Turn-key. Solutions from a Complete Service Provider. [ EMCO Automation]

Transcription

1 Turn-key Solutions from a Complete Service Provider [ EMCO Automation]

2 The EMCO swing loader. The integrated solution. Tailor-made solutions. What would highly flexible universal lathes be without the features afforded by modern automation technology? EMCO has a range of bespoke solutions for unmanned or minimally staffed manufacturing. For pre-formed blanks and parts with a diameter larger than the spindle capacity, we offer an integrated swing loader for fully automatic loading. This has been conceived to work together with the machine as one harmonious unit and is characterized by uninterrupted operation and very short loading times. It is activated using the control unit. [Chain feeding system] [Swing loader] [Finished parts conveyor] Gear wheel (Hard machining/steel) Ball stud (Steel) Connector housing (Aluminum)

3 Maximum output - minimum space. The EMCO swing loader is a universal loading device for all types of preformed blanks. It can be highly customized in line with individual customer requirements. Numerous gripper and handling systems are available. How we do it: We standardize the components and customize the solution. This results in a custom-tailored machine for the same price as a standard unit. [Chain feeding system] [Swing loader] [Finished parts conveyor] Feeding systems for blanks Feed systems specific to particular blanks allow preformed workpieces to be loaded into the main spindle in the correct orientation, which enables economical unmanned operation. Chain feeding system for oriented loading of blanks with a large storage capacity. Multiple infeed chutes for rotationally-symmetrical blanks; the length of the blanks determines the number of infeed chutes. Chain feeding system with V-supports for preformed shaft parts of various shapes Multiple infeed chutes for loading rotationally symmetrical blanks. A sensor monitors the availability of blank parts for each infeed chute. Shaft gripper for automatically loading pre-formed shafts Fully automatic shaft loading. Feed-in via a chain feeding system. Removal via the finished parts collection device. Customization: A wide range of gripper and handling systems are available. 2-finger gripper with 18 rotary module for loading vertically fed blanks 2-finger toggle lever gripper for loading shaft parts Parallel grippers with 18 turning module for loading shaft parts (1st and 2nd clamping cycle)

4 The EMCO gantry loader. The universal solution. The perfect combination. Decades of experience, constant innovation and ongoing refinement have made the EMCO gantry loader one of the fastest and most flexible handling systems on the market. The machine and gantry are constructed by EMCO to match each other perfectly. This results in precise, rapid integration of all units and uninterrupted processes. Our gantry enables the automatic loading of both preformed flanged parts and shaft parts. Manufacturing time can also be reduced significantly through the use of additional features such as a measurement station, marking station, filtering tank, or even mounting assemblies a sure-fire route to economical manufacturing, even in high-wage countries. [Gantry loader] [Pallet magazine (2 station)] Water fitting (Brass) Sprocket wheel adapter (Aluminum) Sprocket wheel (Steel)

5 The gantry loader offers maximum flexibility. Tailor-made solutions. EMCO has a range of bespoke solutions for unmanned or minimally staffed manufacturing. For preshaped blanks and parts with diameters larger than the spindle clearance, EMCO offers a high-performance loading gantry for fully automated loading and unloading. Designed as a compact unit, the machine and gantry loader guarantee uninterrupted operation and very short loading times. It is activated using the control unit. A short-bar loader and a 3-meter bar loader can be used to produce serial workpieces from bar stock. Profile: EMCO gantry loaders significantly reduce the time required for manufacturing processes and enable a large increase in efficiency. They are optimally aligned to the individual machine, resulting in an integrated, highly productive system. Gripper heads Pallet attachments 2x3-jaw double-gripper head 4-station pallet attachment for valve caps 6-station pallet attachment for articulated brackets 4x3 jaw gripper head Shaft gripper head 2-station pallet magazine with customer-specific pallets 2-station pallet magazine with customer-specific pallets Technical data Traverse speed Workpiece dimensions for 4 x 3 jaw gripper Horizontal 12 m/min Max. diameter 12 mm Vertical 6 m/min Max. length 1 mm Max. weight 5 kg Workpiece dimensions for 2 x 3 jaw gripper Workpiece dimensions for 2 x 2 jaw gripper Max. diameter 22 mm Max. diameter 1 mm Max. length 1 mm Max. length 3 mm Max. weight 1 kg Max. weight 1 kg

