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The manufacture of HGV components: great quality, maximum flexibility

Tue, 21 May 2013 14:20:00 +0200

Demand for HGVs will massively increase over the next few years – and that increase will be worldwide. Management consultants McKinsey, for instance, are estimating that the market will grow from a present turnover of € 125 billion to € 190 billion in 2020. Especially emerging economies, such as China and India, will need noticeably greater numbers of HGVs for the development of their infrastructure. That this kind of global dynamic also offers opportunities for the smaller company is illustrated by the example of LASO. The specialists in Olpe have been manufacturing spare parts for HGVs and buses for over 40 years, with the main focus on demanding motorised assemblies, such as oil and water pumps, and on steering elements. The company’s shelves are filled with almost 5,000 different products. To enable them to manufacture such a variety of different components efficiently, they are putting their faith in automated machining concepts. For the machining of cast iron components, for instance, they employ a total of three vertical turning machines from EMAG – turning centres that produce even the smallest batch size at the highest quality.

„Flexibility” is a word frequently used in the automotive industry. At LASO, however, the word is of particular importance, as the manufacture of HGV spares is an extraordinarily wide field to tackle for a small, medium-sized company of around 70 staff. But these specialists do not only produce a large variety of engine components, such as oil pumps, valve seats, injection system components and water pumps. Their catalogue also includes components for all the well-known HGV brands. The result is an enormous spread of LASO products. Add to this the fact that where “spare parts” in particular are concerned component quality is of the utmost importance, as Operations Manager Werner Steuber emphasises: “Our customers must be confident that each HGV spare part assembly is of the same efficiency and stability as the original was before it got damaged. As we gladly give this guarantee for the most varied components, we simply cannot afford to make mistakes or be inaccurate in the production of our components.”

Many different components produced in a variety of batch sizes
That these demands are met with tailor-made manufacturing solutions is indicated by the post-processing of complex cast iron components. For instance, two EMAG VL 5 Turning Centres – linked by a component transfer and turning unit – are used in the machining of small impellers or water pumps. Plain production data alone illustrates the high demands put on those machines – they produce about 25 different components, with batch sizes ranging from as few as 200 up to 3,000 components. The typical EMAG design of the machines forms the cornerstone for the extremely fast, interlinked production process at LASO. The VL 5 machines feature a pick-up spindle that collects the raw-part from a recirculating conveyor and transports it into the machining area, where one side is turned before the workpiece is returned to the conveyor. At LASO, the parts are then conveyed to a transfer and turning unit, to be turned over and then transported to the second turning centre. The second VL 5 also has a pick-up spindle that takes the component to the workstation where its other side is machined. The two VLs can also carry out drilling and other machining operations on these components.

For years – a stable process
„The whole process is highly effective”, explains Axel Fiedler, Regional Sales Executive for EMAG. „For instance, the cycle time for the complete-machining of an impeller is just 48 seconds. Vertical machining also ensures process integrity, as the unhindered chip flow guarantees there is no chip nesting – a very important factor when it comes to a fully automated and lightly-manned operation.” This judgement is confirmed by LASO Operations Manager Steuber: “The machines run a two-shift cycle of around 80 hours a week and have been in use for approximately five years now. During this time we had practically no problems where performance and component quality were concerned. The whole process is a very stable one.”

Similarly important for the spare parts specialists is that the machines are so easy to set up, as Herr Steuber explains. The VL can be set for the machining of a new component in next to no time, making the influence of many EMAG design features more obvious. For instance, the VL 5 machines at LASO feature a turret that accommodates up to 10 different tools, which ensures that it can be optimally equipped to execute complex machining cycles. It is also easy for the operator to access the machines known for their short travels, thus allowing for a fast and easy exchange of tools. “Another factor of great importance to us is that new operators only require a short break-in period and that they can quickly familiarise themselves with the control system. This is decisive in assessing the economic viability of the production process on machines that need to be frequently reset”, elucidates Herr Steuber. Exactly how efficient the actual solution is, is shown by a quick look at the past: the VL 5 twin-machine solution replaced three machines, which only carried out part of the operations each and which had to be loaded manually – all together a much slower, less safe and, last but by no means least, more expensive process.

Turning machine VL 7 as a manufacturing solution for larger components
For the manufacture of larger pump housings and other large cast iron components the specialists in Olpe also rely on an EMAG machine – this time a stand-alone: the VL 7 Turning Centre. It is equipped with a larger workpiece chuck (max. dia. 400 mm) and the maximum travel ratings are also higher. “We did not want to have to do without the advantages of vertical machining and the pick-up principle in the machining of our larger components either”, confirms Herr Steuber. By the by, the small footprint of the EMAG machines also played an important role in LASO’s investment decision: with the EMAG machines the HGV components specialist can machine a large range of complex components on just 20 m² - and that dimension includes the automation equipment. “For us, that was an important argument in favour of EMAG, as we did not want to be forced to expand our production area to accommodate the new machine.”

