG Salach GmbH France La Guerche, founded in 1981, is responsible for the French market

EMAG MILANO S.r.l. San Giuliano Milanese, founded in 2000, responsible for the Italian market

EMAG Middle East FZCO Dubai, United Arab Emirates, founded in 2024 EMAG L.L.C. Farmington Hills, USA, founded in 1995, responsible for the U.S. and Canadian markets

Maquinaria EMAG Mexico S de RL de CV

EMAG China Machinery Co., Ltd.

EMAG Korea Ltd.

Santa Rosa de Jáuregui, Querétaro, founded in 2003

Taicang, China, founded in 2004

Seoul, South Korea, founded in 2004

EMAG (Chongqing) Machinery Co., Ltd.

EMAG India Pvt. Ltd.

Chongqing, China, founded in 2016

Bengaluru, India, founded in 1998

EMAG do Brasil São Paulo, Brazil, founded in 1997

Global market companies (sales and service)

ALWAYS KEEPING THE BEST PRODUCTION SOLUTION IN How can quality and productivity in metalworking be signiﬁcantly improved? This question is at the heart of what we do. That is why we develop manufacturing solutions that are specifically tailored to meet a wide range of requirements and deliver top performance—from cost-effective standard machines to complete manufacturing systems. In doing so, our engineers always keep the entire production process in mind. The focus is not just on the machine itself. The entire process – machining technology, NC programming, tools, automation, and energy consumption – is systematically optimized.

WE OFFER THE RIGHT MACHINE CONCEPT FOR EVERY APPLICATION: ✓

Tool and Mold Making + Universal cylindrical grinding machines

✓

Machining as a contract manufacturer + Machining centers with pick-and-place automation

MIND ADVANTAGES OF EMAG’S VERTICAL PICK-UP MACHINES In many applications, the vertical design and simple pick-up automation of EMAG lathes ensure significantly more efficient production. Compared to horizontal lathes, this means in most cases:

Signiﬁcantly lower production costs – the following design features ensure this performance: + Compact design

Minimal space requirements thanks to a small footprint—ideal for modern production lines with limited space.

+ Integrated automation

Standard storage for raw and finished parts, as well as easy integration with robotic solutions, ensure maximum efficiency.

+ Maximum productivity

Automated loading and unloading via pick-up technology enables short cycle times and reduced non-productive time.

+ Cost-effectiveness even with small batch sizes Short setup times and simple operation ensure cost-effective production even with frequently changing components.

+ High machine stability

The vibration-damping polymer concrete machine bed ensures optimal process reliability and machining quality.

+ Excellent chip removal

Thanks to the vertical machine design, chips fall downward—for clean processes and infrequent cleaning intervals.

✓

Gear and Drive Technology + Machines for gear cutting and grinding

✓

Supplier to automotive, energy and other industries + Custom Machine Building: Complete production line for manufacturing brake discs, etc.

VL-MACHINES The VL Series vertical pick-up turning machines were specially developed for manufacturing precision chucked components. To cover as wide a range of parts as possible, the VL Series is available in four versions for a workpiece diameter ranging from 10 mm to 400 mm.

Machine body

Z-slide

X-slide Spindle (Y)

Turret (optional Y-axis)

Measuring system (optional)

Automation

Intermediate gear

Sprocket

Machines: VL 2 Sawn part diameter: 60 mm Material: C45 2 OPs

Machines: VL 2 Pre-forged part diameter: 50 mm Material: 16MnCr5 2 OPs

Cover

Piston

Machines: VL 2 Sawn part diameter: 100 mm Material: X5CrNi1810 2 OPs

54,6 SEC. 100,8 SEC.

Machines: VL 4 Sawn part diameter: 100 mm Material: 46S20 2 OPs

35,4 SEC.

VL 2/VL 4/ VL 6/VL 8

143,4 SEC.

Workpieces

Main hub Machines: VL 4 Forged part diameter: 120 mm Material: 16MnCr5 2 OPs

100,2 SEC.

Drive gear Machines: VL 6 Forged part diameter: 220 mm Material: 16MnCr5 2 OPs

Housing Line cycle time

154,8 SEC.

212 SEC.

198,6 SEC.

Machines: VL 6 Sawn part diameter: 220 mm Material: 42CrMo4 3 OPs

Spur gear Machines: VL 8 External diameter: 320 mm Material: 16MnCr5 2 OPs

TECHNICAL DATA

VL 2/VL 100

VL 4/VL 200

VL 6/VL 300

VL 8/VL 400

Workpiece diameter, max.

