EMAG NEWS 33 - EN

SCHERER · KOEPFER · RICHARDON · LASER TEC · REINECKER · KARSTENS · KOPP · NAXOS-UNION · WEISS · SU · ECM

4

6

RECISE MACHINING OF P ROTORS & WORMS Customers

Visit to ZLKL in the Czech Republic

12

VSC 400 DDS

Production line for hollow shafts

16

EDNA HMI

Touch panels for every user

NO. 33

TECHNOLOGY. CONNECTED. T

echnology.Connected. stands for nothing less than the future of industrial production – at least as we at EMAG understand it. Networking is the basis of this idea. Networking of machines, technologies and data, as well as, of course, people.

The networking of machines has long been part of our daily business. As an important partner to industry, the EMAG Group develops and supplies networked manufacturing systems for suppliers and OEMs from a wide variety of sectors. A new addition is the digital networking of our manufacturing technologies with our EDNA IoT solutions. The collection and evaluation of production data opens up completely new ways of production optimization for our customers. This ranges from the visualization of production data on dashboards to dynamic production planning using algorithms.

Turning Chucked Components

Gear Grinding

2

Turning Shafts

Cylindrical Grinding

Out-of-round Grinding

nding

In the process, another important interface is added, namely that between the machines, the data and the people. It is no coincidence that we have invested a great deal of time and effort in the development of our new HMI (human-machine interface). The result is impressive, as you can see on pages 16-17.

In general, we have once again compiled a great many interesting topics for you. For us, networking also means facilitating networking between people – our employees and you, our customers.

This issue of EMAG News, which includes submissions from many people from diverse departments and sites at EMAG, should also contribute to this. We hope we have chosen the right topics and that you will find many ideas and suggestions on the following pages. Together, networked, successful – Technology.Connected.

Milling

Gear Hobbing

ECM/PECM

Laser Processing

3

PROFILE MILLING AND GRINDING MACHINES FROM EMAG SU FOR SCREW-TYPE WORKPIECES:

PRECISE MACHINING OF ROTORS, WORMS, AND MORE

The pre-machining and fine machining of rotors, worms, extruder shafts, ball screws and long spiral workpieces is a high-tech task: Pre-machining requires heavy and rigid profile milling machines that can do the milling work with a milling cutter in the shortest possible time. During the subsequent fine machining on the profile grinding machine, the high-precision profile shape and surface are pivotal for the power transfer of the workpieces. EMAG SU has a range of horizontal and vertical profile milling and profile grinding machines in its portfolio that have been specially developed for this task.

P

rofile milling machines for worms and rotors are available in a horizontal version with the corresponding dialog software. Rotors and rotating pistons are manufactured on heavy-duty profile milling machines. All machines can be equipped with appropriate steady rests or automation.

Profile grinding machines from EMAG SU are available as 4-axis or 5-axis machines. Ceramic grinding wheels are used on 4-axis machines for small and medium-sized production batches. The 5-axis machines also have a tangential axis on which a roughing CBN and finishing CBN grinding wheel can be mounted on a grinding wheel mandrel. A dressing unit can be optionally installed on this machine for prototypes or uncommon rotor types so that ceramic profile grinding wheels can also be used here. This allows the tool costs to be significantly reduced. All machines use special rotor grinding software, which is able todress and grind any profile.

PERFECTION VIA A “CLOSED LOOP” The (repeated) dressing of the grinding wheel, the profile check on the component and the finish grinding are intelligently coordinated in an automated process – this is the closed loop process of EMAG SU. Note: There is a special dressing spindle in the machines. It enables the dressing of any profile.

WORKPIECES

4

G-H

SERIES

MILLING OF ROTORS AND WORMS EMAG SU has special rotor and worm milling machines, some in heavy-duty versions for a profile height of up to 80 mm. Steel and cast iron workpieces are machined with a milling cutter either dry or with oil.

ROTORS AND WORMS PROFILE GRINDING:

» CBN grinding wheels and/or ceramic-bonded grinding wheels in use

» Optional dressing units » Adapter for quick tool changes » Integrated measurement technology » Optimum vibration damping and thermal stability » Direct linear and rotary motors » High-precision guides » Rigid tailstock

CBN GRINDING WHEELS FROM EMAG SU EMAG SU manufactures electroplated CBN grinding wheels with customerspecific geometry. These can be used for machining gear wheels, rotors and worms.