With manufacturing solutions like these, the specialists in HGV spares find themselves well set up for the future. “The market for HGV spares is growing. But in the rapidly emerging markets in particular, new competitors are very much in evidence. We defend our position in this field by offering a component quality that is a cut above the norm. And here is where the EMAG manufacturing solutions play an important role too”, concludes Herr Steuber.

eldec joins the EMAG Group: mapping the entire production process

Tue, 21 May 2013 12:49:00 +0200

"Turnkey" is one of the defining catchwords for mechanical engineering of the future. Complex, automated production lines are designed as "turnkey" solutions. Ideally, the entire solution should come from a single source. For years, the EMAG Group has been meeting this requirement for a wide range of automotive components. By integrating eldec Schwenk Induction GmbH into the Group, the mechanical engineering experts at EMAG have added yet another technology specialist to their ranks. eldec develops and manufactures innovative induction hardening machines, generators for induction heating systems as well as inductors. This will open up new possibilities for the EMAG Group. In the future, the entire mechanical engineering process for a production line with hardening processes will take place with the Group.

eldec is the perfect addition to the EMAG's group expertise. Based in Dornstetten near Freudenstadt, Germany, the company has been developing complete hardening machines for decades. Featuring a modular design, these solutions are perfectly tailored to a range of workpiece dimensions, hardnesses or batch sizes. eldec even designs and manufactures heating tools (inductors). The company also has a second production site for these products in the USA as well as a global sales network. The heating technology specialists joined the EMAG Group in February 2013. With this move, EMAG has acquired a company whose technology is a perfect fit for many of EMAG's typical production processes.

Induction hardening is useful for a variety of workpieces that are processed on EMAG machines. For example, power steering components and differential gears use workpieces that are induction-hardened after soft machining. Thanks to eldec, EMAG can now deliver the entire process.

Accurate contour hardening with SDF® technology
Thanks to their adjustable frequencies and maximum power density, eldec induction hardening machines with SDF® generators are outstanding for accurate contour hardening of complex surface geometries. Short process times minimize component warping. This reduces the need for remachining or allowances. SDF® technology is also excellent as a highly flexible solution for smaller batch sizes because medium and high frequencies can be used and controlled completely separate from each other.

Advantages of SDF® technology:

Simultaneous heating with medium and high frequency
Accurate contour hardening of complex surface geometries
Can also be easily used solely as an MF or HF generator
Combination of pulse width modulation and pulse package control
High-speed PLC with eldec control print: short clock frequencies for extremely fast control
Maximum power density => short process times
Short process times
- Can be integrated into automated lines
- Low power consumption / workpiece
- Little or no scaling
- Minimal component distortion

First joint development already completed
eldec technology also integrates perfectly into EMAG machinery, as demonstrated by a new system. The eldec VL-H is the result of collaboration between the two companies and also the first pick-up hardening machine in the world. With this system, all the advantages of EMAG automation come into play during the hardening process. The component is picked up by the pick-up spindle of the machine, heated and hardened by the inductor and then also removed by a spindle. The decisive advantage of this approach is that it is a complete machining process since it is entirely governed by the pick-up concept. The production line is perfectly automated and harmonized.

New opportunities in the market
Decision-makers at EMAG Holding are also expecting new market opportunities for the future thanks to the integration of eldec. The heating technology specialists at eldec not only develop hardening systems, they also manufacture generators, the power source for induction technology. Generators are at the heart of many other processes such as soldering or joining workpieces. As a result, the EMAG Group can now tap into other industries outside of the automotive sector, such as the power industry.

New production location: EMAG expands to China

Mon, 29 Apr 2013 15:16:00 +0200

For the German machine tools industry, China continues to be the most important export market. According to the German Machine Tool Builders' Association, imports from Germany to China increased by a total of 13 percent in 2012. However, the market will change in the future. Competition within China is increasing. By adding a production facility in the Chinese city of Jintan, the EMAG Group will gain a stronger edge in this market. In addition, the mechanical engineering company is developing machines that are specially tailored to the Asian market. EMAG's German locations will also benefit from this strategy.

Over a decade ago, the EMAG Group established a presence in Asia, with sales and service professionals at eleven different branches. This network has been gradually expanded. Local EMAG specialists know the market and the specific requirements in China, India, South Korea or Japan. EMAG is now taking the next step: the Group's first Chinese production facility is being built in Jintan and will be completed by the end of 2013. The foundation has already been poured, and the production facilities are being built. "We want to turn EMAG into an international machine tool manufacturer in the coming years", says Dieter Kollmar, CMO of EMAG Holding GmbH. "In the past, we were highly focused on Germany and Europe. We mainly sold special-purpose machines in Asia. This focus is now changing".

