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Solutions for eMobility and the Digitization of Manufacturing

EMAG highlighted productive and flexible manufacturing solutions for electromobility and more at IMTS. Among other things, the focus was on the vertical pick-up lathes of the VL series, which EMAG now delivers IoT-ready.

"Whether electric drive, hybrid motor or conventional drive, production planners face the great challenge of developing diverse manufacturing solutions for the future," said a company spokesperson. "On the one hand, they need new manufacturing solutions for a wide variety of components; on the other hand, costs must be reduced and production processes optimized."

"EMAG is also aware of this challenge, and therefore, began investing in digital solutions in addition to processing technologies a few years ago," continued the spokesperson. "EMAG's customers now benefit from this investment in networked production, as the combination of highly productive manufacturing technology and data analysis opens up completely new ways of production planning and thus opportunities for cost optimization."


EMAG believes the future belongs to data-optimized production. Optimizing cycle times and unit costs is important, but EMAG goes one step further and focuses on overall equipment efficiency (OEE) and its optimization based on manufacturing data. Through data analysis, unnecessary downtimes due to component wear, for example, or, in the worst case, due to the failure of a machine, can be reduced or avoided altogether. Productivity increases of over 10% are the norm here.

To make it as easy as possible for EMAG customers to enter the world of data-optimized production, the machines in the VL series are now delivered IoT-ready. This means that the machines can be integrated directly into existing IoT networks with little effort. Specifically, this means that the machines are equipped with an EDNA IoT core (an IPC). This IPC is already installed and networked with the machine controller. In addition, the machines are equipped with the EDNA NEURON 3DG sensor technology (one or more acceleration sensors on the spindle and, if necessary, the Y-axis), which enables regular automatic monitoring of the machine's health. Thus, data-optimized production can be started directly.

VL Series Vertical Pick-Up Lathes with New HMI

"Three axes, a tool turret with up to 12 driven tools and integrated automation-these are the distinguishing features of all machines in the VL series," said the spokesperson. In addition to the standard FANUC control, this series can now be equipped with the new EDNA HMI-a touch panel that can be configured to meet a wide variety of requirements.

At IMTS, EMAG showed a VL 4 with the new panel. Workpieces with a maximum diameter of up to 400 mm and a workpiece length of 300 mm can be machined on the vertical lathes of the VL series. Short chip-to-chip times are offered by the integrated automation via pick-up spindle, which automatically removes the components to be machined from the lateral conveyor belt and feeds them to the work area. The turret below the work spindle accommodates up to 12 turning or driven tools. In addition, the lathes can be equipped with a Y-axis in the turret to machine even more complex geometries.

Automated Shaft Production

With the vertical 4-axis VT 2 pick-up lathe, EMAG offers a solution for machining shafts up to 400 mm in length and 100 mm in diameter. "The strength of the system is particularly evident with larger quantities, because its automation solution ensures fast chip-to-chip times and low component costs," said the spokesperson. The raw parts are transported into the machine via workpiece grippers and removed again after processing. Depending on the workpiece, this changeover time only takes six to eight seconds. The actual turning process at a speed of 6,000 RPM also takes place in short cycles. The shaft is clamped vertically between the main spindle and tailstock and machined from two sides. Two tool turrets, each with 12 positions, are available for this, which are equipped with turning tools or driven tools (one position is occupied by the gripper).

As an option, the machine can be equipped with a Y-axis for milling keyways, for example. The vertical arrangement of the component offers long-term process reliability-the free fall of chips avoids chip nests in the machine room. Finally, the external dimensions of the machine are decisive for economic production planning. The basic body of the machine is small because the vertical arrangement takes up little space. Production planners also do not have to plan for additional raw and finished part dispensers-they are an integral part of the VT 2. In addition, the machines can be linked in a tight line arrangement to form a production system.

Horizontal Hobbing Machine K 160

At IMTS EMAG also presented a product from EMAG KOEPFER: the K 160 horizontal gear hobbing machine. These machines have eight activated CNC axes and can be operated fully automatically. "To achieve optimal results, the machine base must be rigid and stable. For this reason, the development engineers at EMAG, as with the lathes in the VL series, opted for a machine bed made of MINERALIT, which has eight times better damping properties than a gray cast iron bed," said the spokesperson. "The polymer concrete forms the statically, dynamically and thermally stable base of the machines and thus ensures a long tool service life and a high surface quality. The base of the K 160 was designed as a closed frame construction, which guarantees the greatest possible rigidity on the tailstock and main spindle, even with the highest clamping and machining forces."

The maintenance-free direct drives in the tool and workpiece axes offer enhanced gearing quality that remain constant over the service life of the machine. To help ensure good chip removal for both wet and dry machining, the milling head on the K series was arranged at an angle on the machine bed. This allows the chips to flow downwards unhindered into the chip conveyor. Good accessibility and an ergonomically designed work area were also important to the developers. This offers the option of attaching further NC-controlled auxiliary tools, for example for deburring with a disc or steel, vibration dampers, sensor carriers for automatic orientation or for special applications such as driven deburring tools.

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