PRODUCT SUMMARY of the EMAG Group
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
TABLE OF CONTENTS » EDNA ONE PRODUCTS
» GRINDING BUSINESS UNIT
Building blocks for the digital factory.............. 4
EMAG UG 400/UG 630/UG 1000/ UG 1500. . ............ 24
EDNA ONE - Product summary........................... 5
EMAG VSC 250 DS/VSC 400 DS/DDS. . ................... 25
Digital solutions for production processes........6
EMAG VSC 250 DUO DS/VSC 400 DUO DS . . ............ 25 EMAG VLC 200 GT/VLC 350 GT . . ........................... 26 EMAG VLC 450 DG .............................................. 27
» TURNING BUSINESS UNIT
EMAG VTC 100 GT............................................... 28
EMAG VL 2/VL 4/VL 6/VL 8.................................. 8
EMAG VTC 315 DS.. .............................................. 28
EMAG VL 3 DUO................................................... 9 EMAG VLC 100/VLC 200/VLC 300/VLC 400. . .......... 10 EMAG VT 2/VT 100............................................. 12 EMAG VT 4/VT 200. . ........................................... 12 EMAG VT Line. . ................................................... 13 EMAG VSC 250/400/500..................................... 14 EMAG VSC 250/400/450/500 DUO....................... 14 EMAG VSC 160 TWIN........................................... 15
EMAG VG 110...................................................... 29 EMAG WPG 7. . .................................................... 30 EMAG ECO 200................................................... 30 EMAG HG 2/HG 204/HG 208 . . .............................. 32 EMAG HG 208 CD ............................................... 32 EMAG HG 208 DW .............................................. 33 EMAG SN 204/208 ............................................. 34 EMAG SN 310/320 .............................................. 34
EMAG VSC 315 TWIN KBG .................................... 16 EMAG VSC 315 KBU/VSC 315 DUO KBU................... 16 EMAG HCM 110................................................... 17 EMAG VSC 400 PS .............................................. 18
EMAG K 160. . ...................................................... 36
EMAG VST 50 .. ................................................... 18
EMAG K 300....................................................... 36
EMAG VM 9 .. . ..................................................... 19
EMAG HLC 150 H . . ............................................... 37
EMAG MSC 5 DUO............................................... 20 EMAG HSC 1.. ...................................................... 20 EMAG USC 850................................................... 22 EMAG USC 21. . .................................................... 22
2
» SOFT GEAR CUTTING BUSINESS UNIT
» ECM BUSINESS UNIT
EMAG CLC 200/300/500/600 W/900 W. . .............. 38
EMAG Premium Integrated (PI)............................. 52
EMAG CLC 260 H/500 H....................................... 38
EMAG Premium Integrated (PS)............................ 52
EMAG CLC-SZ Series............................................ 39
EMAG PECM PTS System..................................... 54
EMAG RASO 200/400. . ........................................ 40
EMAG PECM PO 100 SF System. . ........................... 56
EMAG GS 400..................................................... 40
EMAG PECM PO 900 BF System............................ 56
EMAG G 375/G 500 H/HL/GP 500 H/HL/
EMAG PECM PO 3000 IP System........................... 58
GW 3600 H/TC................................................... 41
EMAG Electrolyt Management System (EMS). . ....... 59
TABLE OF CONTENTS
» HARD GEAR CUTTING BUSINESS UNIT
EMAG G 160/G 250/G 400/G 250 HS...................... 42 EMAG CLC 260 H-FR/CLC 500 H-FR. . ..................... 43 EMAG G 375 H/GR 500 HL/GT 500 HL/
» AUTOMATION BUSINESS UNIT
GW 3600 HD...................................................... 43
EMAG TrackMotion 4/8....................................... 60
EMAG CLC 200 FR............................................... 44 EMAG GW 250/GR 250........................................ 44 EMAG HRG 350................................................... 45 EMAG SCT 3....................................................... 45
EMAG SCS 1/4.. ................................................... 61 EMAG Bin Picking Cell.......................................... 61 EMAG MRC Robot Cell.. ...................................... 62 EMAG CRC Robot Cell.. ....................................... 62
» LASERTEC BUSINESS UNIT EMAG ELC 6....................................................... 46 EMAG ELC 6i. . ..................................................... 46 EMAG ELC 160.................................................... 47 EMAG ELC 600. . .................................................. 48 EMAG ELC 1200 V................................................ 48 EMAG ELC 550 LMD. . ........................................... 49 EMAG ELC LC 4................................................... 50 EMAG ELC 1300 LH.............................................. 50 EMAG SFC 600.. .................................................. 51
3
Building Blocks for the Digital Factory With EDNA ONE, EMAG offers a comprehensive digital solution that is precisely tailored to these requirements. Increase efficiency, flexibility and transparency in your production and secure your long-term competitiveness.
EDNA Transparency of current production output, feature correction, and download area
EDNA Workpiece Data Recorder Workpiece-related data acquisition
EDNA Services » Process support » Data-driven line optimization » Downtime prevention » Identification of potential and development of measures with the customer
4
EDNA Health Inspect Diagnosis for comprehensive machine condition analysis
EDNA Edge Cloud Central edge storage, recording of all machines and data
- Product Summary (from EDNA IoT Core to Health Inspect)
(Internet) EDNA Health Inspect Machine diagnostics
Transmission of measurement data Process data remains at the customer's premises
EDNA Products
EDNA ONE PRODUCTS
Secure EMAG network
EDNA Products
Customer network
(Customer network) EDNA Edge Cloud Server
EDNA Workpiece Data Recorder
EDNA Production Status
EDNA Feature Correction
EDNA Download
EDNA IoT Core Industrial PC1)
EDNA Cortex Software license1)
EDNA Senses Accelerometer
EDNA Apps Fanuc from V16, Siemens from V18
EDNA IoT Ready1) Future-proof, compatible, and machine data
EDNA Cortex Software license
EDNA IoT Core Industrial PC1)
Uninterruptible power supply
EDNA Manual Health Inspect Health status
Control data access with MQTT, REST, OPC-UA, and CSV export Stores data from the PLC and makes it available for further services. Enables clean shutdown of the operating software, e.g. in the event of a power failure
1) means that the EDNA IoT Core and EDNA Cortex are included in the EDNA IoT Ready package.
5
Digital Solutions for Production Processes EDNA Feature Correction Ensure long-term quality EDNA Feature Correction enables manual and automatic correction of features. Operators can display specific information, visualize historical correction trends directly on the feature, and manage features clearly. Visual support in the form of drawings ensures easy adaptation of production processes.
EDNA Production Status The real-time overview for your production EDNA Production Status gives you full control over your production line. The system displays the current production status, quantities, cycle times, and tool status in real time. This overview helps you identify bottlenecks immediately and optimally control production processes to achieve maximum efficiency.
EDNA Cortex Optimal production process through easy access to all machine process data
» Secure, fast, and easy access to all your machine data » Central data interface to all data sources » Recording of historical data » Uniform data format » Our database for EDNA ONE IoT applications » Interfaces: MQTT, REST, OPC-UA, CSV export » Limit value monitoring
EDNA Workpiece Data Workpiece-related data collection and analysis
» Workpiece-related data is available directly from the machine
» Comparison of available workpieces and process variables
» Provision of process parameters over time
6
» Complies with traceability requirements
» Optimize process and workpiece quality based on data
» Optimize processes across multiple EMAG technologies
EDNA ONE PRODUCTS
EDNA Health Inspect Higher availability through predictive maintenance and lower service costs
» Optimized measurement run » Additional machine data to confirm the diagnosis » Differentiated diagnosis with specific recommendations for action » Detection of play, wear, blockages, and geometric shifts of the travel axes
» New sensor with higher sampling rate for more accurate diagnosis » Networked sensor hub replaces USB plug » Notification at the touch of a button, based on automated analysis and limit value management
» Completely new Health Inspect diagnostic portal
Detailed view
EDNA Edge Cloud Central edge storage for recording all machines and data
» Data is stored at a central location in the customer network
» More storage space and computing power » Comparison of multiple machines or lines possible
» Interfaces: MQTT, REST, OPC-UA, CSV export » The data does not leave the customer network » Optional: Supports automatic health inspection EDNA products included Customer network
EDNA Edge Cloud Server
EDNA Cortex Software license
7
EMAG VL 2 · VL 4 · VL 6 · VL 8 VL 2
VL 6
VL 4
VL 8
BENEFITS OF THE VL SERIES
» The machines of the VL Series are space-saving vertical turning machines with integrated automation. They deliver maximum performance and low costs per piece. This performance is based on high-quality components. The machine body is made of MINERALIT® polymer concrete with damping properties.