Focus on quantities and quality
Obviously, this is not just about establishing a production centre in China. The company's strategy reaches far beyond this. Tailored machine concepts will be developed for the Asian market. The existing VL 2 and VT 2 machines will lead the way. These machines are designed for automated machining of chuck and shaft components and offer excellent value for money. EMAG is currently developing manually loaded turning machines, which feature a main spindle at the bottom, and that meet similar criteria. "There is a huge market in Asia for these types of machines that use only one application technology and are specially configured for local requirements", says Dieter Kollmar. Handling is another important issue for China and the Asian market. EMAG's new turning centres are very easy to operate and also highly flexible because they allow for both manual loading and automated use. "All of these solutions ensure maximum productivity for our Asian customers," says Dieter Kollmar.

German locations will also benefit
Decision-makers at EMAG are certain that the whole Group will benefit from the new site. For example, German engineers and technicians at the Salach location will develop new machines for Asia. "EMAG is currently manufacturing about 870 machines per year. This number will increase considerably over the next five years. "We're aiming for an increase at all locations" says Dieter Kollmar. However, the European market will remain important for the whole company. The EMAG Group has a large share of the European production machinery market. The company plans to maintain this excellent position and build on it where possible. At the same time, however, the specialists at EMAG are putting a slightly different emphasis on their development activities, as evidenced by the development of products like the fully automated VLC or VTC series. "We plan to continue developing these high-tech solutions and will obviously sell them in China, South Korea or India, if necessary. However, we need additional solutions in these markets. With our global development and production network as well as tailored solutions for every market, we're perfectly positioned for the future," says Dieter Kollmar, summing up.

Energy efficiency: Keeping sight of total costs

Wed, 13 Mar 2013 12:12:00 +0100

Saving energy in the metal processing industry isn't just a question of protecting the environment. For years, energy consumption has been a decisive cost factor capable of surpassing even the investment costs of the machine over the long-term. Moreover, energy costs are always becoming more important: according to the German Association of Energy Consumers (VEA), power prices for medium-sized industrial companies rose 4.5 percent last year. Two current examples from EMAG illustrate some efficient mechanical engineering solutions poised to counter this trend: the ELC 250 DUO welding system and the Platform 2 vertical lathes. They are dramatic examples of the enormous potential savings that can be achieved in a wide range of applications.

Many users pay most attention to the lifecycle costs of a machine when they want to modernize a production area – and with good reason: if users consider only the initial purchase investment, they will later have to deal with unnecessarily high energy consumption. Experts continue to estimate that the energy costs of a machine tool account for more than 20 percent of total costs incurred over its entire lifecycle. "To ensure economical production, many factors regarding use of the systems must be taken into account," explains Dr. Guido Hegener, Managing Director of EMAG Salach Maschinenfabrik. "The factor of energy consumption is becoming increasingly important because we have to expect energy prices to rise significantly in the future and exert an even greater effect on overall costs than currently."

Laser welding: an example of efficient design
What technologies can counter these spiraling costs? An area of application with especially high energy consumption yields a dramatic answer: welding. To meet this challenge, EMAG mechanical engineers developed the ELC 250 DUO, a system solution with extraordinarily low energy consumption. At its core is EMAG's trademark design. Workpieces are picked up by special spindles and moved with high precision during welding while the welding head inside the machine stays fixed in place. "This has a range of advantages. For instance, additional work processes can be integrated into the system. It also provides very high-precision welding. The design also directly improves energy efficiency," says Dr. Andreas Mootz, Managing Director of EMAG Automation GmbH. It starts with the suction system to remove welding smoke. Since the laser is always located in the same place, smoke is only produced in that one place. This means it can be precisely sucked up and removed with little effort – the first advantage.

Less energy consumption, identical performance
The process itself is responsible for most of the savings – EMAG relies on solid state lasers. Compared to traditional CO2welding, welding with solid state lasers ensures remarkably energy-efficient production processes. While conventional carbon dioxide lasers are rated at only eight percent efficiency, the technology developed by EMAG specialists achieves efficiency of around 20 percent. In other words, considerably less power is required to achieve the same optical performance. This massively cuts production energy costs by up to 50 percent. This advantage can be further compounded thanks to the intelligent system design which allows multiple welding modules to be easily arranged in sequence, which in turn enables rapid production of very high unit quantities. They all share the same laser beam source, which is modified along its path as necessary. This increases the service life of the laser while cutting production costs as well. As welding gas isn't required, this represents yet another efficiency and energy factor. "The solid state laser requires no protective gas for many type of applications, which really pays off. This reduces costs and means welding can progress faster," says Mootz.

Lathes: optimized in every detail
EMAG specialists took a similar approach to improve the energy efficiency of lathes. Key technical components have been optimized thanks to a modular platform which serves as a "platform for success". The best examples are the Platform 2 lathes, which include the models VL 2, VL 2 P and VT 2-4. Despite differing axis configurations, the machines are all equipped with the same spindles and technology modules. Energy efficiency was a major concern right from the development phase. The use of a whole series of optimized components, assemblies and software modules ultimately reduces the energy consumption of the new Platform series by some 47 % compared to machines of the previous generation. This is seen most significantly when it comes to the cooling systems and hydraulic assemblies. Variable-speed pumps in the hydraulic systems dramatically reduce losses within the hydraulic circuit. A secondary effect resulting from the use of variable-speed pumps is that during continuous operation, the hydraulic oil is heated to a much lower temperature than with conventional technology. Through-hole technology also gives users the option of venting the waste heat generated by the amplifier in the control cabinet directly outside. IE 3 motors are optional, rounding out the energy efficiency package of the Platform 2 series.

