Modular System for Line Production to be Shown at HOUSTEX
February 28, 2017
VL machines are part of EMAG's modular standard series. These machines are built on a common machine base but allow the use of a wide range of technologies, similar to the modular platform systems seen in the automotive industry. There are now modular machines available for turning, gear hobbing, and chamfering processes; for grinding (chucked parts and shaft parts); for induction hardening; and also in special designs for laser welding or PECM technology.
Automation Included
The machine base of these modular machines is made out of Mineralit polymer concrete. This material has vibration damping properties. The machine base supports a compound slide rest equipped with an X-axis and a Z-axis, which allows the working spindle to move. The working spindle is the heart of the pick-up automation system that is an essential part of every modular machine. It includes a parts storage unit in every machine, from which the pick-up spindle loads and unloads itself independently. This lowers non-productive time to an absolute minimum as there are only a few seconds between the machining processes. An optional measuring probe can be installed directly alongside the loading position, allowing time-optimized measuring of the parts.
The VL Series Modern Approach to Turning
The vertical pick-up turning centers of the VL series were developed particularly for the production of precise chucked parts. There are now five versions of the VL machine to cover the widest possible range of parts. The smallest machine is the VL 2, designed for chucked parts with a diameter of up to 100 mm. It is followed by the VL 4, VL 6, and VL 8, machines which allow for an increase of 100 mm in diameter with each model increase. These additional models allow the VL series to cover workpieces up to 400 mm in diameter. Each VL machine is equipped with a tool turret with up to twelve driven tools for the machining of chucked parts. This turret is dynamic; its fast indexing cuts non-productive time to a minimum, which in turn reduces cycle times. The machines can also be equipped with a Y-axis in the turret for the machining of complex shapes. This greatly expands the number of possible applications of the machines.
VL 3 DUO - Two Machining Areas
The VL 3 DUO is the first dual-spindle machine in the VL series. Its parts capacity places it between the VL 2 and VL 4, allowing high-productivity manufacturing of chucked parts with a diameter of up to 150 mm. The majority of transmission gearwheels fall into this size category. Every aspect of the VL 3 DUO has been designed for high-volume production, which makes it a suitable solution for the machining of gear blanks that have to be churned out by the millions. The VL 3 DUO is designed for performance. Including the parts storage unit, the VL 3 DUO has a footprint of no more than 13 square meters. That space houses the automation system, the parts storage unit, and two complete machining areas, each with its own working spindle and its own 12-station tool turret. This machine is designed for production in two clamping operations – machining both sides of a workpiece in OP 10 and OP 20, respectively. The part needs to be flipped over between the two operations. "With the TrackMotion automation system, EMAG has found an ingenious solution for this problem," said a company spokesperson.
TrackMotion — Modular Automation Solution
The TrackMotion automation system has been specially designed for modular machines and simplifies the connecting of multiple machines. The TrackMotion automation system is made up of two components: a track, which is a kind of rail routed behind the work area of the machines; and the TransLift, a gripper system that runs along on that rail. This NC gripper, which is programmed directly through the machine's control, provides the transportation of parts between the machines, as well as to and from the storage unit for raw and finished parts. The gripper has a Z-axis so it can also store the parts three-dimensionally, on top of each other, in stackers. This allows a huge number of parts to be stored in a very small space. The gripper also functions as a flip-over unit, turning the TrackMotion into a genuine all-purpose solution for the automation of modular machines.
Modern Manufacturing with VL Machines
EMAG's VL series of vertical pick-up turning centers offers a whole range of machines for all types of applications. In order to demonstrate this machining lines capability and versatility, EMAG L.L.C. will be showcasing a VL 4 at HOUSTEX 2017. "Visit booth 2321 for live demonstrations and to learn more about how this machining line can help you improve your production process," said the spokesperson.
For more information contact:
Kirk Stewart
Sales Director
EMAG L.L.C.
38800 Grand River Ave.
Farmington Hills, MI 48335
248-966-4703
kstewart@emag.com
www.emag.com
HOUSTEX 2017 Booth 2321
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