100

200

300

400

Chuck diameter

160

260

400

500

Swing diameter

210

280

420

520

Workpiece length, max.

150

200

250

300

Travel distances, X/Y (optional)/Z

650/± 50/375

760/± 60/415

900/± 30/495

1.010/± 30/595

inch

6.5

inch

19.5

16.5

30/± 2.3/16.5

15.5

27.5/± 2/15

inch inch

20.5

35.5/± 1/19.5

39.8/± 1/23.5

» Power rating, 40%/100%

Fanuc 15.7/13.9

» Torque, 40%/100%

77/59

74/55

256/202

243/183

491/340

462/340

826/600

776/600

rpm

6,000

4,500

3,100

2,850

Main spindle

» Speed, max. Turret » Turret tool positions

ft-lb

21/19

57/44

Siemens 16.7/14.5

Fanuc 22.7/18

Siemens 24.1/18.1

Fanuc 41.1/28.5

Siemens 43/31.6

Fanuc 47.6/34.6

Siemens 48.8/37.7

22/19

55/41

30/24

188/149

32/24

179/135

55/38

362/251

58/42

341/251

64/46

572/443

65/51

572/443

Quantity

» Revolutions of driven tools

rpm

9,600

6,000

» Torque of driven tools at 30%/100% duty cycle

ft-lb

44/33

40/30

m/min

60/30/30

60/15/30

Rapid-traverse rate, X/Y/Z Control

ipm

32/24

30/22

2,363/1,181/1,181

2,363/591/1,181

Fanuc 32iB+/ Sinumerik ONE

VT-MACHINES Fast processes are required for machining large quantities of shafts. Both the machining process and the loading and unloading processes must be completed extremely quickly. The VT 2/VT 100 and VT 4/VT 200 machines are guaranteed to achieve the maximum performance you require. Four axes, short distances, and a powerful main spindle – these are the strengths of the VT Series. The full effect of these can be felt, in particular, when machining large quantities. A key factor is the machining of parts from two sides. This greatly reduces the machining time. Two tool turrets, each with eleven tool positions which can be equipped with turning tools or driven tools, ensure machine flexibility.

Turret 1 Working spindle with C-axis Turret 2

THE BENEFITS + Ready for integration with the

Tailstock

TrackMotion automation system

Automation

+ Reduced machining times due to four-axis machining

+ Shorter idle times with simultaneous

loading and unloading of components

+ Lower investment costs thanks to integrated automation

AUTOMATION SEQUENCE The gripper in turret 1 takes the workpiece from the raw parts storage area and transports it to the main spindle/tailstock. At the same time, the gripper in turret 2 takes the machined workpiece from the main spindle/tailstock, transports it to the finished parts storage area and deposits it there.

THREE KEY SUCCESS FACTORS + Reduced machining times

due to four-axis machining

+ Shorter idle times

with simultaneous loading and unloading of components

+ Highly productive shaft manufacturing thanks to integrated automation

SEC.

WORKPIECE CHANGEOVER TIME

TECHNICAL DATA

VT 2/ VT 100

VT 4/ VT 200

Chuck diameter

160

250

Swing diameter

210

270

Workpiece diameter, max.

100

200

Workpiece length, max.

400

630

Travel distances, X/Y (optional)/Z

mm 332/±25/625 395/±25/810

inch inch inch inch

8 4

10 10 8

inch

13/±1/24

15/±1/32

» Power rating, 40%/100%

30.1/23.9

32.4/26.4

» Torque, 40%/100%

ft-lb

144/112

246/200

» Speed, max.

rpm

6,000

4,500

33.5/26.5

33.9/29.3

Main spindle (Fanuc) hp

40/32

106/83

43/35

181/148

Main spindle (Siemens) » Power rating, 40%/100%

VT 4

Workpiece diameter, max.: 100 mm

Workpiece diameter, max.: 200 mm

Workpiece length, max.: 400 mm

Workpiece length, max.: 630 mm

45/39

» Torque, 40%/100%

ft-lb

142/112

231/200

» Speed, max.

rpm

6,000

4,500

Rapid-traverse rate, X/Y/Z Revolutions of driven tools, max. Torque of driven tools, 30%/100% Control

105/83

2 x 11

Turret tool positions

VT 2

45/35

(2 x 1 gripper)

m/min

30/15/30

170/148

2 x 11

(2 x 1 gripper)

30/15/30

ipm

1,181/591/1,181

rpm

12,000

9,600

20/16.5

44/33.1

ft-lb

15/12

32/24

Fanuc 32iB/ Fanuc 32iB/ Sinumerik ONE Sinumerik ONE

VL MULTI-SPINDLE MACHINES – VL 3 DUO EMAG has extended the VL Series product range with the VL 3 DUO, a twin-spindle machine solution for the highly productive manufacturing of chucked parts up to 150 mm (6 inches) in diameter. The VL 3 DUO integrates all of the EMAG technological developments (including self-loading spindle, the TrackMotion automation system and the modular design of the machine) to create a highly productive manufacturing system with a minimum footprint. The latest generations of controllers from FANUC and Siemens enable easy operation of the machines.