EMAG trademarks
"At our company, energy efficiency comes standard," says Hegener. "There are a few components and features that are associated with considerably increased investment and we offer these on an optional basis. This gives customers the option of choosing between lower initial investment on one hand, and better energy efficiency on the other." Deciding on a high-performance production system is always the right decision when it comes to energy efficiency, however, since shorter cycle times also cut energy costs per manufactured part.

VT 2-4 Vertical Turning Machine: A step-change in the production of electric motors

Wed, 27 Feb 2013 14:06:00 +0100

According to market experts the demand for electric motors is going to grow dramatically – and this at a time when the new transmission systems are becoming highly efficient. It is the express desire of the EU commission that the inefficient motors presently used in the automotive industry and other sectors should be replaced by the new electric motors by 2020. What does this development mean for motor manufacturers who are trying to use innovation and outstanding quality as a means to reach the top spot in the market? The example of shaft machining provides the answer: to ensure that the manufacture of complex components becomes even more efficient, the focus must be on the systems used to make them. The EMAG Group has developed a tailor-made solution for the manufacture of shafts for electric motors: their fully automated VT 2-4 Vertical Turning Machine. It makes the called for step-change in shaft machining a reality.

According to latest EU guidelines on the manufacture of electric motors, the energy-efficiency of many electric transmission systems is to be increased by 30 percent in the next few years. This provides the first opening for the exploration of an enormous market opportunity for the manufacturers of electric motors. The development does, however, bring with it some challenges, as the manufacture of these components does not only call for manufacturing solutions of greater effectiveness. The design of these modern motors also increases the demands made on its constituent components. “We know about these challenges in the manufacture of the central components for electric motors”, explains Dr Guido Hegener, Managing Director of EMAG Salach Maschinenfabrik GmbH. “A particular focal point is the demanding shaft manufacture, where a lot depends on the machine tool used. In a batch production environment idle times must be kept short and component costs low. But this must be achieved without loss of flexibility in the production process.”

Automation ensures short idle times
The specialists at EMAG have developed such a solution for the machining of shafts of up to 400 mm length and 63 mm diameter in their VT 2-4 4-axis Vertical Pick-Up Turning Machine. When it comes to larger batch sizes, the real strength of this machine becomes very obvious: its automation provides for very fast chip-to-chip times and ensures component costs are kept low. Workpiece grabs are used to transport the raw-parts into the machine and retrieve them again on completion of the machining process. Depending on the component, the changeover time can be as short as six to eight seconds. “In a mass production environment such short idle times soon add up to provide enormous time savings”, adds Guido Hegener. “They also guarantee an energy-efficient production process, as a large part of a machine tool’s energy is consumed during downtimes.”

The actual turning process – with spindle speeds of up to 6,000 rpm – also helps to achieve extremely short cycle times. The shaft is clamped vertically between workspindle and tailstock and machined from two sides. This work is done by two turrets with twelve tool stations each. The stations can be equipped with turning tools and driven tools (with one station being occupied by the grab). For milling work – such as required for keyways – the machine can be optionally equipped with a Y-axis. The vertical alignment of the workpiece ensures permanent process integrity, as the unhindered chip flow prevents the build-up of chip nests in the machining area.

A true space-saver with many options
A decisive factor for economic production is the external dimension of the machine tool. In the case of the VT 2-4 the machine base is already small, as the vertical design does not take up much space. Production planners also don’t have to provide for additional raw-part and finished component storage, as this forms an integral part of the VT 2-4. These machines can also be linked-up in close formation, to form a neat manufacturing line. “We have developed an altogether very compact manufacturing system that is highly flexible and future-proof”, explains Guido Hegener.

Fast chip-to-chip times and the advantages of vertical machining – what are the chances of this concept in the market? “There are a lot of possible applications out there for this system, especially in the manufacture of shafts for electric motors”, says Guido Hegener. “We are offering a machine tool that allows the user to implement demanding machining processes and to save massively on costs. This kind of quality will no doubt assert itself.”

Capacity	Unit	VT 2-4
Chuck diameter	mm	160
Travel in X	mm	340
Travel in Z	mm	525
Spindle	Qty	1
Main spindle power rating 40% / 100% duty cycle	kW	34 / 26.5
Torque 40% / 100% duty cycle	Nm	144 / 112
Speed max.	rpm	6,000

Hard turning on EMAG turning centre: as hard as it gets – and still the costs are reducing

Mon, 25 Feb 2013 14:19:00 +0100

These days, our cars are full of high-tech materials that ensure a long life for the individual components and make the car safe to drive. These materials are also less weighty, which reduces consumption levels. To ensure that they are machined in an economical way – using high-precision processes – requires the right machinery and the correct process. When it comes to the machining of hardened surfaces, hard turning is a particularly efficient solution that – compared to grinding – offers a radical reduction in both machining times and investment costs. With its VL 5 EMAG has a machine in its product range that is tailor-made for hard turning. Its design brings a number of advantages to the machine’s particular, highly demanding field of application.