6 Everything from a single source. The EMCO loading gantry solution provides maximum flexibility in terms of weight and machine size. It allows the integration of various automated systems such as a shaft conveyor, circulating magazine, robot, or measurement station. This enables various combinations of minimally staffed complete solutions to be implemented in line with customer requirements. [Gantry axes] - Robust mechanism - Safety brake - Central lubrication system - Optional: H-loader, machine connection [Control] - Ergonomically placed and pivotable - Multi-channel for machining and parts handling - Siemens 84D-sl incl. ShopTurn - Color LCD monitor - USB interface - Ethernet connection [Tool turret] - 12-position VDI 4-12 tool adapters with coolant feed (block tool) - Synchronized thread cutting and polygonal turning as standard [Blank conveyor / finished parts conveyor] - Shaft conveyor (shown) - Circulating magazine [Gantry] - Electric shaft gripper - Adjustable gripping force - Position monitoring via NC axis - No compressed air required [Hydraulic unit] - Ergonomic operation - Automatic pressure monitoring - Compact and low-maintenance Drive shaft (Steel/C45)

7 Gantry loader offers maximum flexibility: For Maxxturn 95 and 11, Hyperturn 11 The benefits Large number of individual applications For fully automated loading and unloading Complete solution for uninterrupted operation Short loading times [Y axis] - Travel +8/-6 mm - 9 implemented in the machine construction - Large distance between guide rails - Stable and compact construction [Chip conveyor] - Slat band conveyor - Ejection height 12 mm - 35-liter coolant volume - Included in the basic model Technical data: Traverse speed Horizontal 8 m/min Vertical 4 m/min Application example: Maxxturn 95 Workpiece dimensions for flanged parts Workpiece dimensions for shaft parts Max. diameter 25 mm Max. diameter 18 mm Max. length 1 mm Max. length 8 mm Max. weight 25 kg Max. weight 15 kg

8 Flexible and change-over friendly auto EMCO Vertical Turn machines. The user saves costs and programming time involved with automation equipment thanks to the integrated pick-up system that loads the chuck with parts up to a diameter of 16 mm. Short cycle times and the ample parts storage guarantee short chip-to-chip times of up to 5.5 s for two-track loading. The various flexible feeding systems facilitate the integration into production lines: pallet, drag frame or chain conveyor belts. The benefits Flexible automation: for both heavy and light parts, ample and low parts storage Individual customer requests, such as pallets, drag frames, conveyor belts, and the integration of feed systems can be implemented easily Short travels allow short loading times

9 mation solutions for Perfect Automation and integration are parts of the performance offered by the new vertical lathe VT 4 (for chuck parts with up to 4 mm clamping diameters). The automation concept enables customer-specific solutions. Since the pick-up system removes the need for additional loading systems for workpieces, machine linkage and technical adaptation are easily made to fit any customer s individual needs. Quick loading through direct pick-up for high productivity Simple automation solutions for maximum flexibility Small footprint of machine and automation Access to automation: easy to change over and maintain

10 The EMCO Compact Loads. Perfect teamwork. Low price. Strong performance. "Design to cost" was the primary aim when developing the EMCO E-series. These loaders intentionally do not include a dedicated control unit and are instead controlled directly by the machine control system. This results in an unbeatably low price for the entire package - including parts catchers, alarm lamp, and interface. Of course, we also provide tailored bar loader packages for our EMCOTURN E25, E45 and E65. The technology. The loaders in our E-series can be used immediately as a "plug-and-play" solution. Their extremely small footprint enables processes to be automated even if space is tight. All loaders offer comprehensive cycle support and are perfectly aligned to the spindle lengths in the individual machines. Changing over to different bar diameters requires only minimum effort and the loaders can also be used to load individual workpieces. The benefits Smaller footprint Easy to use Short feed times Fast, straightforward changeover Option to load individual workpieces Central diameter adjustment Ergonomic EMCO design The EMCOTURN E65 with EMCO COMPACT LOAD E65 A clever "plug-and-play" solution with comprehensive cycle support The EMCOTURN E25 with EMCO COMPACT LOAD E25 The most compact machine design for fully automatic processing of bar material up to ø 25 (51) mm. Technical data COMPACT LOAD E25 COMPACT LOAD E45/E65 Bar diameter Ø 25 (51) mm Ø 8 65 mm Max. bar length 8 mm 11 mm Min. bar length 1 mm 15 mm Material support approx. 55 mm approx. 55 mm Feed rate 6 m/min 6 m/min Bar change time approx. 1 sec. approx. 12 sec. Dimensions (L x W) 12 x 11 mm 17 x 11 mm Weight approx. 33 kg approx. 535 kg