» A pick-up working spindle moves in the X- and Z-axes with minimum response times and the tool turret guarantees short swiveling times.
» Furthermore, the machines can be fitted with a Y-axis in the turret to allow for the machining of complex geometries. The possible fields of applications for the machines are thus increased massively.
TECHNICAL DATA
8
VL 2
VL 4
VL 6
VL 8
Max. chuck diameter
mm
160
260
400
500
Swing diameter
mm
210
280
420
520
Max. workpiece diameter
mm
100
200
300
400
Max. workpiece length
mm
150
200
250
300
X-axis travel
mm
640
740
885
1,110
Y-axis travel
mm
±50
±30
±30
±30
Z-axis travel
mm
375 15
415
16.5
495
19.5
595
23.5
Power rating (40%/100% duty cycle)
kW
18.1/13.9
25/18
39/28
47.6/34.6
Torque (40%/100% duty cycle)
Nm
ft-lb
77/59
280/202
460/340
780/600
Speed
rpm
6,000
4,500
3,100
2,850
in
in in in in in in
hp
6.5
8.5 4 6
25
±2
24/19
57/44
10
11 8
8
29
±1
34/24
207/149
15.5
16.5 12
10
35
±1
52/38
339/251
19.5
20.5
15.5 12
44
±1
64/46
575/443
EMAG VL 3 DUO TURNING BUSINESS UNIT
VL 3 DUO
MAG has extended the product range of the extremely E successful VL Series in the form of the VL 3 DUO, a twinspindle machine solution for the highly productive manufacturing of chucked parts with a diameter of up to 150 mm. The VL 3 DUO integrates all of the most recent 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. TECHNICAL DATA
VL 3 DUO
Max. workpiece diameter
mm
150
Chuck diameter
mm
210
Max. workpiece length
mm
110
X-axis travel (machining)
mm
505
Y-axis travel (optional)
mm
±30
Z-axis travel
mm
250
Power rating (40%/100% duty cycle)
kW
17.9/15.5
Torque (40%/100% duty cycle)
Nm
ft-lb
144/98
Speed
rpm
5,000
in in in in in in
hp
6
8
4.5
19.5 ±1
10
24/21
106/72
9
EMAG VLC 100 · VLC 200 · VLC 300 · VLC 400 VLC 100
VLC 200
VLC 300
VLC 400
BENEFITS OF THE VLC SERIES
» Individual manufacturing solution: The VLC Series machines can be adjusted individually to the machining requirement. » Turning tools, milling spindles, and multi-spindle drill head modules are available.
TECHNICAL DATA
10
VLC 100
VLC 200
VLC 300
VLC 400
Max. chuck diameter
mm
160
260
400
500
Swing diameter
mm
210
280
420
520
Max. workpiece diameter
mm
100
200
300
400
Max. workpiece length
mm
150
200
250
300
X-axis travel
mm
650
760
900
1,010
Y-axis travel
mm
±50
±30
±30
±30
Z-axis travel
mm
375
415
495
595
in in in in in in
in
6.5
8.5 4
6
26
±2 15
10
11 8 8
30 ±1
16
15.5
16.5 12
10
35
±1
19
19.5
20.5
15.5 12
40
±1
23
TURNING BUSINESS UNIT
11
EMAG VT 2 · VT 4 · VT 100 · VT 200 VT 2/VT 100
VT 4/VT 200
The strength of the VT series machines lies in the 4-axis machining of shafts up to 630 mm in length at high quantities. The fully integrated automated loading and unloading is firmly integrated into the machine concept and enables extremely short distances. Loading and unloading is carried out via the two turrets – a fast and efficient process.
TECHNICAL DATA
The machines in the VT series are equipped with the latest control generations from Fanuc (VT 2, VT 4) and Siemens (VT 100, VT 200).
mm
160
250
Rotary Ø
mm
210
200
» Gripper Ø
mm
100
125
» Workpiece Ø
mm
100
200
Workpiece length max.
mm
400
630
X-axis travel
mm
332
395
Z-axis travel
mm
625
810
Y-axis travel optional
mm
±25
±25
Power rating (40%/100% duty cycle)
kW
30,1/23,9
32,4/26,4
Torque (40%/100% duty cycle)
Nm
142/112
246/200
Power rating (40%/100% duty cycle)
kW
33,5/26,5
33,9/29,3
Torque (40%/100% duty cycle)
Nm
142/112
231/200
1/min
6.000
4.500
Component Ø max.
Fanuc
The grippers integrated in the turret take over loading and unloading of the main spindle. Closed conveyor belts are located to the left and right of the work area for storing raw and finished parts. The VT 200 is also available with a counter spindle or center drive.
VT 4/ VT 200
Chuck Ø
Siemens
A powerful main spindle is used. Two turrets, each with eleven tool positions, are available for machining and can be equipped with both turning and driven tools. The machines can be equipped with Y-axes for complex drilling and milling operations. An optional NC-positionable steady rest supports the machining of long workpieces.
VT 2/ VT 100
Motor speeds
in in
in in in in in in
hp
ft-lb hp
ft-lb
6.5
8.2
3.9 4
15.5
13
24.5 ±1
40/32
104/82 45/35
104/82
10
10.5
4.9 8
25
15.5 32 ±1
43/35
181/147 45/39
170/147
Control » VT 2 / VT 4 » VT 100 / VT 200
12
Fanuc 32i Sinumerik ONE
EMAG VT LINE TURNING BUSINESS UNIT
VT LINE
Complete machining of shafts and shaft-type workpieces in a manufacturing cell, including automation. With standardized automation components, a manufacturing cell can be easily assembled from two or three machines of the VT series. The machine can be optimally configured for each machining step, resulting in a highproductivity solution.
13
EMAG VSC 250/400/450/500 · VSC 250/400/450/500 DUO VSC 250/400/450/500
VSC 250/400/450/500 DUO
Vertical pick-up turning machine for chucked parts with a diameter of up to 440 mm. Excellent use of the VSC Series by technology integration for both soft and hard machining.
The low-cost solution for machining small and medium workpieces in two operations. The DUO design has two separate machining areas, which means that it has overhead slides that can be programmed independently.
Turning, drilling, grinding, milling, gear cutting and honing – all in one machine. The workpiece is measured precisely, quickly and without delays in the machining position by a measuring probe or measuring mandrel.
Each machining area has an EMAG disk-type tool turret at the end that can be independently programmed.
TECHNICAL DATA
14
VSC 250 DUO
VSC 400 DUO
VSC 450 DUO
VSC 500 DUO
Workpiece diameter (nominal)
mm
250
340
400
440
Chuck diameter
mm
315
400
460
500
Swing diameter
mm
330
420
520
520
X-axis travel
mm
900
860
935
935
Z-axis travel
mm
300
315
315
400
inch inch inch inch inch
10
12.5 13
35.5
12
13.5 16
16.5 34
12.5
16
18 21
37
12.5
17.5 20 21
37
16
EMAG VSC 160 TWIN TURNING BUSINESS UNIT
VSC 160 TWIN
The ideal machines for high performance, high accuracy, and large series – the vertical multi-spindle machines for the simultaneous machining of two workpieces. The VSC TWIN Series combines highly productive output with a minimal footprint.
TECHNICAL DATA
VSC 160 TWIN
Workpiece diameter (nominal)
mm
130
Chuck diameter
mm
130/160
Swing diameter
mm
180
X-axis travel
mm
860
Z-axis travel
mm
160
in
in in in in
5
5/6.5
7
34
6.5
15
Machines for Homokinetic Joints VSC 315 TWIN KBG
TECHNICAL DATA
VSC 315 KBU/VSC 315 DUO KBU
VSC 315 TWIN KBG
Chuck diameter
mm
250
Swing diameter
mm
260
X-axis travel
mm
TECHNICAL DATA Chuck diameter
mm
250/250
Swing diameter
mm
260/260
850
X-axis travel
mm
900/900
Z-axis travel
mm
320 12.5
Y-axis travel
mm
in
12.5/12.5
Main spindle
#
2
Z-axis travel
mm
300/300
Spindle flange to DIN 55026
Size
8
Main drive unit
#
1/2
Spindle bearing diameter, front
mm
140
Spindle flange to DIN 55026
Size
8/8
Max. speed
rpm
3,000
Spindle bearing diameter, front
mm
140/140
Spindle distance
mm
500
20
Max. speed
rpm
3,000/3,000
Main drive unit
#
2
kW
28.5/27.5/28.5/27.5
AC asynchronous motor, 60%/100% duty cycle
kW
58/45
AC synchronous motor, 40%/100% duty cycle Maximum power
kW
28.5/28.5
Maximum power
kW
58 78
rpm
700/700
Full performance from spindle speed
Full performance from spindle speed
rpm
900
Torque, 40%/100% duty cycle
Nm
590/375/590/375
Torque, 60%/100% duty cycle
Nm
620/480
Nm
590/590
Nm
620
Maximum torque
in in in in
in
in
hp hp
ft-lb ft-lb
10 10
33.5
5.5
78/60
457/354
Maximum torque
457
KBG
Straight ball raceways
KBU Universal ball raceways
16
VSC 315 KBU/VSC 315 DUO KBU in in in
in
in
hp hp
ft-lb ft-lb
10/10 10/10
35.5/35.5
315/315
12/12
5.5/5.5
1/0.5/1/0.5 1/1
23/15/23/14.5 23/23
TURNING BUSINESS UNIT
HCM 110
TECHNICAL DATA
HCM 110
Max. workpiece diameter
mm
110
Min. workpiece diameter
mm
30
Max. workpiece height
mm
60
Min. workpiece height
mm
15
Max. workpiece weight
kg
in
in in in
lbs
Spindle flange to DIN 55026 Machine weight
4 1
2
0.6
1
2
Size 5 t
lbs
8
18,000
17
EMAG VSC 400 PS · EMAG VST 50 · EMAG VM 9 VSC 400 PS
VST 50
Fast, precise and easy to operate: power skiving has been turned into a highly efficient process for the production of internal and external gear teeth by the VSC 400 PS machine.
