The HLC 150 H by EMAG processes a wide range of parts up to 500 mm (20") in length, up to module 3.
For automation, a high-speed loading gantry with a dual rotation gripper 120 or a V-shaped linear gripper are available.
View of the machining area: The large axis center distance of up to 130 mm (5"), and the powerful 28 kW cutter head ensure flexibility and efficiency.
More than ever, planners in the automotive industry are faced with the crucial challenge of providing flexibility in production technology. Manufacturers continually need to cope with modified ranges of components. For instance, the required geometry of workpieces can change quickly. Particularly, for gear cutting, this development can reach new extremes. Take steering components for example: production planners are looking for flexible machines that can efficiently cut the gears of steering pinions, worm gears and screws. This is how an EPS steering gear can be produced on a single machine. "Innovative machine builders like EMAG are able to accomplish this task, with their horizontal gear cutting machine HLC 150 H - a complete solution in every way," said a company spokesperson. This high-performance machine is able to manufacture a wide range of workpieces - transmission and anchor shafts, pinions and planetary gears with maximum lengths of 500 mm (20"). It includes all relevant gear cutting technologies such as gear hobbing, skiving, screw milling, worm skiving and chamfering. Workpieces up to module 3 can be finished without burrs, meeting high quality requirements.
Due to huge output quantities, a wide variety of workpiece demands and materials ranging from high strength steel to relatively soft plastics, automotive gear production is a large and challenging process. In the case of hybrid drives and various assistance systems, the variety of gearing tends to increase even more. The big question is therefore, more than ever: Which production solutions allow the efficient and comprehensive gearing of the largest possible number of different workpieces?
Low Cost Universal Machining
"This was exactly the question that started the development of the HLC 150 H machine," said Peter Loetzner, President and CEO of EMAG L.L.C. "Our answer was to develop a universal solution with high performance components. We are using all relevant machining technologies including chamfering. We have a large axis maximum center distance of 130 mm (5 inches) and a powerful 28 kW cutter head. As a result, we can efficiently cut gears on a wide range of workpieces up to module 3 with a maximum crown circle diameter of 150 mm (6 inches), and up to 500 mm (20 inches) in length. The customer benefits from lower costs and higher workpiece quality. Transmission shafts are a good example of this approach - the HLC 150 H guarantees hobbing and chamfering completely free of secondary burrs." After first rough-machining the gears, the gearing is deburred. The finish is applied during the second hobbing step. The result is an entirely burr-free chamfered gear. In addition, the HLC 150 H has many features to reduce costs - for instance, the energy-efficient frequency-controlled hydraulic units and the fact that the media supply is only activated when required. Furthermore, the counter bearing with its quick-clamping system and the easy accessibility of the machine allow for quick changing of all tools. Non-productive downtimes, such as for changing batches, are minimized.
Workpiece Quality Guaranteed
It is necessary to examine some of the technical details that contribute to the workpiece quality and process reliability on the HLC 150 H. During the milling operation, for instance, the cutter head with its rigid suspension always completely moves. The shift axis is based on the interpolation of two axes. This results in a large swivel angle for the cutter head, and a large shift path at the same time allow for a very smooth and precise milling process. The quality of the cut gears (verified by the absolute measuring systems) is the very best. A similarly important feature is the chip disposal concept by EMAG. Users benefit from the free downward chip flow without any chip build-up. That is why the machine is also suitable for dry machining. Additionally, different solutions are available including scraper-belt or permanent-magnetic conveyors - with the option of a deep-bed filter with magnetic pre-separator drum for ferromagnetic materials, non-ferrous metals and plastic. "In each case we ensure that the discharge process runs very smoothly, guaranteeing high process reliability," said Loetzner. "Especially during high performance, large-scale production, this is vital."
Modular Automation Concept
A modular automation concept is available for this machine, providing for short chip-to-chip times. The HLC 150 H can be loaded either manually, or with an automation system. As a second option, lighter components up to 3 kg (7 lbs.) are handled by an integrated high-speed gantry loader with rotating twin gripper. However, for heavier workpieces up to 10 kg (22 lbs.) a V-shaped linear gripper is available. Integration into complete EMAG production lines is also simple. "We are confident that this machine sets a new standard for the flexible machining of workpieces with a maximum length of 500 mm (20 inches) in length. Many steering components such as steering pinions, worm gears, screws and transmission shafts fall into this category," summarized Loetzner. "This machine really has it all: high performance machining with the 28 kW cutter head, press deburring integrated in the machining area or chamfering for end-to-end processes and flexible automation for easy integration into production lines. The bottom line is that the costs for machining steering components or transmission shafts will decrease, while the quality increases. We are convinced that the HLC 150 H has the best market opportunities in the automotive industry and with its suppliers."
For more information contact:
Kirk Stewart
Sales Director
EMAG L.L.C.
38800 Grand River Ave.
Farmington Hills, MI 48335
248-996-4703
kstewart@emag.com
www.emag.com
SOUTHWEST
TX, LA
Eric Klenner
Regional Sales Manager
EMAG L.L.C.
248-595-1530
eklenner@emag.com
TX, OK, AR
Glenn Wise
Regional Sales Manager
EMAG L.L.C.
248-756-1641
gwise@emag.com
NM
Shane Cross
Regional Sales Manager
EMAG L.L.C.
248-207-5365
scross@emag.com
SOUTHEAST
MS
Eric Klenner
Regional Sales Manager
EMAG L.L.C.
248-595-1530
eklenner@emag.com
AL, GA, FL, NC, SC, E. TN, VA
Dave Fitzgerald
Regional Sales Manager
EMAG L.L.C.
248-595-1117
dfitzgerald@emag.com
W. TN
Mark Comeaux
Regional Sales Manager
EMAG L.L.C.
248-938-2097
mcomeaux@emag.com
NORTHEAST
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Mark Comeaux
Regional Sales Manager
EMAG L.L.C.
248-938-2097
mcomeaux@emag.com
NY, PA, DE, MD, NJ, CT, RI, MA, VT, NH, ME
Kevin Gadde
EMAG L.L.C.
248-938-2430
kgadde@emag.com
Portions of NY and PA
Jeff Moore
Regional Sales Manager
EMAG L.L.C.
519-835-8425
jmoore@emag.com
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OH, KY, S. IN
Mark Comeaux
Regional Sales Manager
EMAG L.L.C.
248-938-2097
mcomeaux@emag.com
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Peter Vandersluis
Regional Sales Manager
EMAG L.L.C.
616-307-7401
pvandersluis@emag.com
E. MI
Jeremy Elder
EMAG L.L.C.
248-962-8963
jelder@emag.com
ND, SD, NE, KS, MN, IA, MO
Bill Konetski
Regional Sales Manager
EMAG L.L.C.
612-804-0857
bkonetski@emag.com
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Joe Thompson
Regional Sales Manager
EMAG L.L.C.
248-880-0233
jthompson@emag.com
WEST
WA, OR, CA, NV, ID, MT, WY, UT, CO, AZ
Shane Cross, CMTSE
EMAG L.L.C.
248-207-5365
scross@emag.com