HIGH-PERFORMANCE TURNING WITH THE VL 3 DUO The VL 3 DUO scores highly for heavy-duty machining due to its rigid machine design. High feed forces with a large cutting depth reduce the machining time. Standard spindle:

High torque spindle:

ap = 4.75 mm

ap = 8,5 mm

f =

0,4 mm/rev

f =

0,4 mm/rev

vc =

250 m/min

vc =

250 m/min

0.2 in

0.02 in/rev

1,000 in/min

0.3 in

0.02 in/rev

1,000 in/min

TECHNICAL DATA Workpiece diameter, max.

150

Swing diameter max.

240

Chuck diameter max.

210

Workpiece length, max./optional

110/175

Travel distance, X/Y (optional)/Z

505/±30/250

inch

inch inch

4/7

20/±1/10

» Power rating, 40%/100%

Fanuc 17.9/15.5

» Torque, 40%/100%

ft-lb

144/98

» Speed, max.

rpm

5,000

» Power rating, 40%/100%

Fanuc 31.5/28.1

Siemens 31.2/26.3

» Torque, 40%/100%

ft-lb

255/192

» Speed, max.

rpm

5,000

Main spindle (2x)

High-Torque-Spindel – Option

Turret (2x) » Turret tool positions » Speed driven tools

24/21

106/72

42/37.7

188/142

Siemens 20/17.2 145/112

26.8/23

107/83

41.8/35.3 188/142

» Torque driven tools

Qty rpm Nm

12 9,600 44/33

Rapid-traverse rate, X/Y/Z

m/min

60/30/30

Control

VL 3 DUO/VL 150 DUO mm

ft-lb ipm

32/24

2,362/1,181/1,181

Fanuc 31iB/Sinumerik ONE

VL 3 DUO FOR DEMANDING TURNING WORK + Working spindle with 5,000 rpm/32 kW/255 Nm at 40% duty cycle

+ Sturdy mechanical design – spindle flange to DIN 55026, size 6

+ Motor spindle with DirectDrive for minimum run-up

times, maximum true running and diameter tolerances

+ Maximum torque over large range of speeds MACHINING AREA OF THE VL 3 DUO:

+ Water-cooled motor spindle for maximum thermal stability

270

240

40 35

31,5

180

28,1

150

Torque (Nm)

6.000

3.600

Speed (rpm)

4.800

5 4.200

30 3.000

2.400

1.800

120

600

Torque (Nm)

192

Power (kW)

210

5.400

255

300

1.213 1.408

Highly productive machining of chucked parts with a diameter of up to 150 mm (6 inches) with minimum space requirements

Power (kW)

40 % ED

100 % ED

Maximum precision

Machine base made of MINERALIT® polymer concrete, machine weight 10,000 kg, roller guides and direct position measuring systems in all axes

Integrated automation

Pick-up working spindle for loading and unloading

Unique machine concept

Two working spindles and two high performance tool turrets with torque motor

Optimum accessibility

Short distance to the turrets and working spindle ensure optimum accessibility

Maximum ﬂexibility

Parts storage area for up to 400 workpieces and TrackMotion automation system for high speed part transport between the parts storage area and machining areas as well as for turning the workpieces

Minimum ﬂoor space requirement

24.5 m2 for the complete machine: VL 3 DUO + TrackMotion + parts storage area + chip conveyor

* Fully equipped machine including chip conveyor, TrackMotion and parts storage area for up to 400 workpieces (depending on the workpiece geometry)

Classic MACHINES – UG SERIES The UG series is part of the EMAG Classic Line – the efficient entry into precision manufacturing. With grinding lengths ranging from 400 to 1,500 mm, the series covers a wide range of workpiece sizes – from short precision parts to long shafts and complex components with internal and external machining. Thanks to the combination of a robust base machine, high-quality EMAG components, and proven grinding technology, the UG series offers a technically sophisticated solution for workshops, toolmakers, and production companies that want to perform universal grinding tasks efficiently and reproducibly.