The GR 500 H has a high-performance grinding spindle for high removal rates and a dressing unit for large profile heights and profile widths.

5

EMAG AT ZLKL:

SUPPLY COMPANY ZLKL ESTABLISHES HIGH-END MANUFACTURING PROCESSES WITH EMAG It is an impressive success story: Since it was founded in 1993, the Czech supply company ZLKL has shown constant growth. Today more than 200 employees work at three locations. They produce sophisticated components for the electrical and automotive industries. A key success factor is continuous investment in advanced production technology with automation components – EMAG solutions play a major role.

T

he company started investing in EMAG technology about ten years ago. “We realized very quickly that productivity increases significantly with vertical turning.

With many EMAG machines it is also possible to integrate additional operations such as drilling or milling. This ensures a further increase in performance for complex components,” explains Karel Zeman, Senior Manager Machining at ZLKL. “We also benefit from the high reliability of the EMAG machines in continuous operation. Last but not least, we have a competent partner for establishing new production processes.”

As a result, around 25 EMAG machines are already in use at ZLKL – including the modular pick-up turning machines VL 3, VL 3 DUO, VL 4, VL 5, VL 7 and VL 8, the turning center VM 9, the vertical turning machine VTC for multi-axis shaft machining and, starting at the end of this year, a first VL 2. Many powertrain components for electric motors and combustion engines, such as flanges, hubs, housings and shafts, are machined based on the vertical turning technology.

EMAG FILM Find here a video of our visit:

“We rely on high-end manufacturing technologies to develop high-end manufacturing processes.”

Karel Zeman, Senior Manager Machining, ZLKL

6

AVAILABLE AT SHORT NOTICE

ZLKL

Modular standard turning machines are still

Working together towards success (from left): Martin Látal, CNC Programming, Jan Ondruška, Head of Quality Management, Karel Zeman, Senior Manager Machining, Zdenek Tollrian, Head of Engineering (all ZLKL), as well as Martin Deliš and Siegfried Holzer from EMAG Sales.

7

NEW WEBINAR STUDIO AND MANY NEW EXCITING TOPICS

EMAG ON AIR!

Some of you may have already seen it, at least if you attended one of the webinars this year. Our webinar studio has been completely rebuilt, in order to be able to present our exciting topics to you in an even better way.

However, there will not only be a lot to see in the studio, we will also be broadcasting live from the production halls of our various locations to show you exciting projects. To make sure you don't miss any of our webinars, why not sign up now for our webinar newsletter and stay up to date about the EMAG webinar program.

OUR UPCOMING WEBINAR HIGHLIGHTS

» E-mobility

In this webinar, learn how to efficiently implement the production of stator housings on vertical turning machines.

WEBINAR NEWSLETTER The EMAG newsletter provides you with up-to-date information about our machines, technologies and events.

8

» Shaft Machining

Highly productive shaft machining with the 4-axis principle from EMAG. In this webinar, find out which components are worth vertical processing.

» IoT-ready

Our VL Series is now IoT-ready when delivered. In this webinar, you will learn exactly what this means and what advantages it brings.

9

AUTOMATION:

THE NEW STACKER CELLS OF THE SCS SERIES Highly productive manufacturing in the tightest of spaces – that’s what the new stacker cells of the SCS Series promise in combination with the vertical turning machines from EMAG.

W

hether for the machining of chucked parts or shafts, in combination with the SCS stacker cells, EMAG machines become compact, fully automated manufacturing systems that can produce autonomously for hours. Depending on the size of the workpieces to be processed, EMAG offers the automation system in two sizes: the SCS 1 for parts up to 200 mm in diameter and the SCS 4 for parts up to 400 mm in diameter, including automatic palletizing equipment with pallet transfer. The parts handling and the loading and unloading of the machines are carried out by a robot. Of course, the seamless integration of any well-known manufacturer is possible here.