Precision, speed and process reliability for the production of ball pins: with its intelligent machine concept - including robot loading - the new VST 50 from EMAG ensures lower unit production costs for this safety-critical component.
VSC 400 PS
TECHNICAL DATA
18
VST 50
TECHNICAL DATA
Max. chuck diameter
mm
400
Max. workpiece diameter
mm
40
Swing diameter
mm
420
Max. workpiece height
mm
450
Workpiece diameter
mm
340 (400)
X-axis travel
mm
935
Z-axis travel
mm
315
Y-axis travel
mm
280
in in in in in in
16 17
13 (16)
37
12 11
in in
1.5
17.5
TURNING BUSINESS UNIT
VM 9
The vertical turning centers in the VM Series are designed for the highly productive manufacturing of workpiece families with a wide range of parts. A tool turret with twelve tool positions, depending on the required tool interface in a BMT or VDI version, is available for machining. The turret can be equipped with driven tools to carry out drilling operations, for example.
VM 9
TECHNICAL DATA Max. chuck diameter
mm
450
Swing diameter
mm
700
X-axis travel
mm
375
Z-axis travel
mm
500
in in in in
17.5
27.5 14.5 19.5
19
EMAG MSC 5 DUO · HSC 1 MSC 5 DUO
HSC 1
The MSC 5 DUO is a twin-spindle CNC lathe engineered for high-performance batch production. With its innovative split-bed design, powerful spindles and fully integrated 3-axis gantry loader, this machine delivers exceptional precision, reliability and efficiency. Whether in automotive, hydraulics, pneumatics or medical component production, the MSC 5 DUO ensures faster cycle times, reduced downtime and superior machining results.
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). Equipped with main and counter spindles, Y-axis as well as a turret with driven tools, the machine enables turning, drilling and milling in a continuous production process – on a single machine. Automatic spindle transfer ensures high precision and efficient machining of both sides of the workpiece - no manual reclamping required.
TECHNICAL DATA
TECHNICAL DATA
HSC 1
Swing Ø over slide
mm
350
Max. Turning diameter with manual loading
mm
300
50
Turning dia., max.
mm
120
Chuck dia., max.
mm
165/200
Turning length, max.
mm
in
3,3
85
Max. turning diameter with bar feeder
mm
Workpiece weight, max.
kg
3
Max. turning length
mm
kW
7,5/5,5 A2-5 4.500
Main spindle » Rated power, 30 % / 100 % » Spindle nose » Motor speeds, max.
20
MSC 5 DUO in in
min-¹
4,7
6,5/7,9
Main spindle » Rated power, 30 % / 100 % » Spindle nose » Motor speeds, max.
in in in
13,8 11,8 2
570
in
22,5
kW
11/9 A2-6 4.000
min-¹
TURNING BUSINESS UNIT
21
EMAG USC 850 · USC 21 USC 850
USC 21
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. With its robust design, state-of-the-art control technology and excellent machining accuracy, it is ideal for use in the supplier industry, aviation and general mechanical engineering.
The USC 21 pipe processing machine is characterized above all by its rigid machine design. All machine assemblies are mechanically very stable. This is ensured by the base frame made of MINERALIT® polymer concrete.
USC 850
TECHNICAL DATA
TECHNICAL DATA USC 21
290
450
Maximum swing diameter
mm
800
Nominal range- Ø
inch
2-3/8—10-3/4
4-1/2—16
Maximum turning length
mm
2,000
Spindle Ø max.
mm
290
450
mm
700
X-axis travel
mm
350
350
Maximum turning diameter
27.5
Z-axis travel
mm
600
600
Diameter of the chuck
mm
400
Main drive power
kW
120
120
DIN ISO 702-1
A2-11
U/min
2,000
kW
20/30
Spindle nose Type Spindle speed Spindle power (continuous/30 minutes)
22
Machining of external- and internal diameter of pipe ends can be carried out on the pipe threading machine. This concept is ideal for the complete machining of all common thread connections according to API and GOST standard as well as all company-specific thread connections (Premium thread connections and Integral thread connections).
in in in in
32
79
16
TURNING BUSINESS UNIT
23
EMAG UG 400 · UG 630 · UG 1000 · UG 1500 UG 400
UG 1000
UG 630
UG 1500
The UG series from EMAG represents universal cylindrical grinding at the highest technical level. These machines combine precision, flexibility and process reliability in a compact design – ideal for internal, external out-of-round and face-grinding of a wide range of workpieces. With a grinding length of up to 1,500 millimetres, the machine series covers a wide range of applications – from short precision parts to long shafts or complex geometries. Universal cylindrical grinding machines for internal and external machining The combination of a rigid machine base, high-quality EMAG components and proven grinding technology results in universal grinding machines that ensure economical machining with high dimensional accuracy and reproducibility.
TECHNICAL DATA
24
UG 400
UG 630
UG 1000
UG 1500
Chuck dia., max.
mm
100
90
90
-
Center height/Width between center
mm
175/400
175/630
175/1,000
175/1,500
Grinding length (straight wheel/ angular wheel)
mm
400/240
630/450
1,000/825
1,500/1,220
Slide stroke (X-axis)
mm
320
320
320
320
Table stroke (Z-axis)
mm
640
885
1,240
1,860
Spindle motor power
kW
7.5
7.5 (11 optional)
7.5 (11 optional)
7.5 (11 optional)
in in in in in
hp
4
7/16
15/10 12.5 25
110
3.5
7/25
25/17 12.5 35
10 (14.7 optional)
3.5
7/40
40/32 12.5
49
10 (14.7 optional)
-
7/60
60/48 12.5
73
10 (14.7 optional)
EMAG VSC 250 DS · VSC 400 DS/DDS · VSC 250 DUO DS · VSC 400 DUO DS GRINDING BUSINESS UNIT
VLC 250 DS/VSC 400 DS/DDS
VSC 250 DUO DS/VSC 400 DUO DS
The combined turning and grinding centers combine the benefits of vertical hard turning with those of grinding – on a single machine and in a single clamping operation. The optimum, most economical machining process is used, depending on the workpiece and the quality requirements. The benefit for the customer is the flexibility of selecting the best technology for each machining process – hard turning, scroll-free turning, and grinding on a single machine. This machine reduces the process chain and delivers a whole series of benefits for the user: lower investment costs and costs per piece, shorter throughput times and higher workpiece quality with greater process reliability. The twin-spindle turning and grinding machines of the DUO Series are a very economical solution for the machining of larger batches for small and medium-sized workpieces. The DUO has the smallest footprint of the machines for the machining of components in first and second operation. The machines have two separate machining areas which means that they have overhead slides which can be programmed independently.