UG 1000

Grinding length: 1.000 mm

UG 400

Grinding length: 400 mm

UG 630

UG 1500

Grinding length: 630 mm

TECHNICAL DATA

Grinding length: 1.500 mm

UG 400

UG 630

UG 1000

UG 1500

Center height/Width between center

175/400

175/630

175/1,000

175/1,500

Grinding length (straight wheel/angular wheel)

400/240

630/450

1.000/825

1,500/1,220

120

150

Weigth between center, max.

in in

7/16

16/9

7/25

25/18

7/39

39/32

59/48

132

176

100

3,5

Table stroke

640

885

1,240

1,860

Min. increment / pulse

mm Nm

0.0001 8

0.0001 12

8.5

Slide stroke

320

Travel min./pulse

0.0001

Min. increment / pulse

Clamping Ø (chuck) max.

3,5

264

7/59

331

Longitudinal axis (Z-axis)

Feed servomotor torque Machine table swivelling range Wheel slide (X-axis)

Machine table swivelling range Swivel axis (B axis) Swivel range B- Axis Resolution Swiveling time for 180° B- Axis Positioning Repeatability

ft-lbs

5.9

12.5

8.8

12.5

8.8

12.5

8.8

12.5

ft-lbs

5.9

8.5

° ° s

-15 bis +225 0.0001 8

arc seconds

±2

UG 400 Wheel Head (OD/face grinding) Grinding wheel (left/right) Ø

500 × 40 (50ROS) × 203.2

UG 630 500 × 63 (80ROS) × 203.2

UG 1000 500 × 63 (80ROS) × 203.2

UG 1500 500 × 50 (80ROS) × 203.2

20 x 1.5 (50ROS) x 8

20 x 2.5 (80ROS) x 8

20 x 2 (80ROS) x 8

Spindle motor power Peripheral speed Internal grinding unit HF spindle mount Ø

kW m/s

7.5 60

7.5 (11 optional) 60

7.5 (11 optional) 40

7.5 (11 optional) 50

120

Speed range Grinding wheel Ø

rpm mm

20,000–125,000 50

Workpiece spindle (workpiece head) Centering cone Spindle speed (stepless) Swivel range Motor torque

– rpm ° Nm

MT4 30–800 0 to +30 12

A2-4/MT4 (MT5) 30–800 0 to +30 22

– mm

MT4 60/40

MT5 65/40

±0.040

Tailstock Centertaper Quill diameter/quill stroke Micro Taper Correction Dressing systems For external grinding/For internal grinding Hydraulic power unit Fuel tank capacity Engine power

ft-lbs

8,8

2/1.5

2.5/1.5

On workpiece head, dressing blades/on table swing arm type l kW

30 0.75

OTHER EMAG MACHINES Classic MACHINES An efficient introduction to precision manufacturing. Classic machines combine maximum efficiency with the high quality you expect from EMAG. These machines focus on the essentials and offer an optimized range of functions for typical machining requirements. The base machine is purchased from selected partners and equipped by EMAG with proven process and machining technology, such as chucks and tools. You benefit from EMAG‘s worldwide service network and fast spare parts supply – the ideal choice for cost-efficient production without compromising on reliability.

MSC 5 DUO

HSC 1

USC 850

The MSC 5 DUO is a twin-spindle CNC lathe engineered for highperformance batch production.

The HSC 1 is a compact, powerful CNC lathe for the economical machining of turned parts in two consecutive machining operations (OP 10 / OP 20).

The USC 850 is a state-of-the-art universal lathe that has been specially developed for the precision and efficient machining of large turned parts.

TECHNICAL DATA

MSC 5 DUO

HSC 1

USC 850

Workpiece diameter, max.

120/240

375

700 (575)

Workpiece length, max.

85/145

570

2,000

Swing diameter max.

327

610

800

inch

5/10

3/6

inch

OD CYLINDRICAL GRINDER WPG 7 – Compact, High-Precision Flexible OD Cylindrical Grinding Machine including Automation Thanks to its integrated linear gantry with a dual gripper, the machine handles the loading and unloading of workpieces autonomously and reliably, with extremely short chip-to-chip times. It is perfectly suited for short shafts up to 250 mm in length as well as for chucked components, and is ideal for flexible batch production with the shortest possible cycle times.

TECHNICAL DATA

Workpiece length, max.