The conditions faced by sub-suppliers and manufacturing companies alike have been the same for decades: optimal component quality, flexible batch sizes and low workpiece costs. These are the kind of demands made by customers in all branches of industry and all fields of application. However, it is particularly difficult to achieve in the machining of already hardened surfaces. Grinding, the method used most often for the purpose, is very time-consuming and known for its relatively high tooling costs and energy consumption. One alternative process that is being used more often, both in the small batch and the mass production of hardened workpieces, is hard turning. With good reason, as the process offers identical surface finishes and allows for the process chain to be shortened by a complete stage. Last, but by no means least, turning machines are noticeably cheaper than grinders and their energy consumption is lower. Unlike the grinding process, hard-turning can often be carried out dry – a much more environmentally friendly method.

The design scores heavily when it comes to hard turning
In the VL 5 the turning experts from EMAG have created a tailor-made solution for the application of this innovative process. Its design features make a particularly positive impression in handling the heavy stresses exerted on tools and machine during hard turning. For instance, its machine base is in Mineralit, a polymer concrete with a vibration resistance eight times that of cast iron. “A vibration resistant machine leads to an improved surface finish on all components it machines, with tool life being much improved too”, says Peter Loetzner, CEO EMAG L.L.C. The vertical design is another feature that ensures an economical process, with the work spindle and the workpiece located above the tool. This offers ideal chip flow conditions, with the material removed being taken out of the machine by a chip conveyor. All guideways are located above and away from the machining are, keeping them safe from any possible ingress of chips or dirt. This increases the constantly maintained component accuracy and reduces the maintenance effort.

Another important quality feature of the vertical turning centres from EMAG is their integral automation. They all use a recirculating conveyor chain into which are inserted carrier prisms holding the raw-parts. The chain conveys the workpieces directly into the pick-up station, where they are picked up by the work spindle and then machined. Workpiece changeovers are very fast, as the distance travelled between loading and machining position is only 550 mm. This leads to a massive shortening of the time span between machining processes.

Convinced by low investment costs
The possibilities offered by hard turning on the fully automated, vertical turning machines from EMAG is best shown by the example of a gear production for a sub-supplier to the automotive industry. The VL 5s run by the customer produce a total of eight different gears for a dual-clutch transmission system. Following the hardening process, the workpieces are pre-turned on the machine, to remove the hardened top layer. This is followed by a synchronous ring being welded onto the workpiece away from the VL 5. The component is then returned to the EMAG machine and finish-turned. Before the customer used VLs for the job, he carried out the comparable operations on grinders. “Some time ago, this company started to invest in VL 5 machines for their hard turning process, as the investment costs were so much lower”, adds Peter Loetzner. And it has to be noted that the surface finish on the component is as excellent as ever. “Hard turning on the VL 5 is in no way inferior to the previously employed grinding process; and the machining times are noticeably shorter”, explains Peter Loetzner further.

From bearing ring to gear
When can hard turning successfully replace the grinding process in the machining of a component surface? “That depends on a number of factors. For instance, the desired surface texture is of great importance. We advise our customers on this point and show them the best way to proceed”, explains Peter Loetzner, “and where hard turning is possible, it often becomes first choice.” Apart from lower investment costs, many users are also impressed by the elimination of the grinding operations. On the VL, the turned part can be finish-machined in a single setup. It is no longer necessary to take it to another machine for finishing. The result: the output level of the whole production increases quite considerably.

The turning specialists from EMAG can look back on having already delivered a total of 3,500 VL machines. The know-how this has provided is something the new user also profits from. “Our design team orients themselves on customer demands. This ensures that the strengths of our machines are targeted on what is required.” The types and numbers of components produced on these vertical turning machines are of great diversity. Toothed components, such as gears and crown wheels can be produced with the same efficiency as bearing rings. “The system can be adapted to suit any batch size and impresses with its short cycle times and its high component quality. These advantages captivate the customer again and again. If, in addition, you can also save on a whole process stage, the user of a VL 5 will, of course, be able to enjoy an unbeatable cost advantage”, emphasises Peter Loetzner in conclusion.

Small grinding center offers big productivity boost

Mon, 07 Jan 2013 13:39:00 +0100

Automobile manufacturers all over the world were able to enjoy an increase in their turnover figures last year! The biggest increases were experienced in the USA, China, India and Russia. However, the rapidly increasing number in vehicles also brought some production challenges – for instance the sub-contractors’, have to deal with the increasing output levels and also have to ensure that process safety and component quality do not suffer. In fact, even the smallest components with complex geometries have to be produced with increasing levels of precision. In the development of the VLC 100 G Vertical Grinding Center from EMAG, the grinding specialists have made sure that the machine concept offers efficient, error-free machining processes for the production of small chucked components.

