Vertical Twin-Spindle Machines en

VERTICAL TWIN-SPINDLE MACHINES MODULAR SOLUTIONS

VL 1 TWIN – HIGHLY PRODUCTIVE SIMULTANEOUS M Twin-spindle turning center for the highly productive manufacturing of workpieces up to 3 inches in diameter The VL 1 TWIN has two main spindles in one machining area which can simultaneously machine two identical workpieces.

This method allows for a massive increase in output quantities and lowers cost per piece.

The diameter and length of both components can be corrected independently of one another using both spindles. In addition, the machine has a direct position measuring system and a linear motor in the X-axis to ensure the highest machining quality and maximum productivity.

TECHNICAL DATA Max. workpiece diameter

mm

75

Chuck diameter

mm

140

Swing diameter

mm

160

Workpiece length, max.

mm

75

kg

1

X-axis / Z-axis travel

mm

605 / 200

Main spindle »» Power rating, 40% / 100% duty cycle

kW

13 / 11.7

»» Torque, 40% / 100% duty cycle

Nm

113 / 88

»» Max. number of revolutions

rpm

Workpiece weight

Rapid-traverse rate, X / Z Tool stations

2

CNC controller

inch inch inch inch lb

inch

hp

ft-lb rpm

m/min

ipm

3 6

Planetary Gear

7

Workpiece dia: 38 mm / 1.5 in Material: 20CrMoH

3

Sleeve

Workpiece dia: 51 mm / 2 in Material: 21NiCrMo2

2

17 / 16

83 / 65

6,000 6,000

60 / 30

2,400 / 1,200

2 x 4 – VDI30 / BMT45 Fanuc 31i with Manual Guide i

16 SEC.

12 SEC.

24 / 8

Flange Workpiece dia: 52 mm / 2 in Material: CrNi1810

26 SEC.

VL 1 TWIN Workpieces Cycle Time*

Cam

Workpiece dia: 42 mm / 1.5 in Material: 100Cr6

9 SEC.

MACHINING SIMULTANEOUS MACHINING

HIGHLIGHTS ++ High Precision

Machine base made of MINERALIT® polymer concrete with optimal vibration-damping properties, size 45 linear roller guides and direct position measuring systems in the X-axis for optimal positioning, repetition and long-term accuracy.

++ Integrated Automation

Two pick-up working spindles for loading and unloading. Machines are automation ready making it possible to link with other EMAG machines/ technologies (ex. gear hobbing).

++ Unique TWIN Concept

Simultaneous machining of two identical workpieces possible, doubling the output and reducing the cost per piece. Diameter and length (X/Z direction) of both components can be corrected independently of one another using the two spindles.

++ Optimal Dynamics

Linear drive in the X-axis for maximum dynamism (21 mph acceleration), minimal wear and maximum positioning accuracy.

AUTOMATION INCLUDED

Linking two VL 1 TWIN machines including parts storage area and TrackMotion automation system Access to e-container and hydraulics

Number of spindles

Machine 1 (OP 10 / OP 10)

Access to e-container and hydraulics

TrackMotion automation system

Number of spindles

Machine 2 (OP 20 / OP 20)

* Cycle time of 9 sec., for example, for a machining time of 18 sec. (2 spindles)

Parts storage area

On the VL 1 TWIN machines, the working spindles are not only used to machine workpieces, but also to load and unload them. This saves money, space and unnecessary peripheral devices.

FULLY INTEGRATED MEASURING SYSTEM

Measuring systems installed between the machining area and the pick-up station are available as an option.

To save time, these measurements are performed during the parts’ movement to and from the loading/ unloading station.

3

VL 3 DUO – TWIN-SPINDLE TURNING MACHINE FOR THE HIGHLY PRODUCTIVE MANUFACTURING O EMAG has extended the VL Series product range with the VL 3 DUO, a twin-spindle machine solution for the highly productive manufacturing of chucked parts up to 6 inches in diameter.

The VL 3 DUO integrates all of the most recent EMAG technological developments (including self-loading spindle, TrackMotion automation system and the modular design of the machine) to create a highly productive manufacturing system that delivers maximum productivity with a minimum footprint.

Access to E-Container and Hydraulics OP 10 NC Shuttle TrackMotion Automation System

Spindle 1

Central Machining Area Extraction Unit OP 20 NC Shuttle

Spindle 2

Parts Storage Area

NOW AVAILABLE

SIEMENS 840D SL

HIGH PERFORMANCE TURNING WITH THE VL 3 DUO The VL 3 DUO is perfect for heavy-duty machining thanks to its rigid machine design. High feed forces with a large cutting depth allows for the reduction of machining time.