250

Center height

100

Center length

380

inch inch inch

10 4

27.5 (22.5) 79

31.5

GEAR-CUTTING MACHINES Gear technology for high-productivity gear manufacturing. Whether it’s state-of-the-art gear hobbing technology or the right machines for chamfering and deburring – EMAG has the right solutions for gears and worm gears. Many factors play a role in establishing an efficient production process. That is why EMAG develops highly creative, customized solutions based on its standardized gear cutting machines. The EMAG Group‘s range of gear cutting technologies:

+ Grinding Machines for Gear

+ Gear Hobbing Machines

+ Gear Shaving Machines

+ Skiving Machines

+ Gear Generating Grinding Machines

+ Gear Shaping Machines

+ Gear Profile Grinding Machines

Cutting Tools

+ Profile Milling Machines

TECHNICAL DATA

HLC 150 H Gear hobbing machine

CLC 200 HC Hobbing and Chamfering Machine

G 160 Gear generating grinding machine

GR/GW 250 Worm-type proﬁle grinding machine

CLC 260 H FR Worm milling machine

Module range, max.

3 (5)

Workpiece diameter, max.

150

250

160

250 (150)

260

Workpiece length, max.

500

300

550 (500)

1,800/2,300

inch inch

10 12

6.5 12

10 (6)

21.5 (20)

71/90

EMAG LASERTEC

Systems for Laser Material Processing

Laser Welding

Laser Cleaning

Laser Hardening

Laser Cladding

EMAG’s laser systems set the standard for modern manufacturing processes. With innovative technologies, they sustainably improve the quality, efficiency, and productivity of your production. You benefit from significantly reduced lead times and perfectly coordinated process flows. Whether as a stand-alone solution or fully automated, EMAG laser systems enable the cost-effective production of highperformance, precision, and durable components – all with consistently high quality. This allows you to take your manufacturing to a new level and secure decisive competitive advantages.

TECHNICAL DATA Processes

ELC 6

ELC 6i

ELC 160

LSW, VW, F

LSW, LR, VW, F, DMC

LSW, LR, VW, F

Outer diameter, max.

300

Workpiece height, max.

300

TECHNICAL DATA

ELC 2500

ELC 1500 LMD

ELC 550

Processes

LSW, LMD

LMD

inch inch

12 12

Outer diameter, max.

2,500 x 1,500

600

550

Workpiece height, max.

600

1,500

250

inch inch

98 x 59 24

Process Legend: LSW = Laser Welding; LR = Laser Cleaning; LMD = Laser Metal Deposition; VW = Preheat; F = Joining, DMC = DMC Marking

EMAG ECM

Systems for Electrochemical Machining Electrochemical machining is based on the principle of electrolysis. The tool is connected as the cathode to a DC voltage source with the workpiece acting as the anode. A charge exchange takes place between the cathode and anode in an aqueous electrolyte solution, which targets specific areas of the workpiece. This can be used to create contours, ring ducts, grooves, or bell hollows with no contact but very high precision. The removed material is precipitated from the electrolyte solution in the form of metal hydroxide. The machining can be carried out regardless of the structural condition of the metal. Both soft and hard material can be machined. The components are not subjected to either thermal or mechanical stress.

TECHNICAL DATA

PTS

PI Premium Integrated

PS Premium Standard

PO 100 SF PO 900 BF

Generator capacity

A (DC)

2,500

400 – 2,500

2 x 2,500 – 5,000

Generator capacity

A (Puls)

6,000 – 12,000

400 – 8,000

2 x 6,000 – 12,000

Moving cathode

In the stationary cathode process, the workpiece is connected to the positive terminal, the anode. The tool serves as the stationary cathode. Both the cathode and the anode are connected to a power electronics unit. Depending on the application and quality requirements, the process can be operated using a constant DC current or a pulsed current. A continuously flowing electrolyte stream continuously flushes away the removed hydroxides. Typical applications include deburring or rounding off sharp edges on metal components.

In this process, the cathode – which is connected to the negative terminal and serves as the tool – is moved at a constant feed rate. The cathode has the negative contour of the geometry to be formed. The workpiece acts as the anode and is connected to the positive terminal. A constant electrolyte flow removes the hydroxides generated from the working gap. In most cases, the connected power electronics supply a pulsed DC current. This enables applications such as drilling and broaching.