Small chucked components are typically produced in large quantities. The demand for components, such as gearwheels, planetary gears, chain gears and flanged components for cars, for instance, have necessary quantities that typically go into the millions; and short cycle times in the production of these components have become mandatory. For instance, the internal contour of a gearwheel must be ground in the shortest possible time and the machine’s workholding unit must be loaded with a new workpiece just as quickly. In many production environments this represents a critical moment, because the idle time is commonly a decisive factor in establishing the economic viability of the whole process.

Automatic loading scores heavily
High output levels – short cycle times. This is exactly what the VLC 100 G Vertical Grinding Center from EMAG, for small chucked components with a maximum diameter of 100 mm, was developed for. The machine utilizes its pick-up system to load itself. And while one workpiece is being machined, the operator – or the automation system – is putting the raw-parts on the conveyor belt. This reduces idle times and increases output rates. Another benefit is the vertical machining concept; the design ensures that the grinding sludge falls to the bottom of the machine unhindered, where it is then transported out of the machine.

Quality control is integrated
Measuring processes can also be integrated into the machine, making quality control an integral part of the whole process. The measuring probe is located between the machining area and pick-up station, where it is protected from contamination.

In use are two different grinding wheels
An important feature of the VLC 100 G Vertical Grinding Center is that it offers the possibility to use two grinding spindles, which can be used to perform different grinding operations, or to handle both rough- and finish-grinding work. In other words, the first wheel performs the “rough” job of removing excess material from the raw-part at high feedrates (the CBN wheel is specially designed to absorb the necessary forces), while the second wheel (with different specifications) takes over the finishing work to guarantee a perfect surface finish on even the most challenging geometries. With the help of this intelligent tooling combination, EMAG design engineers have succeeded in drastically reducing the grinding time of even very complex components. “For the removal of large amounts, two wheels offer a shorter cycle time than one, with the first wheel designed to do the rough-grinding and the second one in charge of finish-grinding work”, explains Dr. Guido Hegener, Managing Director of EMAG Salach Maschinenfabrik GmbH.

A convincing machine concept
The combination of fast loading and efficient grinding processes leads to a very compelling machine concept. The VLC 100 G Vertical Grinding Center works very well with the dynamic developments in automotive production. Now with the rapid increase in required quantities, the demand is for new machine concepts that can be integrated into existing production without any problem. With the VLC 100 G Vertical Grinding Center two features enable it to be integrated without any problems. “Programming the workpieces with our new EMAG NAVIGATOR software is simple and intuitive, saving valuable setup time. For many production environments this is an advantage that should not be underrated, “confirms Dr. Hegener. Furthermore, the exceptionally small floor plan for the VLC 100 G Vertical Grinding Center should make the work of every production planner easier. The stand-alone machine only takes up around 4.5 square meters (48 square feet), making sure that the growth of a production facility of this kind will not be limited by floor space requirements.

The advantages of the VLC 100 G Vertical Grinding Center

Compact grinder with the highest precision
The machine can accommodate both internal and external grinding spindles.
Integral automation, short travel times = short chip-to-chip times
Vertical machining = unhindered chip flow, with the grinding sludge falling to the bottom
Optimal access = fast setups
Great process safety through the use of an optional measuring probe

Of utmost precision and highly productive: laser welding in “Transmission Manufacture 2.0“

Wed, 28 Nov 2012 12:07:00 +0100

From Dual-Clutch Transmission to the classic differential: modern transmission technology is a pivotal research sector in the automotive industry. With new materials and altered geometries designers optimise the functionality of the different gearwheels. Furthermore, these wheels are required in ever larger quantities owing to the fact that the number of speed-gears in many passenger cars is on the increase. The innovations that promote the effectiveness of the production processes being applied include, for example, laser welding. With their ELC series of machines, the specialists at EMAG have developed integrated solutions for the application of processes with high output rates. The company’s in-depth knowledge of the production processes used for many transmission components, has added to its competency.

A first glance at a typical transmission component makes it plain where the challenges lie: even a small wheel with integrated synchronous gear represents a relatively complex design. To manufacture it efficiently and at the highest precision calls for the two different parts to be produced separately and subsequently joined in a joining+welding process. It is at this point in modern transmission manufacture that laser welding comes into its own”, explains Dr Andreas Mootz, Managing Director of EMAG Automation. “The process allows you to concentrate a carefully dosed amount of the energy emitted by the laser beam on the welding point, minimising possible warping, whilst still achieving high welding speeds.“ Furthermore, the welding process from EMAG uses solid-state lasers of outstanding energy efficiency. Whereas a classic carbon dioxide laser will achieve an efficiency factor of just about eight percent, the EMAG specialists can rely on an efficiency factor of approximately 20 percent with their technology. In other words: the power used to achieve the same optical performance is noticeably less, with energy costs in the production department massively reduced.