TECHNICAL DATA

SCS 1

SCS 4

Max. workpiece size

mm

200

400

Max. basket/pallet size (height is adjustable)

mm

600x400

600x500

Max. basket/pallet weight (incl. workpieces)

kg

-

20

Max. pallet drawer weight (incl. workpieces)

kg

45

-

Max. weight per unit

kg

-

250

1

1

in in

lb

lb lb

8

24x16 -

99 -

16

24x20 44 -

551

LOADING THE SCS 1 The SCS 1 is loaded via workpiece carriers in drawers. The robot removes the parts from the workpiece carrier and loads the machine. The number of possible drawers and parts per pallet depend on the components to be processed.

1

2

LOADING THE SCS 4 The SCS 4 is loaded via pallet or basket units, which are loaded into the system either manually or fully automatically.

10

SCS

SERIES

ADVANTAGES OF THE SCS SERIES

» Perfect solution for VL and VT Series machines and K Series machines from KOEPFER

» Compact complete manufacturing solution from a single source from EMAG

» Economical production thanks to optimal machine utilization

» Low load on staff » High storage density with a small footprint » Comparatively low investment costs » Easy retrofitting option for existing EMAG machines

11

VSC 400 DDS AND EMAG ROBOT CELLS:

PRODUCTION LINE FOR HOLLOW SHAFTS

T

his production line is characterized by high flexibility and productivity while at the same time being extremely compact: It is flexible, since practically every component in a family of parts can be manufactured with this concept, and it is also productive, since the system basically never stands still, thanks to a well thought-out retooling process. A parts buffer was integrated into the robot cell for this purpose.

RETOOLING OF THE LINE

» The last parts of the first series are temporarily stored in the parts buffer. » Retooling of the first machine (OP 10), while production continues on the second machine using the parts from the parts buffer (OP 20). » Retooling of the second machine (OP 20), while new workpieces are already machined in OP 10 and stored in the parts buffer.

The parts buffer is gradually unloaded and loaded with new parts until the entire system is supplied with new parts. The system is therefore never at a standstill, thus ensuring high overall plant efficiency.

Robot cell OP 20 VSC 400 DDS

» Machining of the second side,

both inside and outside

» Turning, grinding and

milling are possible

12

» Parts handling » Measurement » Marking » Buffering

VSC 400

LINE

BENEFITS OF EMAG ROBOT CELLS

» No set-up needed » Flexible parts handling » Parts buffer can be integrated » Ability to integrate measuring systems » PLC and NOK compartments » Laser station can be integrated for labeling » Packaging unit can be integrated

OP 10 VSC 400 DDS

» Machining of the first side, both inside and outside

» Turning, grinding and

milling are possible

Loading and unloading

13

ELC 1200 V:

LASER WELDING MACHINE FOR SHAFTS The vertical laser welding machine is designed for workpieces up to 1,200 mm in length and impresses with its fast machining, a small footprint and extreme ease of operation.

T

he 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 makes it easy to implement quick changeovers for the laser welding of part families, for example. Of course the clamping system is just as flexible as the laser lens. The key highlight, however, is the graphical user interface with which the machine can be controlled and programmed.

Anyone who has ever operated a device with a touchscreen will feel at home here immediately. This makes laser welding practically as easy as using a smartphone.

LOADING STATION Due to the loading and unloading on a rotary indexing table in parallel with the main time, the machine is practically never at a standstill.

The machine can be loaded both manually and fully automatically.

WELDING STATION The laser lens has X- and Z-axes as well as an additional B-axis for rotating the laser lens. Thanks to the optional NC control, the production of families of parts can be implemented without any problems.

Z B

X C

HMI ADVANTAGES WITH THE ELC 1200 V 14

» HMI specially developed and optimized for laser applications

» Easy-to-learn operation through graphical user guidance » Easy set-up of new workpieces using “Teach in”

» SIEMENS CNC screen still fully usable » IoT interface for data-optimized production (connection to IPC and other EDNA software)

» Multi-device – data can be called up on mobile devices

ELC 1200 V EDNA HMI Learning to control and program the ELC 1200 V has been extremely simplified by the EDNA HMI developed

by EMAG.

EMAG FILM See an animation of the machine here:

The vertical construction of the machine enables an extremely small footprint of just 4.3 square meters, excluding the laser source.