TECHNICAL DATA
VSC 250 DS
VSC 400 DS/DDS
VSC 250 DUO DS
VSC 400 DUO DS
Max. chuck diameter
mm
250/315
400
250/315
400
Max. swing diameter
mm
330
420
330
420
X-axis travel
mm
900
850
900
850
Z-axis travel
mm
300
315
300
Y-axis travel (optional)
mm
± 50/100
315
± 50/100
in
in in in in
10/12.5
13
35.5
12
2/4
15.5
16.5
33.5 12.5 12.5
10/12.5
13
35.5
12
2/4
15.5
16.5
33.5
315
12.5
315
12.5
25
EMAG VLC 200 GT · VLC 350 GT VLC 200 GT
VLC 350 GT
Too often, finishing processes are thought of in multi-machine concepts – in the end, people rely entirely on the grinding process. Optimization potential is wasted here because those who feed parts with a large oversize to the grinding process pay for the high surface quality with long process times and higher tool costs. With our machines from the VLC GT Series, we regularly prove to our customers that there is another way to make the combination machining of components possible. In short, where turning is possible, turning is done and where grinding is necessary, grinding is done. The time savings with the combination of turning + grinding works much faster, as there is much less excess material left after turning. The optimally adaptable machining area offers a lot of freedom in process design; even components with non-round contours can be processed in this way.
TECHNICAL DATA
26
VLC 200 GT
VLC 350 GT
260
400
160
350
Chuck diameter
mm
Max. machining diameter (grinding)
mm
Max. workpiece length
mm
100
200
X-axis travel
mm
1,700
2,390
Z-axis travel
mm
250
350
in in in in in
10
60 to 2.5 to
6.5
4
67 10
16
14 8
94 14
EMAG VLC 450 DG GRINDING BUSINESS UNIT
VLC 450 DG – Machine for grinding hard coating of brake discs. Designed specifically for high-volume machining of hard coating of brake discs, this production system meets the highest productivity levels and workpiece quality requirements. KEY POINTS
» Both grinding spindles are arranged in parallel;
the brake disc is machined in cross-grinding mode
» The grinding wheels are self-sharpening » A mineral oil-free solution is used as the process cutting fluids
TECHNICAL DATA
VLC 450 DG
Outer diameter of friction ring max.
mm
450
Diameter friction ring inside max.
mm
250
Friction ring thickness
mm
in
10–45
0.4–1.8
Hub bore diameter
mm
60–100
Chamber diameter
mm
140–250
in in
in in
18 10
2–4
5.5–10
27
EMAG VTC 100 GT · VTC 315 DS
28
VTC 100 GT
VTC 315 DS
Versatile solutions for shafts: The VTC 100 GT ensures a quick process for hard turning and grinding. The tool turret completes all turning operations and the workpiece loading work. A powerful grinding spindle is available for precision external cylindrical machining. This can be fitted with both CBN and aluminum oxide grinding wheels.
The perfect machine for machining demanding shafttype workpieces – vertical turning and/or grinding.
TECHNICAL DATA
TECHNICAL DATA
VTC 100 GT
Whether it is turning, drilling, milling, simultaneous grinding, synchronous support grinding, or combined turning & grinding – the VTC is suitable for all variants of process integration for shaft parts.
VTC 315 DS
Max. chuck diameter
mm
180
Chuck diameter
mm
in
12.5
Max. workpiece diameter
mm
100
Max. workpiece diameter
mm
240
Max. workpiece length
mm
400
mm
700
X-axis travel
mm
150
Max. workpiece length including clamping device
390
Z-axis travel
mm
660
X-axis travel
mm
Z-axis travel
mm
950
in in in
in in
7
4
15.5 6
26
in in in in
315
9.5
27.5 15.5
37.5
EMAG VG 110 GRINDING BUSINESS UNIT
VG 110
The VG 110 is a high-precision grinding machine designed for internal and external out-of-round machining of chucked parts. The machine is typically fitted with two high-speed grinding spindles and is ideal for CBN use. As an option, the machine can also be fitted with a combination of an internal grinding spindle and a tool block holder for combination machining.
TECHNICAL DATA
VG 110
Chuck diameter
mm
Max. internal machining diameter
mm
60
Max. grinding length
mm
40
X-axis travel
mm
460
Z-axis travel
mm
225
in in in in in
100 4
to to
190
7.5
2.5 1.5 18 9
29
EMAG WPG 7 · ECO 200 WPG 7
ECO 200
Machine workpieces up to 250 mm in length and with a maximum diameter of 200 mm extremely efficiently with the WPG 7 from EMAG.
The ECO 200 conventional cylindrical grinding machines deliver grinding quality from EMAG for minimal investment costs. These precision cylindrical grinding machines are particularly aimed at users, who do not require a CNC control system but, nevertheless, want top machining quality.
This is made possible by a rigid machine design, very dynamic axes, a powerful grinding wheel drive unit, and an extremely small footprint. Overall, the WPG 7 only requires around four square meters of space!
TECHNICAL DATA Center height
100/125
Distance between centers
mm
Longitudinal axis (Z), longitudinal travel
TECHNICAL DATA
ECO 200
Grinding length
mm
400
280
Center height
mm
100
mm
390
External grinding diameter
mm
1/100
Longitudinal axis (Z), feed rate
m/min
ipm
15
590.5
kg
Longitudinal axis (Z), table adjustment
°
8
Max. on-the-fly workpiece weight, MK4 Max. workpiece weight between centers
Lateral axis (X), lateral travel
mm
190
in in in
in
4/5
11
15.5
7.5
Lateral axis (X), feed rate
m/min
ipm
394
Grinding wheel diameter
mm
400/500
Max. grinding wheel width
mm
80
Grinding wheel bore
mm
127/203
Grinding wheel peripheral speed
m/s
50
Workpiece headstock – mounting taper Workpiece headstock – speed
30
WPG 7 mm
in in in
10
15.5/19.5
3
5/8
W20 (W25 or MK4, MK 5) m/s
0 – 2,000
in in in
15.5 4
0/4
10
lb
22
kg
30
lb
66
GRINDING BUSINESS UNIT
31
EMAG HG 2 · HG 204 · HG 208 · H 208 CD/DW HG 2 · HG 204 · HG 208
HG 208 CD
The ideal machine system for the external cylindrical grinding of shaft-type precision parts.
Hollow shafts and similar parts on which internal boreholes and external diameters must be produced with high precision relative to each other in other words machined ready for installation can be produced on the HG 208 CD center drive grinding machine.
The HG Series is specially designed for the highly productive mass production of shafts. The series of machines features a wide range of possible automation options and can be easily integrated in production lines.
TECHNICAL DATA
32
These parts include transmission shafts, which are often used in modern manual transmissions in cars. The external cylindrical grinding machine machines the hollow shafts inside and outside simultaneously in a single clamping operation. This production method is significantly more precise than production on two separate machines.
HG 2
HG 204
HG 208
TECHNICAL DATA
HG 208 CD
Max. workpiece diameter
mm
200
200
200
Max. workpiece diameter
mm
100
Max. workpiece length
mm
400
400
800
Max. workpiece length
mm
400
X-axis travel
mm
360
360
360
X-axis travel
mm
360
Z-axis travel
mm
1.000
1.000
1.600
Z-axis travel
mm
600
in in in in
8
15.5
14
39.5
8
15.5
14
39.5
8
31.5
14
63
in in in in
4
15.5 14
23.5
GRINDING BUSINESS UNIT
HG 208 DW
The HG 208 DW four-axis grinding machine for simultaneous machining can complete two external grinding operations on shaft-type workpieces at the same time. This process is ideal for workpiece families that always involve the same machining operations, but are located at different intervals from each other. These include steering pinions, transmission shafts, engine shafts and compressor shafts, for example.
TECHNICAL DATA
HG 208 DW
Max. workpiece diameter
mm
200
Max. workpiece length
mm
600
X-axis travel
mm
360
Z-axis travel
mm
800 31.5
in in in in
8
23.5 14
33
EMAG SN 204/208 · SN 310/320 SN 204/208
SN 310/320
This series is designed for all out-of-round grinding tasks for camshafts, for grinding external contours for single part and series production. The machines in the SN Series are specially tailored to the part geometry as required and can be equipped with one, two, or three grinding wheels for external cylindrical and/or external out-of-round machining.
TECHNICAL DATA
34
SN 204
SN 208
SN 310
SN 320
Max. workpiece diameter
mm
380
380
380
620
Max. workpiece length
mm
600
950
1,000
2,000
X-axis travel
mm
360
360
500
500
Z-axis travel
mm
1,000
1,600
1,700
2,700
in in in in
15
23.5 14
39.5
15
37.5 14
63
15
39.5 19.5 67
24.5 78.5
19.5
106.5
GRINDING BUSINESS UNIT
35
EMAG K 160 · K 300 K 160
K 300
The K 160 hobbing machine features the very latest generation of control systems and can provide high speeds at its milling head and main spindle.
The K 300 hobbing machine is a fully automatic machine with nine activated CNC axes to allow the flexible machining of gear wheels up to module 4.
In conjunction with a high-speed loading device, it can operate at high cutting speeds and correspondingly low cycle times, even on shafts and pinions with very low numbers of teeth.