11 The EMCO short bar loaders. Universal, high-performance. Short and to the point. Faced by ever-increasing pressure on floorspace for machines, EMCO has developed the most compact short loaders on the market: The EMCO LM8 and EMCO LM12/15 are the perfect solution for automatic feeding and loading of cut-to-length bars. The key advantages are a small footprint and rapid loading times resulting from shorter strokes. The technology. The loaders in our LM series can be used immediately as a "plug-and-play" solution. Their extremely small footprint enables processes to be automated even if space is tight. In contrast to the EMCO COMPACT LOADs, the loaders in the LM series are fitted with their own control units, which also enables the loaders to be used together with other machines. The controls are perfectly coordinated with the machine interfaces, which are identical on all three models. All loaders offer comprehensive cycle support and are optimally aligned to the spindle lengths in the individual machines. Changing over to different bar diameters requires only minimum effort and the loaders can also be used to load individual workpieces. EMCO LM8 For use with MAXXTURN 25/45. EMCO LM12 Compatible with the machines EMCOTURN E65-BB, MAXXTURN 65, HYPERTURN 45, HYPERTURN 65. Infeed of profile bar stock using a chain feeding system (option) The benefits Smaller footprint Easy to use Short feed times Fast, straightforward changeover Option to load individual workpieces Central diameter adjustment Dedicated control Ergonomic EMCO design Technical data LM8 LM12 LM15 Bar diameter Ø 6 52 mm Ø 8 65 mm Ø mm Max. bar length 8 mm 12 mm 15 mm Min. bar length 1 mm 15 mm 15 mm Material support approx. 55 mm approx. 55 mm approx. 55 mm Feed rate 6 m/min 6 m/min 6 m/min Bar change time approx. 1 sec. approx. 12 sec. approx. 14 sec. Dimensions (L x W) 12 x 11 mm 17 x 11 mm 2 x 11 mm Weight approx. 33 kg approx. 535 kg approx. 55 kg

12 EMCO TOP LOAD. The premium class. Quality by the meter. The EMCO TOP LOAD series was designed to automatically load 3-meter long bar stock into EMCO machines. Loaders are available for diameters of 4-25 mm, 8-42 mm, and 1-65 mm. The oil-coolant-fed loading channel, lined with plastic shells, reduces vibrations to a minimum, even at high speeds. Bar stock is fed in via a servo motor which controls both the speed and feed force. A patented guidance system with several guide rests guarantees optimum feed quality. Time-consuming conversions and channel changes are a thing of the past. The bar loader can be switched from one diameter to another within one or two minutes. EMCO TOP LOAD 1-65/33 in the MULTI-LEVEL version. Multiple material supports enable even longer unmanned operation. EMCO TOP LOAD 8-42/32 in the SINGLE LEVEL version. Pieces of bar stock are laid on a slanted feed track (35 mm) and fall into the guide channel one by one. EMCO TOP LOAD 4-25/33 in the SINGLE LEVEL version. Pieces of bar stock are laid on a slanted feed track (35 mm) and fall into the guide channel one by one.