15

HMI:

CUSTOMIZED OPERATION FOR EVERY USER An operating concept that suits everyone? That simply didn't exist until now. The new EDNA HMI completely changes the operation experience.

F

rom the requirements of the programmer, who needs to access every value, to those of the operator, who simply supplies the machine with workpieces – this is the range that a modern HMI must cover. Until now, mainly due to the hardware, control concepts could only be configured to different requirements to a very limited extent.

The advent of smart devices and touchscreens provided another route. Although, the underlying hardware remains the same, the interaction possibilities are adaptable to the customers’ needs. It is precisely this concept that EMAG used when developing EDNA HMI for operating machine tools, allowing customization for every user.

3 QUESTIONS FOR:

Peter Strohm – Business Development Manager IoT

1 / You hear again and again that touch panels are prone to dirt and scratch easily and are therefore not suitable for industrial use. What do you think of that?

This prejudice has persisted for years, although today’s touchscreens have nothing in common with those from the early days. Our touch screens are designed for industrial use, as well as for working with gloves in harsh environments. The underlying hardware has been used successfully worldwide for many years.

2 / Operators keep saying they need hardware buttons to operate the machine “blindly“.

How do you deal with that?

Our new EDNA panel was designed together with machine operators who do nothing else but set up machines every day. The requirements for the hardware buttons that are now on the panel were derived from this. It is also possible to add additional hardware buttons. The deliberately reduced number of hardware buttons, in combination with the user-focused interface, allow for much easier operation.

3 / Can every EMAG machine really be equipped with the HMI you developed?

That’s the long-term plan, but we’re not there yet. We have implemented operating concepts for turning machines and laser welding machines and are currently in the process of equipping the first grinding and hobbing machines. This is how we are gradually expanding our portfolio.

16

EDNA

HMI

BENEFITS » Operation of the FANUC CNC screen with the EDNA components (keyboard, other software controls, Fanuc Controls)

» Future-proof platform for further innovative applications and updates

» Retrieval of manufacturing information on the panel (e.g. product drawings)

» IoT interface for data-optimized production » Industry 4.0 applications can be used

(EDNA Visualize Dashboards, Health Check, etc.)

» Multi-device – data can be called up on mobile devices » User-friendly due to swiveling feature

EMAG FILM See a detailed presentation of the new HMI here

17

Modular standard turning machines are still

AVAILABLE AT SHORT NOTICE

E-MOBILITY:

LINAMAR TECHNOLOGY HUNGARY RELIES ON EMAG “We chose EMAG because the company offers and masters a wide range of technologies.”

István Bíró, Linamar

18

LINAMAR High precision, plus rapidly growing quantities – the success of electromobility is challenging production planners. The example of the supplier Linamar Technology Hungary shows how this task can be solved effectively. The specialists for e-drives rely on production solutions from EMAG.

L

inamar is a globally operating company and produces, among other things, a large portfolio of components related to power generation and storage, electric drive systems, and structural and chassis systems for e-vehicles.

Extensive engineering and manufacturing know-how make Linamar a market leader here in terms of quality, system integration and time to market.

One of Linamar's central production sites for electric mobility is its subsidiary Linamar Technology Hungary. The specialists based in Békéscsaba manufacture and assemble, among other things, transmission components as well as aluminum housings and covers for a new e-car platform that has been on the market since last year. On board for this: various machines from EMAG. "We chose EMAG because the company offers and masters a wide range of technologies," explains Linamar's István Bíró. "In addition, EMAG develops innovative solutions that help us make our production processes leaner."

Specifically, Linamar Technology Hungary uses the VL 6 and VT 2-4 vertical lathes and the VLC 200 GT vertical turning and grinding center for hard machining of gears and shafts. The company also has the ELC 160 laser welding machine for welding gear wheels. What experience has Linamar gained with the various machines? "We are currently in the start-up phase and produce around 60,000 parts per type per year. In the future, however, we will produce around 430,000 parts per type per year," explains István Bíró. "In this respect, it is important for us that the machines ensure a stable process. This is absolutely the case. In addition, we have not yet fully exploited the potential of the machines at present. For example, we can reduce the measuring effort if we use the integrated measuring probes. Overall, we are very satisfied with the solution."

