How can particularly large and heavy components be produced using lean production solutions? This question is becoming increasingly important, especially in the commercial vehicle sector, because price pressure in the market demands the lowest possible unit production costs. In this context, the VSC 500 and VSC 500 DUO machines from EMAG are real “game changers” for manufacturers. They load themselves and then ensure fast and precision complete-machining in a single setup or two. A conversation with Peter Gröner from the Turning Business Unit at EMAG about the enormous possibilities of this technology.
Mr. Gröner, in which areas are the VSC 500 and VSC 500 DUO machines used?
Peter Gröner
That is a very broad spectrum. It ranges from commercial vehicle production and the machining of components in oilfield technology to manufacturers of large industrial gearboxes. Ultimately, it is suitable for all rotationally symmetrical components with a maximum diameter of 450 millimetres and a maximum length of 200 millimetres – for example wheel hubs, couplings, bevel gears or brake discs.
The VSC 500 machines workpieces up to a diameter of 450 mm and is used as a production system for truck components.
Why do customers rely on this machine?
We impress here with precision, process reliability and efficiency, which is not a matter of course, especially with large components. For many users, loading is very time-consuming, the solutions take up a lot of space and the establishment of gantry loaders generates high capital investments. We counteract this with our pick-up technology, as the machines load themselves. Various machining processes can then be carried out in a single setup. A 12-station turret is available for this purpose.
VSC 500 – automated machining of large workpieces. The components are picked up directly from the spindle at the pick-up station and transported into the work area.
What role does the “precision” factor play?
It is of paramount importance to us, as can be seen from a whole range of technical details. For example, our Mineralit® base body has 8 times better damping than cast iron, which increases tool life and precision. There is also a hydrostatic guide principle in the Z-axis. The guide cylinder moves in an oil film, which provides greater stability during hard machining. The symmetrical design of the machine is similarly effective. On the one hand, it ensures a closed flow of force and, on the other, reduces thermal influences.
VSC 500 in symmetrical design for machining large workpieces.
Why are the machines available in two versions?
We offer customers tailor-made solutions for their respective tasks. The DUO variant has two spindles in separate base bodies and can be used in different ways. For example, you can machine a component in two separate setups from two sides. For this purpose, the VSC 500 DUO uses a turning device between the two operations. However, it is also possible to finish two identical components in parallel on the same side – for example, to increase the output quantity.
You can find even more information about the two machines in this blog post.
You modernized the entire VSC series some time ago. What was involved?
We have optimized a whole range of details. For example, it was important to us to improve the accessibility of the machine. This is why the machines are now open at the top when the front door is open. A maintenance platform can also be easily mounted, making it easy for service personnel to access the overhead slide. We have also worked on the quality of the workplace. That is why there is now a bellows as an additional cover for the headstock. It seals off the work area, especially during loading and unloading.
How much space do these solutions require?
Very little – the VSC 500, for example, has a footprint of just eight square meters. This compactness also characterizes our production lines, as all VSC machines can be linked-up very easily. The pick-up technology forms an ideal basis for this. It takes over the “internal” loading of the work area, which is why the line automation (e.g. by gantry loader or robot) only has to ensure the connection between these machines.
The work area can also be adapted to the respective requirements. Here is a work area with powerful milling and drilling spindles.