UDC

Time t/s

Processing time per workpiece

UDC

Time t/s

Tool = Cathode

Electrolyte

Tool = Cathode

Precision Electrochemical Electrochemical machining (PECM) Precision electrochemical metal machining (PECM) takes this a step further. This process allows three-dimensional shapes to be machined from a workpiece. The basic setup is similar to the process described above, with the workpiece serving as the anode and the tool as the cathode. In addition, an oscillating motion of the tool is superimposed on the feed and pulse electronics. The working gap is significantly smaller than in the moving cathode process, which enables precision metalworking with tighter tolerances.

Processing time per workpiece

Tension U/V

Processing time per workpiece

Tension U/V

Vertical cathode (ECM)

Oscillation stroke z/mm Tension U/V

UDC

Feed

Time t/s

Pulse train in the UT region

Tool = Cathode Electrolyte

Electrolyte

Workpiece = Anode

AUTOMATION SOLUTIONS FROM EMAG Automated production technology, precisely tailored to the requirements of components and material ﬂow – with this goal in mind, EMAG develops a wide range of automation solutions. As a result, the entire production process becomes faster, less prone to errors, and more cost-effective. Our wide range of automation systems spans from gantry systems to our TrackMotion and robotic cells, all the way to our stacking cells in the SCS series. Thanks to this range of automation solutions, EMAG can implement a wide variety of manufacturing scenarios. Automation Systems: Integrated Material Flow for Increased Productivity

Image without safety fences

Do you want to compensate for labor shortages while simplifying processes and reducing unit production costs at the same time? Our automation solutions provide the ideal foundation for this. It is by no means necessary to commit to a large-scale system from day one. On the contrary: EMAG offers scalable automation solutions, such as EMAG’s own TrackMotion or our modular robot cell. Best of all, everything comes from a single source and is provided with precision, tailored to the customer’s requirements.

TRACKMOTION AUTOMATION SYSTEMS With TrackMotion, the TransLift moves along a rail system (“track”) through the automation aisle between the machines. The TransLift handles the tasks of picking up parts at various heights, as well as positioning and turning the workpiece. This makes it very easy to perform link-ups between machines, whether for parallel processing of identical operations or for sequencing successive operations.

+ Minimal setup time: The Track-

+ Integration of measuring

+ Space-saving, since the automation

+ Easy to maintain: The Track-

+ High reliability thanks to its simple

+ Short component transport

Motion automation system is ready for use once the workpiece height and part diameter have been entered. system is installed entirely behind the machines and sturdy design

devices, marking systems, cleaning machines, and many other functions is possible

The raw-parts are supplied via a parts magazine. This magazine has a storage capacity of up to 400 components, depending on the workpiece geometry.

Motion automation system is easily accessible from all sides. time: Travel speeds: 150 m/min horizontally and 35 m/min vertically

From small to large without retooling. The tool-free NC gripper ensures the fastest possible machine setup.

SCS STACKING CELL Highly productive production in a conﬁned space – this is what is promised by the new stacking cells of the SCS series Whether for machining sleeve or shaft components, when combined with SCS stacking cells, EMAG machines become compact, fully automated manufacturing systems capable of operating autonomously for hours on end. While the SCS 1 is designed for smaller components fed on workpiece carriers, the SCS 4 can handle wire baskets up to 600 x 500 mm in size and weighing up to 40 kg. Part handling as well as machine loading and unloading are performed by a robot.

MRC ROBOT CELL: BIN PICKING Among other things, the modular automation solution enables the loading of machines with raw-parts directly from bulk material. EMAG’s vertical pick-up turning machines are highly automated in their own right; that is, both machining and unloading/loading via the pick-up spindle from the integrated workpiece conveyor are fully automated. The MRC is the perfect complement to this system, increasing autonomy and enabling the integration of secondary processes such as cleaning, measuring, or marking. If necessary, unsorted raw-parts can also be fed via a bin-picking module. A 3D camera system determines the positions of the raw-parts in the feed container. This data is used for the robot’s path planning, enabling it to pick the individual components one by one from the container (bin picking) and then place them on the machine’s workpiece conveyor.

CRC ROBOT CELLS Automation of Machine Tools with CRC robot cells – reliable, fast and efficient The CRC stacking cell is perfectly designed for handling smaller components. Loading occurs using workpiece carriers housed in drawers, each of which can hold up to 45 kg. An integrated robot handles the components as well as the loading and unloading of the machines. The machine operator is only responsible for replacing the workpiece carriers. If necessary, this can be done in parallel with the main machining time to ensure a continuous production flow.

www.emag.com

Display of the machines in their trade show configuration (with optional trim kit)

All EMAG Locations

At Home All Over The World.