The combination of an inclined base and closed frame design ensures maximum stability for both dry and wet machining.
TECHNICAL DATA
TECHNICAL DATA
K 160
Max. module
36
2.5
K 300
Max. module
4
Max. workpiece diameter
mm
100/140
Max. workpiece diameter
mm
140/195
Max. milling distance
mm
200/480
Max. milling distance
mm
300
Max. workpiece length
mm
300/1,000
Max. workpiece length
mm
300/800
Max. cutter width
mm
250
Max. cutter width
mm
200
Shifting path
mm
160
Shifting path
mm
160
Main spindle speed
rpm
4,000
Main spindle speed
rpm
800
Cutter speed
rpm
5,000
Cutter speed
rpm
2,500/4,000
in in in in in
3.9/5.5 8/19
12/39.5 10
6.5
in in in in in
5.5/7.5
12
12/31.5 8
6.5
EMAG HLC 150 H SOFT GEAR CUTTING BUSINESS UNIT
HLC 150 H
The HLC 150 H, the most modern horizontal hobbing machine available from EMAG, is a universal solution for hobbing and skiving, as well as worm milling and skiving processes, for components up to module 3. The HLC 150 H features a large axis spacing of up to 130 mm, a milling head swivel angle of -45°/+135°, and a milling head with a rating of 28 kW.
TECHNICAL DATA
HLC 150 H
Max. module
3
Max. workpiece diameter (fully automatic)
mm
150
Max. workpiece length
mm
500
Max. shifting path
mm
220
Max. cutter diameter
mm
120
Max. torque
Nm
140
Max. milling head drive rating
kW
28
Main spindle speed
rpm
4,000
Cutter speed
rpm
4,000 (up to 12,000 as an option)
in in in in
ft/lb hp
6
19.5 8.5 4.5
103 38
37
EMAG VERTICAL AND HORIZONTAL HOBBING MACHINES VERTICAL HOBBING MACHINES
HORIZONTAL HOBBING MACHINES
CLC SERIES
The hobbing machines are characterized by a stable structure with hand-scraped tangential axes. Both the table and the milling head are equipped with direct-drive axes. Processing can be done with oil, with emulsion, or dry. To order, a range of options can be installed in the machines, such as equipment for skiving, milling single parts, measuring on the machine, and a deburring and chamfering device. Shafts, worm wheels, and gear wheels can be manufactured on the machines, making the series an innovative solution for the hobbing process.
VERTICAL HOBBING MACHINES
HORIZONTAL HOBBING MACHINES
The machines can be equipped with NC-controlled 2station or 4-station ring loaders. Robotic loading and an optional deburring and chamfering unit are available. This means that these machines can be used to produce gear wheels, gear shafts and worm wheels economically.
Gear wheels, worm wheels, and long toothed shafts can be machined on the horizontal hobbing machines with excellent results. Retooling for new workpieces can be completed quickly, which makes the machine very interesting for single parts and small series. Furthermore, an optional automation system is available. On the CLC 260 H, worm shafts can also be milled with a milling cutter. For this purpose, an attachment spindle is installed on the standard milling head. Optionally, these machines can be equipped with a steady rest that can be moved to the appropriate position on an additional NC axis.
Max. module range (mm/in)
Axial travel (mm/in)
Max. diameter (mm/in)
5
370
250
CLC 300
7 (5)
400
350
CLC 500
10 (6)
600
500
CLC 500 H
CLC 600 W
24
1.000
800
CLC 900 W
24
1.000
1.000
1) Worm milling 2) Longer versions on request
TECHNICAL DATA CLC 200
38
16 16
24
39 39
10
14
20 32
39
TECHNICAL DATA
Max. module range (mm/in)
CLC 260 H 1)
Axial travel2) Max. diameter (mm/in) (mm/in)
6
1,500 (2,000/3,000)
260
22
2,000 (3,000)
500
59 (79/118) 2)
79 (118)
10
20
EMAG GEAR SHAPING MACHINES HARD GEAR CUTTING BUSINESS UNIT
GEAR SHAPING MACHINE
CLC-SZ SERIES
Thanks to an innovative modular system, this series is extremely flexible and can be easily configured for any machining task involving gear wheels and shafts. A wide range of options is available for this purpose, such as an electronic inclined guideway for shaping gears with an angle of inclination, shuttle shaping, keyway shaping and the production of crowns/tapers using the CNC controller. The machines are available with and without a retainer and with automation. As an option, the machine can be equipped with a tool changer so that roughing and finishing tools can be exchanged, which means that process and tool costs can be reduced.
TECHNICAL DATA
Max. module Axial travel Max. diameter Gearing width range (mm/in) (mm/in) (mm/in) (mm/in)
CLC 200 SZ
6
400
200
150
CLC 300 SZ
7
400
300
200
CLC 500 SZ
10
500
500
150 (200)
CLC 750 SZ
10
600
800
200 (250)
12
600
1,000
250 (300)
12
700
1,500
250 (300)
CLC 1000 SZ CLC 1500 SZ
16 16
20 24 24
27
8
12
20 31
39 59
6
8
6 (8)
8 (10)
10 (12) 10 (12)
39
EMAG Gear Shaving Machines and Shaving Cutter Grinding Machines GEAR SHAVING
GRINDING & SHARPENING SHAVING TOOLS
RASO 200 – RASO 400
GS 400
The entire manufacturing process must be considered for gear shaving: machines, cycles, tools that include a provision for the hardening process, fixtures, automation, etc. With our shaving machines, developed by the experts at EMAG SU, we can significantly improve the performance and quality of your shaving process.
The GS 400 tool grinding machine sets new standards in terms of accuracy, reliability and productivity when sharpening shaving cutters and grinding master wheels.
Gear shaving takes place before the hardening process and produces low-noise gears. This makes it a costeffective alternative to gear grinding. EMAG SU machines have a modular design and can be configured with three, four, or five NC axes.
Shaving cutters or high-precision test wheels can be ground on the shaving cutter grinding machine. Through the point contact of the grinding wheel and the workpiece, all conceivable modifications can be made to the gear wheel. The machine concept, with its linear motors and direct drives, is state of the art and all axes are NC-controlled.
Deburring, oil slinging, marking, and optical component recognition are available as options. All common shaving processes such as plunge, parallel, underpass, diagonal and combined cycles can be used.
TECHNICAL DATA Max. external diameter
mm
in
Module range Max. face width (plunge) Number of CNC axes (optional)
40
mm
in
TECHNICAL DATA
RASO 200
RASO 400
200
400
Min./Max. workpiece diameter
0.5/5
1/8
Max. module range
100 (42)
160
Max. face width
3 (5, 7)
5 (7)
8
4 (1.5)
16
6.5
GS 400 mm
in
68 – 400 2 – 16
0.5/15 mm
in
70 (90) 3 (3.5)
EMAG Horizontal Profile Grinding Machines HARD GEAR CUTTING BUSINESS UNIT
UNIVERSAL HORIZONTAL PROFILE GRINDING MACHINES
G SERIES
These highly flexible production machines from EMAG SU can be configured with or without a tangential axis (GP). Interchangeable spindles for different grinding wheel sizes mean that components with collision points can also be machined. Linear motors in the main axes ensure durable operation with a low wear. The machines of the G Series are ideal for the profile grinding of straight and angled internal and external gears, trapezoidal screws, ball screws, crown wheels, extruder shafts, hydraulic pumps, worms, small rotors and screw-type workpieces. Optionally, straight or angled internal gears can also be ground with very small grinding wheels. The machine software is able to dress involute and non-involute profiles according to XY coordinates. The profile is automatically corrected by measuring in the machine or in a closed loop to an external measuring machine. The profile grinding machines in the GW Series from EMAG SU have been specially developed for the high-precision grinding of long screw-type profiles, such as single-shaft extruders for plastic injection molding or recirculating ball screws. Optionally, these machines can be equipped with a tool changer (TC) and automatically moving steady rests.
TECHNICAL DATA Max. workpiece diameter
mm
in
Max. module range
G 375 H
G 500 H/HL
GP 500 H/HL
GW 3600 H/TC
375
500
500
500
15
0.5 – 22
0.5 – 15
10
15
20
20
20
Max. workpiece length
mm
870
1,250 (2,100)
1,250 (2,100)
3,200
Dia. of vitrified-bonded grinding wheels
mm
12/300
12/360
12/300
240/360
Max. workpiece weight
kg
350
350
350
Number of axes Internal grinding head
in
in
lb
34
1/2 /12
49 (83)
1/2 /14
49 (83)
1/2 /12
126
9/14
500
771.5
771.5
771.5
1,102
4
4
5
4 (5)
✓
✓
✓
41
EMAG Generating Grinding Machines VERTICAL GENERATING GRINDING MACHINES
G 160 – G 250 – G 400 – G 250 HS
EMAG SU offers a range of generating grinding machines for the machining of gears and shafts from small series to large series production. Customer-oriented solutions, such as topological grinding and fine or polishing grinding, are paramount. Due to its innovative axis concept with a chip-to-chip time of less than 2 seconds, the G 160 is one of the fastest generating grinding machines on the market and is ideal for large series. On the larger generating grinding machines (G 250/G 400), components can be profile-ground and generating-ground, which also makes them interesting for smaller series. The G 250 HS is equipped with a high-speed head. This means that components with collision points can undergo profile and generating grinding on the main spindle using very small grinding wheels. All machines can be operated using automation.