Stationary welding device scores heavily
Similarly effective within the total process is the integration of different production sequences on the ELC system. For starters, the work spindle uses the pick-up principle to load itself. The components involved are then clamped and pressed together in the joining press. The clamping technology used ensures the highly accurate positioning of the components, providing ideal conditions for the welding process. The design of the stationary optic ensures great operating safety and optimal stability of both machine and welding process. Dependent on workpiece or material, the components can be induction-preheated prior to the welding process and brushed after it – and whatever is required, the process is completed in a single setup. The complete joining+welding process for a gearwheel takes just 12 seconds. This ensures that the components for a differential are thus finish-welded within no more than 40 seconds.

Laser welding leads to advances in light-weight construction
The differential housing as an example clearly shows the possibilities the laser welding technology opens up in the general development of vehicle production. For some time now, automotive companies have been replacing the screw-type connection between differential housing and crown gear with a welding seam. The result: the cost of materials reduces and the weight of the assembly falls by approximately 1.2 kg. “When looking at the advances made in light-weight construction in the automotive industry, these kind of savings mean the world”, explains Dr Mootz.

The customer benefits from practical knowledge
Seen in context, the welding specialists from Heubach, Germany are able to look back on a truly impressive history of success. Over 50 ELC systems have been sold in the last decade. All leading automobile manufacturers are using them. EMAG is the world leader in solid-state laser systems for the production of transmission and powertrain components. How did this success come about? “It is of decisive importance that we have at our disposal a large reservoir of know-how in the manufacture of these components. We know the whole of the manufacturing process, from turning and grinding, and from welding right up to the concluding ultrasound testing process”, emphasises Dr Mootz. “We can develop and construct the whole of the process chain. This massively simplifies the planning of new production sites and the expansion of existing ones.“

General market development is positive
The general market development does play into the hands of the German machine builder: It is not only the successful dual-clutch transmission that ensures the need for more gears. Conventional transmission systems too tend to have more speed gears, as this reduces petrol consumption and improves the driving comfort. “Having said that, we are offering a well proven welding technology that provides an energy-saving, high-precision manufacturing process and, at the same time, helps to advance light-weight construction and reduce production costs. This is no doubt a very successful and persuasive combination”, concludes Dr Mootz.

“Energy Efficiency Award“: The ZF Group honours EMAG commitment

Mon, 29 Oct 2012 13:58:00 +0100

According to the “Future Panel“ of the IW – the Institut der deutschen Wirtschaft (Institute for German Economic Research) – the subject of energy efficiency is gaining ever greater importance in the metalworking industry. The panel suggests that over 60 percent of the companies interviewed are hoping for “an impetus for innovation“. EMAG is an initiator of such innovations. Its experts develop machine tools and production processes that consume noticeably less energy. This has now also been confirmed by the recent contest for the “Energy Efficiency Award“ of the ZF Group: EMAG’s contribution has been honoured as one of the top five.

From most efficient manufacturing technology to economical design and construction, the machine builders at EMAG have shown their combined, in-depth know-how and experience in one of the most important fields of industrial development, to compete for the “Energy Efficiency Award” from ZF. The result has convinced the jury at ZF: EMAG’s competition entry under the heading “Energy-efficient Production Machines“ has been honoured as one of the “Top 5 Projects“. In fact, in this particular sector EMAG was the only machine builder so honoured. In the run-up to the competition, and as part of its “Year of Energy“, ZF wrote to approximately 600 of its suppliers, inviting them to participate in the competition. From 30 eligible entries, the specialists in driveline and chassis technology picked the top five. These five companies were invited to present their particular approach to efficiency on the 13th of September at ZF, Saarbrücken.

EMAG has been focusing on the subject for years

“We are very pleased to have received this award“, declared Dr Guido Hegener, Managing Director of EMAG Salach, Maschinenfabrik GmbH. “It is an incentive for us to continue on the chosen path. Our focus has been on energy efficiency for years.“ During his presentation Herr Hegener pointed out the various development highlights at EMAG:

The intention to replace less economical processes, such as the classic grinding process, with more energy-efficient manufacturing methods, such as scroll-free turning or hard turning, the energy requirement of which is up to 90 percent less. “Cycle times for these processes are noticeably shorter and the runtime of auxiliary equipment is much reduced. This brings massive energy savings“, explained Herr Hegener.
On the other hand, EMAG engineers are breaking new ground in the design of manufacturing systems. Within the framework of a collaborative research project, this led to the development of a software package that allows for the energy consumption of machine components and complete systems to be determined already at the development stage, on the computer.

“We have established how much energy each component consumes and where the biggest potential for savings lies“, explained Wolfgang Rummel, Head of Control Technology Development and Design at EMAG Salach Maschinenfabrik GmbH. He also made reference to the concrete measures taken: EMAG includes the most efficient components already in their standard machine design – for instance hydraulic packs of greater efficiency, low-wattage valves and intelligent auto-standby circuitry.