EMAG BLOG Read the full blog post here.

19

ECM TECHNOLOGY:

MACHINING OF FINISHED MACHINED WORKPIECES ECM is one of the few technologies that can be used for burr-free finishing of mechanically fine machined surfaces

W

hy it can be worthwhile for production planners to use ECM technology is exemplified by the connecting rod on the right in the picture. Here, an oil groove and two bores are made in the machined component using ECM – all in one step. The advantage is obvious: First, there are no interrupted cuts during machining. Secondly, the use of ECM is residue- and burr-free, i.e. no reworking is necessary on the finished machined component. And thirdly, the hardness of the component is irrelevant for ECM technology, i.e. components that have already been hardened can also be machined without any problems.

All in all, as an additional process step on the finished component, ECM offers numerous advantages that can significantly simplify the production planning of components.

20

ECM ADVANTAGES OF ECM DRILLING:

» No drilling cap or burr formation » Absolutely zero burr – no secondary burr » No thermal or mechanical stresses » Hard and soft machining » Stable process » No interrupted cutting » Multiple boreholes in a single process step

THE PREMIUM INTEGRATED (PI) 800: THE OPTIMAL ENTRY INTO THE (P)ECM PROCESS The (P)ECM machining area, a control cabinet with control system and the electrolyte management system are all mounted on one machine frame (single frame).

This means that the PI has a small footprint, is compact, and can be transported with a forklift truck!

TECHNICAL DATA

PI 800

Machining area

mm

1,150 x 950

Clamping surface

mm

600 x 400

Generator capacity

A (DC)

400 – 2,500

Generator capacity

A (pulse)

400 – 8,000

inch inch

45 x 37.5 24 x 16

21

VLC GT SERIES:

USING COMBINATION MACHINING CORRECTLY Too often, finishing processes are thought of in terms of multi-machine concepts – in the end, people rely entirely on the grinding process.

Optimization potential is often wasted here because if you start the grinding process with a lot of stock allowance, you pay for the high surface quality with long process times and higher tool costs.

W

ith 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 combination of turning and grinding saves a great deal of time, 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. So the next time you plan a finishing process, think of the VLC GT machines – there is a lot of potential here.

WORKPIECES Combination machining can be used for many components from a wide variety of industries. Here is a small selection: 22

VLC GT

SERIES

MACHINE HIGHLIGHTS

» Through the combination of hard turning, external grinding and internal grinding, gear wheels and many other workpieces can be completely machined in just one clamping operation.

» Additional technologies can be integrated, making the machine extremely flexible.

» The separate dressing spindle means that also rotating dressing tools can be used.

» The large service door in the front ensures excellent access to make setting and tooling work easier.

» The turret can be supplemented with a Y-axis as an option. Driven tools can then be used to mill longitudinal grooves, for example.

» The optional B-axis brings other possibilities into play.

TECHNICAL DATA VLC 200 GT VLC 350 GT Max. workpiece diameter

200 mm

350 mm

Chuck diameter

260 mm

400 mm

Max. workpiece length

100 mm

200 mm

1,700/250 mm

2,390/350 mm

Travel distances, X/Z

8 in

10 in

4 in

67/10 in

14 in

16 in

8 in

94/14 in

EMAG FILM See a VLC 200 GT Turning Grinding Center here:

HOLLOW SHAFT Combination machining is also used for manufacturing hollow shafts for e-bike drives. A perfectly coordinated process and an optimal tool configuration ensure the rapid and highly precise machining of the inner and outer diameters.

