The standard vertical turning center for chucked components was – in appreciation of its high productivity rating, its outstanding precision and the minimal set-up times – received with great enthusiasm by large and small manufacturers and sub-contractors alike.
EMO Press release: The VL 3 Vertical Turning Center from EMAG
01.08.2007 - Oliver Hagenlocher
Large and small manufacturers – and those of turned parts in particular – are being subjected to ever greater cost pressures. Component manufacturers deal with small and large batches of a great variety of workpieces. For the smaller batches they require a universal machine that is easy to program and to set up, whereas the larger batches call for an automated high-efficiency production tool. The VL series has been successful in providing both in one machine. When it comes to the machining of chucked components the VL is a real cost cutter.
Three frame sizes
The larger VL 5 (chuck diameter 250 mm) and VSC 7 (chuck diameter 400 mm) complement the VL 3 (chuck diameter 160 mm) and greatly extend the application range (Fig. 2203). Together they cover a considerable number of the sub-contractors applications.
The success of the VL series is based on its purposeful design for flexible use by sub-contractors, backed up by the experience gained with 5.000 vertical machines from EMAG out in the field. The self-contained Lean concept of the VL standard turning machine has been adapted to suit the requirements of medium size manufacturers and the sub-contractor.
- Automatic workpiece changeover in the shortest possible time = fixed production quantities
- Integrated automation, low capital outlay
- Short travels between loading and machining points, resulting in very short cycle times
- High degree of availability
- Ideal chip flow conditions, with the chips falling away to the bottom
- Very short chip-to-chip times
- Small footprint
VL series: self-contained Lean concept
A favourable price/performance ratio for a machine without frills, but one that is technically sophisticated and fully equipped for the purpose: chip conveyor, fume extractor, fluid-cooling system for spindle motor and turret, automated workhandling system.
Short set-up times through flexible automation
Every VL features an automation system with recirculating chain conveyor (Fig. 1470A), on which carrier prisms are mounted that convey the workpieces to and from the pick-up station. It allows for a wide range of workpieces to be machined automatically without re-setting. The advantage of such a system is obvious: the automated system provides for a fixed production cycle, as a new raw-part is available as soon as the previous one has been machined.
With the pick-up station located behind the machining area, the operator can, at any time, remove finished components and insert new raw-parts at the conveyor belt from the front. Where asymmetrical or long and thin workpieces have to be machined, or where components have to be specially aligned, workpiece receptors and pallets of simple design can be inserted into the carrier prisms. This allows for the fully automatic loading and unloading of a large variety of workpieces.
Idle times are drastically reduced
With less than 400 mm to travel between loading and machining position at the turret on the smaller and only 550 mm on the larger machine, the VL is unbeaten when it comes to the speed of a workpiece changeover. Chip-to-chip times too are very short. Shorter idle times mean better output rates and lower unit production costs.
The VL series − a miracle in space saving
The VL machines work miracles in reducing floor space requirements. They are also the perfect solution in matters of operational ease and accessibility. This provides ideal preconditions for multiple-machine operation.
Permanently lower running costs
Energy is a valuable commodity and costs money. The VL has seen a consistently careful and responsible application of resources. Only those components which serve the process capability and the component quality have been retained.
The VL is – and this it has inherited from the multi-tasking VSC machines – so stable and vibration resistant that tool life is prolonged considerably.
All guideways are well protected from chips and dirt, as they are located above and outside the machining area. This increases and constantly maintains accuracy and the integrity of the process capability and reduces the maintenance effort. Telescopic covers – so susceptible to failure – are not in use on the VL.
For smallest batches and for mass production
The short set-up times allow for the VL to be used for the smallest component batches. At the same time, the VL also presents a highly efficient, automated manufacturing cell for mass production, where the chuck of the pick-up main spindle automatically collects the raw-part from the conveyor belt, takes it into the machining area at speed and – after completion of the machining cycle – collects the finished component, to return it to the conveyor belt.