At the end of his competition presentation Director Dr Hegener introduced a new overall objective: the development of the “sustainable factory“. He suggested that in future the production – together with the building in which it is situated and its technological contents – is evaluated as a single entity. In conclusion, he expresses his belief that the measures taken to reclaim and recycle energy can lead to a potential saving of another max 40 percent.

Chinese automotive company opts for all-vertical shaft machining

Wed, 25 Jul 2012 09:45:00 +0200

Long-term forecasts for the Chinese automotive industry have and continue to look outstanding. PricewaterhouseCoopers, estimates that within five years, the production of cars in China will nearly double from the current rate of around 14.5 million to 27 million units. Achieving this boost in capacity requires new production facilities, which translate into an enormous task for planners. How can an efficient production process be created at a new location in minimal time, and when complex components are needed? A mechanical engineering company that specializes in a wide range of production technologies can provide the answer, in this case the turning and grinding specialists at EMAG, who have partnered with Chinese customer Changan Automobile. The main focus is the camshaft machining, a highly skilled discipline in the metalworking industry. In the future, the comprehensive turning, drilling, and grinding work required for this critical engine part will be handled using a multi-stage production line from EMAG. All machining processes will also be done vertically, a process that has never been used at Changan before and contains many benefits.

Based in Salach, Germany, EMAG has designed a large number of machining centers that operate according to the vertical principle. During the machining process, the tool is located adjacent to the vertically positioned workpiece. This ensures that chips and shavings are removed when the workpiece is turned or ground, guaranteeing stable and reliable machining. To meet the requirements for Changan Automobile, EMAG had to take the technology a step further by using vertical machining to handle all aspects of soft and hard machining a camshaft within a multi-stage production line. "We really did enter new territory with this all-in-one solution," explains Dr. Guido Hegner, Managing Director at EMAG Salach Maschinenfabrik GmbH. "It goes without saying that we have a lot of experience with horizontal grinding and drilling processes. The accompanying step of deep-drilling a shaft in the vertical direction is in itself unusual, since the bit must drill 320 millimeters into the component. Our goal from the very beginning was to apply the principle of vertical machining to the entire line to exploit the benefits it provides."

EMAG technology in action
The camshaft production line began in Chongqing, China in May at the production headquarters of Chnagan. This solution features two almost identical production lines, installed parallel to each other, for the intake and exhaust camshaft. Interlinked shaft machining is initiated with two VTC 250 DUO turning centers from EMAG. While one VTC 250 DUO is used to mill the shaft and machine its ends, the other carries out deep drilling, drills radial oil holes, and mills a marking surface. Two VTC 315 DS grinding centers from EMAG then perform all necessary grinding steps, where the first center grinds the shaft bearings and the second executes out-of-round grinding on the cams. What really sets these machines apart, however, is that they integrate two grinding disks, which contact the camshaft on both sides and run in different directions. Feed forces are counteracted by the opposing arrangement of the grinding disks. This design is beneficial in more than one way: First, the rigid bracing facilitates extreme grinding feed rates for a camshaft. The time saved here is then complemented by the two disks, which further reduce machining time.

Intelligent automation, efficient cooling
The EMAG technology is also the key to enabling the distinct automation efficiency of the entire line for all turning and grinding processes. Integrated pick-up conveyors for the turning centers remove the components from a shuttle and place them on a different shuttle. Transport then continues. Inside the grinding centers are robots that secure transfer of the workpieces from shuttle to shuttle. "Coolant is also supplied throughout the entire plant in a very efficient manner," adds Hegener. "The fact that the two lines for the intake and exhaust camshaft are close to each other and are almost identical in design made it possible to combine the cooling supply for their machining centers. Only two systems are used to clean the coolant.“ One system supplies coolant to the turning centers of both production lines, while the other cools all grinding centers – an effective solution that also decreases investment costs. The downstream production sequence for machining the camshaft also includes a series of systems which safeguard component quality by crack testing and measuring as well as finish components so that they can be installed by washing them and applying a protective coating.

Short cycle times guaranteed
Two turning centers, two grinding machines, a deburring and finishing process, an additional machine for mounting gear wheels, and quality assurance measures – no camshaft takes more than 69 seconds to complete each of these steps during production. How can such short cycle times be maintained? "Several factors come into play. The synchronous support grinder, for example, has two grinding disks to expedite rotary grinding. The same applies to the 4-axis turning assembly. Non-productive time is also minimized, since parts are loaded and unloaded simultaneously," explains Hegener.

All-in-one solution
Changan will profit from an efficient solution that ensures very high component quality. The all-vertical machining helps safeguard process reliability as well. "There are many reasons why this solution is attractive," Hegener summarizes. "A key aspect that persuaded our Chinese partners to commission us for the project, however, was the great deal of know-how we possess when it comes to machining shafts. We designed and assembled the entire production line, including all interlinks and peripheral equipment required. This all-in-one solution then made it much easier to develop the new production facility."