Standard spindle: ap =

4.75 mm

f =

0.4 mm/rev

vc =

250 m/min

0.2 in

0.02 in/rev

1,000 in/min

High torque spindle:

4

ap =

8.5 mm

f =

0.4 mm/rev

vc =

250 m/min

0.3 in

0.02 in/rev

1,000 in/min

* Fully equipped machine, including chip conveyo

OF CHUCKED PARTS

NEW!

HIGH TORQUE SPINDLE WITH 32 KW CAPACITY

VL 3 DUO FOR DEMANDING TURNING WORK

++ Working spindle with 5,000 rpm / 32 kW / 255 Nm at 40% duty cycle

++ Sturdy mechanical design – spindle bearing, front:

100 mm (4 in) in diameter, spindle flange to DIN 55026, size 6

++ Motor spindle with DirectDrive for minimum run-up times, maximum true running and diameter tolerances

MACHINING AREA OF THE VL 3 DUO:

++ Maximum torque over large range of speeds – baseline spindle speed: 1,408 rpm (at 100% duty cycle)

Highly productive machining for chucked parts with a diameter of up to 6 inches.

++ Water-cooled motor spindle for maximum thermal stability

50 45 40

255 196 175 150 125 100 75 50

25 20 15 10

25

Integrated Automation

Pick-up working spindle for loading and unloading

Unique Machine Concept

Two working spindles and two high-performance tool turrets with torque motor

Optimum Accessibility

Short distance to the turrets and working spindle ensure optimum accessibility

Increased Flexibility

Parts storage area for up to 400 workpieces and TrackMotion automation system for high-speed part transport between the parts storage area and machining areas as well as for turning the workpieces

Minimum Floor Space Required

24.5 m (264 ft ) for the complete machine: VL 3 DUO + TrackMotion + parts storage area + chip conveyor 2

2

Machines shown in trade show format.

or, TrackMotion and parts storage area for up to 400 workpieces (depending on the workpiece geometry)

Torque (Nm) 40% duty cycle 100% duty cycle

Power [kW] 40% duty cycle 100% duty cycle

Number of revolutions (rpm)

TECHNICAL DATA

5,400

4,800

4,200

3,600

3,000

2,400

1,213 1,408 1,800

5 600

Precise Machining

Machine base made of MINERALIT® polymer concrete Machine weight 10,000 kg (11-tons), size 45 linear roller guides and direct position measuring systems in all axes

Power [kW]

35 30

6,000

Torque (Nm)

225

Max. workpiece diameter

mm

150

Max. chuck diameter

mm

210

Workpiece length, max.

mm

110

Travel distance: X (machining stroke) / Y (optional) / Z Main spindles (2x) – Standard

mm

505 / ±30 / 250

»»Power rating, 40% / 100% duty cycle

kW

18 / 15

»»Torque, 40% / 100% duty cycle

Nm

144 / 98

»»Max. number of revolutions

rpm

5,000

»»Spindle flange to DIN 55026

Size mm

»»Spindle bearing dia., front High torque spindle (option)

inch

inch inch

inch

hp

ft-lb rpm

inch

6 9

5

20 / ±1 / 10

24 / 21

106 / 72

5,000

6 100 4

»»Power rating, 40% / 100% duty cycle

kW

32 / 29

»»Torque, 40% / 100% duty cycle

Nm

255 / 196

»»Max. number of revolutions

rpm

5,000

Turrets (2x) »»Turret tool positions Rapid-traverse rate X / Y / Z

hp

ft-lb rpm

Qty m/min

44 / 39

188 / 145 5,000

12 60 / 30 / 30

ipm 2,362 / 1,181 / 1,181

5

VL 5 DUO – TWIN SPINDLE TURNING MACHINE FOR COMPONENTS UP TO 250 MM (10 IN) Two separate machining areas provide maximum production flexibility Whether it is a “one-machine solution” for OP 10 and OP 20 or a TWIN turning machine for OP 10 and OP 10 – the VL 5 DUO can be configured to fit a variety of manufacturing scenarios.

Machines shown in trade show format.

The machining areas on this system mirror one another, and each is equipped with its own working spindle which, with a rating of up to 34.1 kW (46 hp) and a torque of up to 593 Nm (437 ft-lb) with a duty cycle of 40%, has plenty of power to achieve high speed, precision machining. A twelve position tool turret is also available in each machining area (VDI 40 or BMT 55 interface), with either turning or driven tools and a Y-axis.