23

Salach Austraße 24 73084 Salach Germany Phone: +49 7162 17–0 Fax: +49 7162 17-4027 E-mail: info@salach.emag.com

Austria Glaneckerweg 1 5400 Hallein Austria Phone: +43 6245 76023–0 Fax: +43 6245 76023-20 E-mail: info@austria.emag.com

Frankfurt Martin-Behaim-Strasse 12 63263 Neu-Isenburg Germany Phone: +49 6102 88245–0 Fax: +49 6102 88245-412 E-mail: info@frankfurt.emag.com

Sweden Glasgatan 19B 73130 Köping Sweden Phone: +46 221 40305 E-mail: info@sweden.emag.com

Hungary Gerenda 10 1163 Budapest Hungary Phone: +36 30 9362-416 E-mail: lbujaki@emag.com

Poland ul. Krzycka 71A/6 53-020 Wrocław Poland Phone: +48 728 389 989 E-mail: info@poland.emag.com

Czech Republic Lolkova 766 103 00 Praha 10 – Kolovraty Czech Republic Phone: +420 731 476070 E-mail: mdelis@emag.com

Turkey Sanayi Cad. No.: 44 Nish İstanbul Sitesi D Blok D: 155 Yenibosna – Istanbul Turkey Phone: +90 532 694 54 44 E-mail: ckoc@emag.com

NEWS 33/03.2022 · © Copyright EMAG · Printed in Germany

EMAG Salach GmbH

Marketing companies EUROPE

AMERICA

ASIA

EMAG MILANO S.r.l.

Via dei Mille 31 20098 San Giuliano Milanese (Mi) Italy Phone: +39 02 905942-1 Fax: +39 02 905942-24 E-mail: info.milano@emag.com

EMAG L.L.C. USA 38800 Grand River Avenue Farmington Hills, MI 48335 USA Phone: +1 248 477-7440 Fax: +1 248 477-7784 E-mail: info@usa.emag.com

EMAG MILANO S.r.l.

Succursale en France 5 Avenue de l’Europe 18150 La Guerche sur l’Aubois France Phone: +33 02 48 7711-00 Fax: +33 02 48 7111-29 E-mail: info.france@emag.com

EMAG MEXICO Maquinaria EMAG Mexico S de RL de CV Av. Hercules 301 Nave 1 Poligono Empresarial Santa Rosa 76220 Santa Rosa Jauregui, Querétaro Mexico Phone: +52 442 291 1552 E-mail: info.mexico@emag.com

EMAG (China) Machinery Co., Ltd. Sino-German Advanced Manufacturing Technology International Innovation park Building 2, No. 101, Chen Men Jing Road 215400 Taicang Jiangsu, China Phone: +86 512 5357-4098 Fax: +86 512 5357-5399 E-mail: info@emag-china.com

EMAG MILANO S.r.l.

Sucursal en España Pasaje Arrahona, n° 18 Polígono Industrial Santiga 08210 Barberà del Vallès (Barcelona) Spain Phone: +34 93 7195080 Fax: +34 93 7297107 E-mail: info.spain@emag.com

EMAG DO BRASIL Edifício Neo Corporate Offices, CJ 1503 Rua Enxovia, 472 04711-030 São Paulo SP Brazil Phone: +55 11 38370145 Fax: +55 11 38370145 E-mail: info@brasil.emag.com

EMAG KOREA Ltd. Rm204, Biz center, SKn Technopark 124 Sagimakgol-ro, Sangdaewon-dong, Jungwon-gu, Seongnam City, Gyeonggi-do, 462-721 South Korea Phone: +82 31 776-4415 Fax: +82 31 776-4419 E-mail: info@korea.emag.com

Subject to technical changes.

Illustration of all machines in trade show versions, may differ from the standard.

EMAG (Chongqing) Intelligent Technical Co., Ltd Building 7, No. 24 Fangzheng Avenue Beibei District Chongqing 400714 China Phone: +86 23 49783399 Fax: +86 23 49783388 E-mail: info@emag-china.com TAKAMAZ EMAG Ltd. 1-8 Asahigaoka Hakusan-City Ishikawa Japan, 924-0004 Japan Phone: +81 76 274-1409 Fax: +81 76 274-8530 E-mail: info@takamaz.emag.com EMAG INDIA Pvt. Ltd. Technology Centre No. 17/G/46-3, Industrial Suburb 2nd Stage, Yeshwantpur Bengaluru – 560 022 India Phone: +91 80 50050163 E-mail: info@india.emag.com

EMAG OOO ul. Akademika Chelomeya 3/2 117630 Moscow Russia Phone: +7 495 287 0960 Fax: +7 495 287 0962 E-mail: info@russia.emag.com

RICHARDON

ECM

www.emag.com