TECHNICAL DATA Max. workpiece diameter
mm
in
Module range
42
G 160
G 250
G 400
G 250 HS
160
250
400
250
0.5 – 3
0.5 – 7.0
0.5 – 7.0
0.5 – 5
6
10
16
10
Max. workpiece length
mm
300
550
750
550
Max. face width
mm
180
380
380
380
Max./Min. grinding wheel diameter
mm
275/210
250/160
300/220
160/70
Number of workpiece tables
2
2
1
2
Profile grinding
χ
in
in in
12 7
11/8
21 15
10/6
✓
30 15
12/8
✓
21 15
6/3
✓
EMAG Machining Worms And Rotors HARD GEAR CUTTING BUSINESS UNIT
HORIZONTAL MILLING CUTTER FOR ROTORS AND WORMS
PROFILE GRINDING OF ROTORS AND WORMS
CLC 260 H FR (W) – CLC 500 H FR
G 375 H – GR 500 HL – GT 500 HL – GW 3600 HD
The CLC milling cutters are heavy, powerful rotor milling machines. Rotors, rotary piston shafts, and worms can be machined with single-part cutters on these machines. The tool table is equipped with direct drives. Cutters with large diameters and lengths can be accommodated.
Profile grinding machines with four and five NC axes are available for profile grinding rotors and rotary pistons.
The machine can also be configured for dry milling and fitted with a measuring system.
4-axis concept: » These machines have a dressing device for grinding with vitrified-bonded grinding wheels (G 375 H, GR 500 HL, and GW 3600 HD). » The 4-axis machines are suitable for a wide variety of individual parts and for medium batch sizes.
5-axis concept: » Tangential axis for grinding with roughing (CBN) and finish grinding wheel (CBN or ceramic grinding wheel; GT 500 H and GW 3600 HD). » The 5-axis machines are highly productive, but can also be used for prototypes or uncommon rotor types (optional dressing device).
CBN grinding wheels: » EMAG can also supply CBN profile grinding wheels for grinding rotors, worms and gear wheels.
TECHNICAL DATA
CLC 260 H FR1)
CLC 260 HW2)
CLC 500 H FR2)
25
42
80
Max. profile height
mm
Axial travel
mm 1,500/2,000 in
59/79
Max. diameter
mm
Swivel angle
°
in
in
1
1.6
2.3
1,500 2,000/3,000 59
79/118
260
160
500
+/- 60
+/- 60
+90/-60
10
6
20
1) Milling machine for worms 2) Milling machine for rotors
TECHNICAL DATA
G 375 H
GR 500 HL
GT GW 500 H 3600 HD
Max. workpiece diameter
mm
250
400
350
500
Max. profile height
mm
30
80
80 (100)
100
Max. workpiece length mm
870
1,300
1,600
2,500
Number of axes
4
4
5
4 (5)
CBN
χ
χ
✓
(optional)
in in in
Ceramic grinding wheel
10
1
34
✓
16 3
51
✓
14
3 (4) 63
✓ (optional)
20 4
98
✓
✓
43
EMAG Highly Productive Worm Processing Machines WORM MILLING
PROFILE GRINDING OF WORMS
CLC 200 FR
GR 250 – GW 250
The CLC 200 FR milling machine for worm shafts features a milling head for installing milling cutters and a vertical workpiece axis. A 2-station or 4-station NC ring loader is available for the machining process. As an option, an additional process can be integrated at the 90° position of the ring loader.
These profile grinding machines are equipped with a double table, which greatly reduces the chip-to-chip time. The position of the gearing and the oversize are measured at the loading and unloading position, making this machine highly productive. A measuring system can be installed as an option. GR 250 The GR 250 has a grinding head for a dressable ceramic grinding wheel. GW 250 The GW 250 has two parallel grinding spindles for grinding worms, one for the CBN roughing wheel and one for a CBN finish grinding wheel. As an option, this machine can be equipped with a tangential slide, so that rotors can be machined with a CBN roughing and finish grinding wheel. Loading and unloading processes, as well as the measurement of components, are carried out parallel to the machining process. Due to the short workpiece changeover time, the spindle operates almost continuously.
TECHNICAL DATA Max. workpiece diameter
CLC 200 FR mm
in
Worm production
8
✓
TECHNICAL DATA Max. workpiece diameter
mm
in
Module range mm
GW 250
GR 250
150
250
0.7/7
0.7/7
550
550
6
10
Milling cutter diameter
mm
240/275
9/11
Max. workpiece length
Tooth depth
mm
22
Number of axes
5
4
Number of workpiece spindles
2
2
in in
Number of workpiece tables Swivel angle
44
200
7/8
1 °
+/- 60
in
21
21
EMAG Tool Grinding Machine and Deburring Machine HARD GEAR CUTTING BUSINESS UNIT
TOOL GRINDING MACHINE
CHAMFERING AND DEBURRING
HRG 350
SCT 3
The HRG 350 profile grinding machine is suitable for reprofiling and producing hobs and form cutters. These can be helical or threaded hobs.
Components are chamfered and deburred with the help of a roller deburring tool on the SCT 3 chamfering and deburring machine. The material is pressed to the flat surfaces via a forming process and removed with secondary deburring disks.
As an option, worm gear cutters and milling cutters can be ground. The tools to be ground can have involute and noninvolute profiles. Ceramic grinding wheels are used. A dressing unit is incorporated into the machine.
TECHNICAL DATA
HRG 350 mm
300
Max. grinding length
mm
0.6 – 10 (25 as an option) 450
Grinding wheel diameter (profile + relief grinding)
mm
30/100
Max. cutter diameter
in
Max. module range in in
12
17.5
1.5/4
TECHNICAL DATA
STC 3
Max. external diameter
mm
25/350
Max. workpiece length
mm
500/750
Max. gearing length
mm
200
Module range Number of tool heads
in in in
1/14
20/30 8
1/8 2
45
EMAG ELC Series ELC 6
ELC 6i
The EMAG ELC 6 is a production laser welding system for maximum output and is ideal for classic powertrain components with round welds. The machine is based on a rotary indexing system with a machining station and a loading and unloading station.
With the ELC 6i, EMAG presents a fully integrated laser welding system for the cost-effective batch production of powertrain components in high quantities. Up to six process steps—from cleaning and joining to welding and marking—including component handling are integrated in a compact system.
THE MAIN FEATURES OF THE ELC 6 ARE AS FOLLOWS:
Thanks to its modular design, central rotary transfer system, and end-to-end automation, the ELC 6i offers maximum efficiency with a minimal footprint, making it ideal for price-sensitive projects in the automotive industry.
+ Rotary indexing system to achieve the best possible cycle time
+ Maximum operating safety thanks to the “Fixed lens/moving workpiece” principle
ADVANTAGES:
+ Initial tension for welding up to max. 10 kN possible
+ Standardized, fully interlinked system for up to 6
(30 kN available as an option)
process steps
+ Compact design and excellent accessibility
+ Maximum operational reliability thanks to the “fixed optics/moving workpiece” principle
+ Short retooling times
+ Pre-tensioning for welding up to max. 10 kN
+ Minimization of equipment and change parts
(optionally 30 kN) possible
+ High level of flexibility in terms of technology,
+ Compact design and excellent accessibility + Short changeover times + Limitation of fixtures and changeover parts to a minimum
output, and automation
TECHNICAL DATA Max. external diameter
300
Max. workpiece height
mm
300
Axial welding diameter
mm
75/200
Radial welding diameter
mm
75/250
CNC controller
46
ELC 6 mm
in in in in
12 12
3/8
3/10
SIEMENS SINUMERIK ONE
TECHNICAL DATA
ELC 6i
Max. external diameter
mm
300
Max. workpiece height
mm
300
Axial welding diameter
mm
75/200
Radial welding diameter
mm
75/250
CNC controller
in in in in
12 12
3/8
3/10
SIEMENS SINUMERIK ONE
LASERTEC BUSINESS UNIT
ELC 160
The EMAG ELC 160 is a production laser welding system for high output, offering maximum flexibility and particularly suited to classic powertrain components with circular seams. The machine is based on a linear system with a spindle unit. KEY FEATURES OF THE ELC 160 INCLUDE:
+ Linear system with modular configuration and high flexibility for workpiece adaptation and process integration
+ Highest operational reliability thanks to the “fixed optics/moving workpiece” principle
+ Preload for welding up to max. 10 kN (optionally 30 kN) possible
+ Short changeover times + Limitation of fixtures and replacement parts to a minimum
TECHNICAL DATA
ELC 160
Max. external diameter
mm
300
Max. workpiece height
mm
300
Axial welding diameter
mm
75/200
Radial welding diameter
mm
75/250
CNC controller
in in in in
12 12
3/8
3/10
SIEMENS SINUMERIK ONE
47
EMAG ELC Series ELC 600
ELC 1200 V
The ELC 600 from EMAG LaserTec is a system for laser welding large workpieces. This makes the machine ideal for components from the commercial vehicle segment, for example, for truck differential housings. These components weigh up to 130 kilograms and have a diameter of up to 600 millimeters.
