With the rise of electric mobility, the focus in manufacturing is shifting significantly: Components that could “run along” in internal combustion engines due to masking noises and vibrations are evaluated much more critically in electric drives. The reason is simple: The internal combustion engine generates a broad spectrum of noise that masks many background sounds. In electric drives, this acoustic “background noise” is largely absent, making deviations in shape, position, and surface significantly more noticeable.
Technologies
The production of steering pinions poses a particular challenge in the modern automotive industry. These precision gear components are indispensable parts of steering systems and must meet the highest quality standards while also being produced economically in large quantities. The combination of required dimensional accuracy, surface finish, and process stability demands specialized manufacturing solutions.
In this interview, Konstantin Ungefuk, Head of the Gear Cutting Soft Business Unit at EMAG, explains the complex process chain involved in machining steering pinions. He provides detailed insights into every machining step – from turning the raw-parts to soft-state gear hobbing, precision grinding of the bearing seats after hardening, and the final skiving of the hardened tooth profiles.
Wave generators are central drive elements in strain wave gears, which are used in robotics in particular due to their high reduction ratios and compact design. The component consists of a ball bearing with an elliptically shaped outer ring, which is mounted on a shaft and typically acts as the input side of the gearbox.
Producing these components presents significant technical challenges for manufacturers: The required shape tolerances in the single-digit micrometre range combined with complex elliptical geometries and thin-walled structures require specialized manufacturing strategies and highly capable machine tools.
Experience the new generation of EDNA Feature Correction and EDNA Production Status.
EDNA Feature Correction is a core component of EDNA ONE and enables the manual or automatic adjustment of production features in real time. This ensures that product quality remains stable over the long term and process deviations can be corrected immediately.
EDNA Production Status is a central module of EDNA ONE and displays the current status of a machine as well as the overall production progress in real time. Operators receive a clear overview of active programs, upcoming work steps and possible downtimes. This makes machine operation more transparent, reaction times are reduced and production can be controlled much more efficiently.
With the introduction of Sinumerik One, EMAG continues its commitment to the latest CNC control technology from Siemens. Replacing the proven 840D sl platform, SINUMERIK One serves as the foundation for the next generation of digitally connected manufacturing systems. Combined with EMAG’s new WinCC Unified-based software, this future-ready control system delivers maximum performance, intuitive operation and seamless integration of smart data applications.
As automation continues to expand in industrial manufacturing, companies face clear demands: short commissioning times, high flexibility with changing workpieces and seamless integration into existing production environments. The MRC – Modular Robot Cell, was developed specifically to meet these requirements, offering a flexible automation solution for automated workpiece handling in machining production.
The MRC was first introduced as a bin-picking solution, but has been designed from the beginning as a universally applicable automation system. The modular design allows different applications to be implemented using standardized modules, making it easy to adapt the systemto new tasks without major redesigns.
In modern manufacturing operations, energy efficiency is one of the key parameters for profitability and sustainability. With the new EDNA Energy Manager, EMAG now offers a software solution that addresses this challenge: It enables intelligent control of FANUC-controlled machines and targeted energy savings – without operator intervention. Automated time and energy saving profiles can be used to optimally plan and implement both the start-up process and idle phases. The result: lower energy costs, higher machine availability and a contribution to sustainable production.
The insertion of field rifling profiles into a barrel – such as those used in sporting rifles – is a very demanding task. The complex internal geometry is difficult to achieve using conventional cutting and forming tools and must be manufactured with extreme precision. While forming processes are often used, they require high capital investment and generate additional process costs. Electrochemical machining (ECM) from EMAG offers an alternative: a fast and effective process that delivers high-precision surfaces. In this interview, Daniel Plattner, Technical Sales Manager at EMAG ECM, discusses the possibilities of this innovative production method for rifling.
Today we talk to Syl Kastrati, responsible for development at EMAG, about the new diagnostic tool EDNA Health Inspect, which has been specially developed for VL (Single/Duo), VSC (Single/Duo) and VT.
The design and development of coated brake discs are becoming increasingly important in the automotive industry. The main driver behind this shift is the need to reduce brake dust emissions, as mandated by international regulations like GTR 24 and the Euro 7 standard. These regulations set strict limits on particulate emissions (PM10): capping them at 7 mg/km for passenger cars and as low as 3 mg/km for electric vehicles. These standards will be enforced across the European Union starting in November 2027, with a similar regulation expected to take effect in China between 2028 and 2030 under the National 7 standard.
To meet these emission targets, manufacturers are increasingly turning to coated brake discs, with Laser Metal Deposition (LMD) emerging as a promising technology. However, the precision required to manufacture these complex components presents significant challenges. The key to achieving high-quality, cost-effective brake discs lies in the coordination between the laser coating process and the subsequent grinding process.