TECHNICAL DATA Max. workpiece diameter

250 mm

Chuck diameter

315 mm

»»Power rating, 40% / 100%

Swing diameter

340 mm

»»Torque 40% / 100%

593 / 501 Nm

Max. workpiece length

175 mm

»»Max. speed

4,500 rpm 60 / 30 m/min

Workpiece weight Travel distances, X / Y (optional) / Z CNC controller

6

10 in

12 in

13 in 7 in

40 kg

88 lbs

750 / ±30 / 350 mm

30 in / 1 in / 14 in

Fanuc 31i with Manual Guide i

Main spindle

Rapid-traverse rate, X / Z Tool stations

34.1 / 28.9 kW 46 / 38 hp

437 / 370 ft-lb

197 / 98 ft/min

2x12 – VDI40 / BMT 55

POWERFUL! 34 KW / 46 HP

HIGHLIGHTS ++ Maximum precision

Machine base made of MINERALIT® polymer concrete with optimal vibration-damping properties, size 45 linear roller guides, and a direct position measuring system in the X-axis for the highest positioning accuracy, repeat accuracy and long-term accuracy

++ Highly productive DUO concept

Machining OP 10 and OP 20, or simultaneous machining in OP 10 and OP 10 of two identical workpieces is possible

++ Main spindle

with 34.1 kW (46 hp), 593 Nm (437 ft-lb) at 40% duty cycle

++ Motor spindle

with DirectDrive for minimum run times, maximum true running and diameter tolerances

++ Maximum torque

covering large range of speeds – baseline working spindle speed: 550 rpm

++ Water-cooled motor spindle 750

50

675

45

593 501 450 375

40 35 30 25 20 15

300 225

10

150

5

Speed (1/min) Drehzahl (1/min)

5.000 5.000

4.500 4.500

4.000 4.000

3.500 3.500

3.000 3.000

2.500 2.500

550 550 Drehmoment Torque (Nm) (Nm) 40 % ED 40% 100 % ED 100%

1.000 1.000 1.500 2.000 2.000

75

Ring gear

Leistung (kW) Power (kW)

Drehmoment (Nm) Torque (Nm)

for maximum thermal stability

Leistung Power (kW) (kW) 40 % ED 40% 100 % ED 100%

Differential housing Workpiece Ø: 165 mm / 6in Material: GGG60

Workpiece Ø: 230 mm / 9 in Material: 20MnCr4

64 SEC. Car wheel hub

100 SEC. Annulus gear

VL 5 DUO

Workpiece Ø: 136 mm / 5 in Material: C55

Workpiece Ø: 135 mm / 5 in Material: 27MnVs6

workpieces Cycle time

86 SEC.

40 SEC.

TRACKMOTION AUTOMATION SYSTEM The VL 5 DUO and the TrackMotion automation system are perfectly fit for one another. The TrackMotion system performs the loading and unloading process, transports the parts and turns the parts between operations.

FULLY INTEGRATED MEASURING Gear wheel

CVT part Workpiece Ø: 163 mm / 6 in Material: 15 CrMo5

145 SEC.

80 SEC.

Workpiece Ø: 220 mm / 9 in Material: 20 NiMoCr65

A measuring station is available as an option for each machining area. The measuring station is installed between the machining area and the pick-up stations.

7

TRACKMOTION AUTOMATION SYSTEM – TRANSPOR RAILS AUTOMATION EXAMPLE: SOFT MACHINING OF GEARS (COMPLETE LINE)

Parts storage area for up to 400 workpieces, including TrackMotion

Turning of first and second side (OP 10/OP 20)

AUTOMATION EXAMPLE: SOFT TURNING OF PULLEYS FOR CVT TRANSMISSIONS

AUTOMATION EXAMPLE: SOFT TURNING OF SPROCKETS (COMPLETE LINE)

Turning of the first side (OP 10)

8

Turning of the second side (OP 20)

93 SECOND CYCLE TIME

RTING PARTS AS IF THEY WERE ON

28 SECOND CYCLE TIME

2

Gear hobbing (OP 30)

3

1

++ TrackMotion automation system, consisting of 1 Track Roller deburring (OP 40)

2 Lift and turn-over unit (TransLift) 3 E-container

++ Completely modular system (ex. adaptable in length)

Turning of both sides (OP 10 and OP 20)

++ TransLift lift and turn-over unit ++ Adaptable to a wide variety of components (chucked and shaft parts)

37 SECOND CYCLE TIME

++ Replaces belts, pick-and-place units and changers ++ Z-stroke of up to 650Â mm (26 in) is possible

Parts storage area for up to 400 workpieces, including TrackMotion

++ Raw and finished parts storage area can be adapted to a wide variety of components (chucked and shaft parts)

++ The use of stacker pallets enables the storage of up Gear hobbing (OP 30)

Roller deburring (OP 40)

to 400 raw and finished parts.

9

Turning

Milling

Grinding

Gear Hobbing

AT HOME, AROUND THE WORLD! EMAG Salach GmbH Salach

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