The vertical laser welding machine ELC 1200 V is designed for workpieces up to 1,200 mm in length and impresses with its fast processing, a small footprint and extreme ease of operation. The ELC 1200 V offers maximum flexibility in production. The 3-axis laser lens is NC-controlled and can be configured to meet a wide variety of individual requirements. In combination with the NC-controlled C-axis of the clamping device, the welding lens can also produce interpolated welds. This means that, for example, a quick conversion for laser welding of families of parts can be implemented without any problems. The clamping system is, of course, just as flexible as the laser lens. The key highlight, however, is the HMI (Human Machine Interface) with which the machine can be controlled and programmed.
TECHNICAL DATA
TECHNICAL DATA
Max. workpiece diameter
600
Max. workpiece height
mm
600
Max. workpiece weight
kg lb
55
Max. welding clamping force
kN
CNC controller
48
ELC 600 mm
in in
ELC 1200 V
Max. workpiece diameter
mm
300
Max. workpiece length
mm
1,200
120
Min. workpiece length
mm
50
100
Max. workpiece weight
kg
24 24
SIEMENS SINUMERIK ONE
CNC controller
in in in
lb
12
47
0.2
10
22
SIEMENS SINUMERIK ONE
LASERTEC BUSINESS UNIT
ELC 550 LMD
The ELC 550 LMD is a laser coating machine that has been specially developed for the production of wear-resistant brake discs. It can be easily integrated into various automation concepts. Its single-module design allows the system to be adapted with precision to a wide range of production scenarios – from single-part production to mass production. The machine is already optimized for the new generation of optics for commercial vehicles. ADVANTAGES ELC 550 LMD
+ Flexible module concept + Minimized downtime thanks to rotary indexing table + High system availability + Optimized process control + New technology package with Weldmetrix and Comexis TECHNICAL DATA
ELC 550 LMD
Max. workpiece diameter
mm
550
Max. workpiece height
mm
250
Max. layer thickness
mm
in
0,6
0,02
Max. workpiece weight
kg
22,5
Laser power
kW
30
CNC controller
in in
lb
22 10
50
SIEMENS SINUMERIK ONE
49
EMAG LC 4 · SFC 600 · ELC 1300 LH LC 4
SFC 600
The LC 4 laser cleaning machine evaporates the impurities on surfaces using a high-energy laser beam.
The joining machine SFC 600 features our patented thermal stress-free joining process combining precision and high flexibility for the heat shrinking of components (cams, bearing rings, sensor wheels, etc.) onto camshafts.
The machine is designed for components with a maximum diameter of 200 mm and a maximum height of 350 mm. To order, the laser lens can be aligned by the NC controller.
TECHNICAL DATA Footprint (without suckers) Laser capacity (fiber laser)
in
1,500 x 3,050
60 x 120
D
200-600
Max. axis speed (rapid-traverse) X-/Z-axis
m/s
in/s
0.4/0.5
0.01/0.02
Typ. C-axis feed rate
m/s
0.05
CNC controller
50
LC 4 mm
in/s
0.002
SIEMENS SINUMERIK ONE
The efficiency of the machine is mainly the result of its modular design with short cycle times and quick retooling times.
TECHNICAL DATA
SFC 600
Max. workpiece diameter
mm
40
Max. component diameter
mm
70
Max. workpiece length
mm
600
CNC controller
in
in in
1.5 3
23.5
SIEMENS SINUMERIK ONE
LASERTEC BUSINESS UNIT
ELC 1300 LH
The ELC 1300 LH is a horizontal production laser machine designed for laser hardening, welding, and coating of shaft-type workpieces. The machine design with NCmovable optics reduces the programming effort for new workpieces to a minimum. In laser hardening, for example, this means that a wide variety of workpieces with the same hardening zones can be converted very easily. Thanks to its kinematic design, the machine is also ideal for laser welding or coating shaft-type components with lengths of up to 1,300 mm and diameters of up to 400 mm.
TECHNICAL DATA
ELC 1300 LH
Max. workpiece diameter
mm
400
Max. workpiece length
mm
1,300
Max. workpiece weight
kg
50
CNC controller
in in
lb
16 51
110
SIEMENS SINUMERIK ONE
51
EMAG (P)ECM Systems PREMIUM INTEGRATED (PI)
PREMIUM STANDARD (PS)
The PI machine with its die-sinking, deburring, rifling, or oscillation module and integral electrolyte management system is a compact entry-level machine to the (P)ECM precision machining process:
The PS machine with its die-sinking, deburring, or oscillation module is the parallelizable machine platform for (P)ECM precision machining:
+ Modular design + Machining area: die-sinking module, oscillation module, rifling module, or deburring module
+ Scalable generator technology up to 2,500 A + DC, pulse and PECM technology + Flexibly configurable pulse technology + Individual cathodes can be selected/deselected + Single cathode monitoring + Process control using time, distance, and ldt + Touch panel and S7-1500 controller from Siemens + Conductivity monitoring + Temperature control + pH value control with metering + Can be transported with a forklift truck
module or deburring module
+ Scalable generator technology up to 2,500 A + DC, pulse and PECM technology + Flexibly configurable pulse technology + Individual cathodes can be selected/deselected + Single cathode monitoring + Process control using time, distance, and ldt + In the form of a die-sinking module: 400 mm Z stroke + In the form of an oscillation module: 200 mm Z stroke + Touch panel and S7-1500 controller from Siemens + Conductivity monitoring + Temperature control + pH value control with metering
Options:
Options:
» Microfiltration
» Fast short-circuit shutdown
» Fast short-circuit shutdown
» Automatic cathode cleaning
» Automatic cathode cleaning
» Oscillation at up to 100 Hz and stroke from 0 to 0.6 mm
» Oscillation at up to 100 Hz and stroke from 0 to 0.6 mm
» C-axis for interpolated multiple die-sinking movement
» C-axis for interpolated multiple die-sinking movement
» IoT Ready
» IoT Ready
» Automation interface
» Automation interface
» Can be combined with all electrolyte management systems from 20 to 600 l/min
» Single nest pressure control » Single nest flow monitoring » Automatic machining area door
52
+ Machining area: die-sinking module, oscillation
» Automatic machining area door
ECM BUSINESS UNIT
53
EMAG PECM Systems PTS
The economical solution for PECM process development and for the PECM machining of challenging 2D and 3D geometries.
+ Scalable generator technology up to 12,000 A + DC/Pulse/PECM technology + Flexibly configurable pulse technology + Fast short-circuit shut-down + Process control using time/distance/ldt + Machine base made of Mineralit + Clamping table: 800 x 550 mm (W x D)
Options: » Individual cathodes can be selected/deselected » Single cathode monitoring » Single nest pressure control » Single nest flow monitoring » Automatic machining area door » Cathode cleaning » XY worktable » C-axis » Scalable electrolyte management systems » IoT Ready » Automation interface » Oscillation at up to 100 Hz and stroke from 0.05 to 0.6 mm
54
+ Machining area: 1,070 x 700 x 515 mm (W x D x H) + Footprint: 2,100 x 3,200 x 2,900 mm (W x D x H) + Oscillator with play-free precision drive + Z-axis with 350 mm stroke and max. 25 kN axial load + Hydraulic zero point clamping system + Siemens Sinumerik 840D sl controller
ECM BUSINESS UNIT
55
EMAG PECM Systems PO 100 SF
PO 900 BF
The economical solution for the synchronous machining of both sides of turbine blades.