13 [Technology] The benefits Optimized length through use of a releasable feeder Programmable diameter adjustment on the control panel Servo-controlled feed motor (programmable) Oddments ejected to the front or rear Longitudinal sliding unit (approx. 8 mm) Quick-change systems result in lower changeover effort Extremely short setup time of just 1 to 2 minutes No changeover sets required thanks to the patented guidance system Includes installation accessories Standard guide rests (8-42 and 1-65) Integrated and automatic travelling guide rests center the bar stock at several points and enable to material to be fed through in the optimal manner. A patented system with great results: High rotational speeds, economical cutting data, and excellent productivity. Standard guide rest (4-25) When machining smaller items of bar stock, the integrated guide rest ensures improved centering and reduces vibrations. Accessories The feed grippers are placed in the loader to match the bar width. A quick-change system ensures that the system can be changed over quickly and without the need for tools. Steel feed gripper for ejection of oddments to the rear. Steel-Vulkollan feed gripper is milled according to the bar diameter (1 item provided in the basic configuration) Taper adapter for forward ejection of oddments (basic configuration) Technical data TOP LOAD 4-25/33 TOP LOAD 8-42/32 TOP LOAD 1-65/33 Bar diameter Ø 4 25 mm Ø 8 42 mm Ø 1 65 mm Max. bar length 33 mm 32 mm 33 mm Min. bar length 15 mm 15 mm 15 mm Material support approx. 35 mm approx. 2 mm approx. 35 mm Feed rate 1 m/min 3 m/min 3 m/min Bar change time approx. 3 sec. approx. 7 sec. approx. 75 sec. Dimensions (L x W) 439 x 867 mm 431 x 79 mm 441 x 19 mm Weight approx. 11 kg approx. 12 kg approx. 22 kg

14 Unloading through the counter spindle The length of the workpieces determines the distance between the centers on the lathe. The "unloading through the counter spindle" option enables long workpieces to be manufactured using compact machines with short dimensions. Machined parts, whether round or contoured, are transported onward easily through the counter spindle. Long parts are stored on a sloping surface or on a chain feeding system. This enables the extremely efficient manufacturing of typical shaft parts such as piston rods, cylinder tubes, drills, drive shafts, shock absorbers, and many more. On machines without counter spindles, long workpieces may also be unloaded using modified tailstock slides. MAXXTURN 45 with unloading through the counter spindle Workpieces measuring up to 1, mm in length and up to a maximum of 32 mm in diameter may be unloaded through the counter spindle. Short parts measuring up to 12 mm in length are unloaded through the parts catcher. This system may also be installed on the HYPERTURN 45 (up to ø 45 mm). MAXXTURN 65 with unloading through the counter spindle Workpieces measuring up to 12 mm in length and up to a maximum of 54 mm in diameter may be unloaded through the counter spindle. Short parts measuring up to 175 mm in length are unloaded through the parts catcher. This system can also be installed on the HYPERTURN 665. Machine layout MAXXTURN 45 and HYPERTURN 45 with unloading via the counter spindle Details in millimeters

15 [ Installation plans] Machine layout MAXXTURN 45 with swing loader n A F1Z23 21 A A A A A A A A A A A R7Z3 6 A A R2Y641 3 S4Y6 2 S4Y62 1 S4Z3 Pos. Zeichn.Nr. Z Machine layout HYPERTURN 45 with swing loader Details in millimeters

16 [ Installation plans] Machine layout MAXXTURN 65 with gantry loader installation space for chip conveyor ,5 D roh F 3,2 F F schruppen,8 F Name Gezeichnet Norm gepr Nr. Änderung Datum Oberflächenschutz : Maßstab Untolerierte Maße nach DIN / ISO 1:3 2768mK / 693 / 857BF 79 Unterstrichene Maße nicht maßstäbl. gez. Für diese Zeichnung _ Name Änd.Nr. schlichten Prototyp,4 feinschlichten Geprüft hoellbam schleifen Datum ZV: Datumsstempel / Unterschrift Rohteil-Nr: Werkstoff: Masse: _ Teil-Benennung: Zeichnungs Nr.: Blatt: Machine layout HYPERTURN 65 - POWERMILL with gantry loader Details in millimeters

17 [ Installation plans] Machine layout MAXXTURN 95 with gantry loader Machine layout MAXXTURN 11 with gantry loader Details in millimeters

18 [Installation plans] Machine layout EMCO COMPACT LOAD E45/E65 Machine layout EMCOTURN E25 with EMCO COMPACT LOAD Machine layout EMCO LM ,5 ~ , , Machine layout EMCO LM Machine layout EMCO LM Maschinenachse Maschinenachse Details in millimeters

19 [Installation plans] Machine layout EMCO TOP LOAD 4-25/ Machine layout EMCO TOP LOAD 8-42/32 Multi-Level Machine layout EMCO TOP LOAD 1-65/ Multi-Level Details in millimeters

20 EN457. 8/13. Technical modifications reserved. Errors and omissions excepted. EMCO MAIER Ges.m.b.H. Salzburger Str Hallein-Taxach. Austria Phone Fax