The alternative for the traditional machining of blisks and IBRs:
+ Scalable generator technology up to 24,000 A + DC/Pulse/PECM technology + Single cathode monitoring + Fast short-circuit shut-down + Process control using time/distance/ldt + Machine base made of Mineralit® + Clamping table: 370 x 450 mm (W x D) + Machining area: 750 x 600 x 360 mm (W x D x H) + Footprint: 2,800 x 2,300 x 2,600 mm (W x D x H) + Oscillator with play-free precision drive + X1-/X2-axis with 200 mm stroke and max. 25 kN axial load
+ Y-axis for interpolated feed: 100 mm stroke + Hydraulic zero point clamping system + Siemens Sinumerik 840D sl controller
and B-axis
+ X-, Y-, Z-, and C-axis with interpolated feed + Zero point clamping system for cathodes and workpiece + Siemens Sinumerik 840D sl controller
Options:
Options:
» Parallel machining of blades
» Cathode cleaning
» Cathode cleaning
» Scalable electrolyte management systems
» Scalable electrolyte management systems
» IoT Ready
» IoT Ready
» Automatic machining area door
» Automation interface » Single nest pressure control » Single nest flow monitoring
56
+ Scalable generator technology up to 12,000 A + DC/Pulse/PECM technology + Flexible step technology and type management + Fast short-circuit shut-down + Process control using time/distance/ldt + Machine base made of Mineralit® + Component diameters of up to 900 mm + Workpiece weight up to 300 kg + Footprint: 4,400 x 6,600 x 4,500 mm (W x D x H) + Oscillation at up to 50 Hz and stroke from 0.05 to 0.9 mm + Oscillator with play-free precision drive + X1-/X2-axis with 250 mm stroke and max. 50 kN axial load + Compound slide for holding workpieces with Y-/Z-axis, C-axis,
» Oscillation at up to 100 Hz and stroke from 0.05 to 0.6 mm
ECM BUSINESS UNIT
57
EMAG PECM Systems PO 3000 IP
With its electrochemical machining principle, the PO 3000 IP from EMAG ECM sets new standards for rifling gun barrels. The machine enables contact-free, stressfree internal machining with exact reproducibility – ideal for calibers up to 63 mm and barrel lengths up to 9,000 mm.
TECHNICAL DATA Inner diameter
mm
20–63 (optional up to 160)
Outer diameter (optionally extendable)
mm
up to approx. 121
ADVANTAGES OF ECM RIFLING:
+ Machining irrespective of material hardness or
structure + Feasible for complex geometries (e.g., gain twist) + No influence on the edge zones or mechanical stresses + No need for straightening processes or thermal post-treatment + Low cathode wear
58
P0 3000 IP
Component length
Feed speed
in
in
0.8–2.5 (optional up to 6.30) up to approx. 4.8
in
1,000–3,000 (optionally expandable to 9,000)
mm/min
up to 85
mm
39.4–118.1 (optionally expandable to 354.3)
Cycle time (reference)
~35 min at Ø 22 mm / 3,000 mm length
Electrolyte monitoring
Temperature, pressure, flow, pH, Cr⁶+
Workholding technology
Double lining with guide rollers
Cathode guide
Non-conductive multi-point guide
ECM BUSINESS UNIT
ELECTROLYTE MANAGEMENT SYSTEM (EMS)
Both systems with chamber filter presses and with microfiltration are available for filtration purposes. The filtrate quality and volume can thus be tailored precisely to requirements. Systems from 40 to 900 l/min filtration capacity are available as standard. High reproducibility of machining results is ensured by monitoring conductivity, temperature, pressure, flow rate, and pH value. The sludge can be discharged either manually or automatically depending on cutting volume and can be designed to operate without interrupting production on request.
59
EMAG TrackMotion 4/8 TRACKMOTION 4/8 TrackMotion is a linking system to connect two or more VL/VLC or VT/VTC machines and additional components such as feeding and discharge belts, measuring equipment, etc. The TransLift lift and turn-over unit runs on a modular rail system and features a programmable electric gripper which can transport and turn workpieces.
TM 4-20 TECHNICAL DATA
60
TM 8-70
VL 2
VL 4
VL 6
VL 8
Max. workpiece diameter
mm
100
200
300
400
Max. workpiece length
mm
150
200
250
300
Max. workpiece weight (gripper)
kg
20
20 44
70
154
70
154
Distance between transport and pick-up
mm
1,200
1,425
1,515
1,830
Horizontal travel speed
m/min
ipm
150
5,907
150
5,907
150
5,907
150
Vertical travel speed
m/min
35
35
35
in in
lb in
4 6
44 47
8 8
56
12
10
59.5
1,378
15.5 12
72
5,907
35
ipm
1,378
1,378
1,378
Time for turning through 180°
sec.
1.2
1.2
1.7
1.7
Max. horizontal travel length
m
20
20
20
20
ft
85.5
85.5
85.5
85.5
Stroke in Z (TransLift)
mm
450
450
650
650
Speed
rpm
6,000
4,500
3,100
2,850
in
17.5
17.5
25.5
25.5
EMAG SCS 1/4 EMAG Bin-Picking Cell BIN-PICKING CELL
Highly productive manufacturing with a minimum footprint – that is what the SCS Series stacking cells deliver. Whether they are for machining chucked parts or shaft parts, EMAG machines become compact, fully automated production systems that can produce autonomously for hours when combined with the SCS stacking cells. Depending on the diameter of the workpieces being machined, EMAG can supply the automation system in two sizes: the SCS 1 for parts up to around 200 mm in diameter and the SCS 4 for components up to around 400 mm in diameter, including an automatic palletizing device with a pallet pick-and-place unit. The parts are handled and the machines are loaded and unloaded by a robot. Naturally, the integration of components from any major manufacturer is always possible.
The smart automation solution enables machines to be loaded direct from workpiece bins. The vertical pickup turning machines from EMAG are already highly automated, in other words, both the machining process and the loading and unloading by pick-up spindles from the integral workpiece belt is fully automated. The binpicking cell allows machines to be loaded direct from a bin. The positions of the raw parts inside the bin are identified in real-time using a 3D camera system. These data are used to control a robot arm, which picks the individual components one by one out of the bin (bin picking), and then places them on the workpiece belt of the machine. FEATURES
+ 3D camera system
SCS 1
SCS 4
+ Mobile control panel
Workpiece size up to approx.
mm
200
400
+ Roller shutter door for fast loading and unloading
Max. basket/pallet size (height is adjustable)
mm
600 x 400
600 x 500
Max. basket/pallet weight (incl. workpieces)
kg
-
25
55
+ Gripper with collision monitor
Max. pallet drawer weight (incl. workpieces)
kg
45
-
+ Individual grippers to suit component contours
Max. weight per unit
kg
-
250
TECHNICAL DATA in in
lb
lb lb
8
24 x 16
-
99 -
16
24 x 20
-
551
AUTOMATION BUSINESS UNIT
SCS 1/4
(optional)
+ Level indicator with residual quantity estimate
+ Bins can be changed by AGV (automated guided vehicle)
61
EMAG Robot Cell MRC ROBOT CELL
CRC ROBOT CELL
The MRC robot cell was developed to make it easy to load and connect our machine tools. The new MRC robot cell provides a modular automation platform for machine loading and . With the bin-picking module, raw-parts can also be handled as bulk material in an efficient and resource-saving manner.
The CRC stacking cell is perfect for components with a diameter of up to 200 mm. It is loaded using workpiece carriers, which are housed in drawers and can carry up to 45 kilograms per drawer. A robot handles the parts and loads and unloads the machines. The machine operator is only responsible for replacing the workpiece carriers, which takes place simultaneously with the main processing time to ensure a continuous production flow.
ADVANTAGES
+ Flexibility:
Fast changeover between different component families, raw-parts and machining processes by using a robot with camera system and optional gripper quick-change system.
+ Volume:
Virtually noiseless picking up of components by the robot, no annoying noises due to mechanical separation.
+ Minimal non-productive time:
Direct loading into the spindle reduces the loading/ unloading time to just 4 seconds.
+ Compact automation solution:
Space-saving design and easy integration.
+ Economic advantage:
+ No shuttle required:
+ Integration:
TECHNICAL DATA
Reduced worker constraints for manual pre-alignment or other preliminary work on raw-parts and, thus, greater autonomy.
Simple integration of handling processes, such as aligning, cleaning or measuring components.
62
ADVANTAGES
Direct transfer between robot and machine. CRC mm
200
in
8
Basket/pallet size max. (height adjustable)
mm
600 x 400
in
24 x 16
Pallet drawer max. weight (incl. workpieces)
kg
45
lb
99
Workpiece size max.
AUTOMATION BUSINESS UNIT
63
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