EMAG LLC

Farmington Hills,  MI 
United States
http://www.emag.com
  • Booth: 2321

EMAG equipment covers the entire spectrum of machining processes in the metalworking industry, offering the latest technological advances in turning, drilling, milling, grinding, gear cutting, electro-chemical machining, and laser welding. Active in the automotive, oil field, power generation, aerospace and large equipment industries, EMAG is a trendsetter in the field of vertical turning centers and multi-functional production machines. The German based company is an important partner in the realization of complete manufacturing lines world-wide with their US representation located in Metro-Detroit.

EMAG offers machines and complete manufacturing systems for the oil field industry. With over 30 years of experience in the machining of oil field components, such as tube ends and couplings, tool joints, drill bits and rock bit cones, pump impellers and pump housings the name EMAG stands for the highest quality and reliability in the use of cutting-edge technologies. For more information visit www.emag.com


 Show Specials

  • (Feb 15, 2017)
    New customers will save 25% on our VL 2 and VL 4 Modular Machines! With purchase of a machine, we'll also include a $10,000 Technology Kit for free! Stop by booth 2321 for more information or visit ncp.emag.com.

 Press Releases

  • Modular System for Line Production: the VL Series from EMAG

    Vertical production machines are EMAG's territory. It all began with the VSC series, which laid the foundation for the successful machine concept of the vertical pick-up turning center. This machine concept runs through nearly the entire product range of the manufacturer, and it takes on its latest form in the VL series.

    VL machines are part of EMAG's modular standard series. As the term suggests, these machines are built on a common machine base but allow the use of an extremely wide range of technologies, similar to the modular platform systems seen in the automotive industry. There are now modular machines available for turning, gear hobbing, and chamfering processes; for grinding (chucked parts and shaft parts); for induction hardening; and also in special designs for laser welding or PECM technology. Essentially, they are available for virtually all the technologies offered by the EMAG Group.

    Automation Included

    The machine base of these modular machines is made out of Mineralit® polymer concrete. This material has exceptional vibration damping properties, which is the basis for the machines' excellent process quality. The machine base supports a compound slide rest equipped with an X-axis and a Z-axis, which allows the working spindle to move. The working spindle is the heart of the pick-up automation system which is an essential part of every modular machine. It includes a parts storage unit in every machine, from which the pick-up spindle loads and unloads itself independently. This lowers non-productive time to an absolute minimum as there are only a few seconds between the machining processes. An optional measuring probe can be installed directly alongside the loading position, allowing time-optimized measuring of the parts. The designers have thought of everything to make these machines as efficient as possible.

    The VL Series—the Modern Approach to Turning

    The vertical pick-up turning centers of the VL series were developed particularly for the production of precise chucked parts. There are now five versions of the VL machine to cover the widest possible range of parts. The smallest machine is the VL 2, designed for chucked parts with a diameter of up to 100 mm. It is followed by the VL 4, VL 6, and VL 8 machines which allow for an increase of 100 mm in diameter with each model increase (see image). These additional models allow the VL series to cover workpieces up to 400 mm in diameter. Each VL machine is equipped with a tool turret with up to twelve (driven) tools for the machining of chucked parts. This turret is exceptionally dynamic; it’s very fast indexing cuts non-productive time to a minimum, which in turn reduces cycle times. The machines can also be equipped with a Y-axis in the turret for the machining of complex shapes. This greatly expands the number of possible applications of the machines. The fifth machine in the set is the VL 3 DUO with dual spindle.

    VL 3 DUO—Two Machining Areas Ensure Productivity

    The VL 3 DUO is the first dual-spindle machine in the VL series. Its parts capacity places it between the VL 2 and VL 4, allowing high-productivity manufacturing of chucked parts with a diameter of up to 150 mm. It's no coincidence that the majority of transmission gearwheels fall into this size category. Every aspect of the VL 3 DUO has been designed for high-volume production, which makes it the ideal solution for the machining of gear blanks that have to be churned out by the millions. The VL 3 DUO is pure performance. Including the parts storage unit, the VL 3 DUO has a footprint of no more than 13 square meters. That space houses the automation system, the parts storage unit, and two complete machining areas, each with its own working spindle and its own 12-station tool turret. This machine is ideal for production in two clamping operations – machining both sides of a workpiece in OP 10 and OP 20, respectively. Of course, the part needs to be flipped over between the two operations. With the TrackMotion automation system, EMAG has found an ingenious solution for this problem.

    TrackMotion—Modular Automation Solution for Modular Machines

    The TrackMotion automation system has been specially designed for modular machines and drastically simplifies the connecting of multiple machines. The example of the VL 3 DUO makes this very clear. The TrackMotion automation system is made up of two components: a track, which is a kind of rail routed behind the work area of the machines, and the TransLift, a gripper system that runs along on that rail. This NC gripper, which is programmed directly through the machine's control, provides the transportation of parts between the machines, as well as to and from the storage unit for raw and finished parts. The gripper has a Z-axis so it can also store the parts three-dimensionally, on top of each other, in stackers. This allows a huge number of parts to be stored in a very small space. The gripper also functions as a flip-over unit, turning the TrackMotion into a genuine all-purpose solution for the automation of modular machines.

    Modern Manufacturing with VL Machines

    EMAG's VL series of vertical pick-up turning centers offers a whole range of machines where everybody can find the perfect tool for their application. Whether as standalone machines, or linked with other modular machines, the VL series promises state-of-the-art production of chucked parts with top of the line quality, at rock-bottom unit cost.

  • With the new VM 9 modular turning machine, EMAG has introduced a platform that covers a broad spectrum of applications thanks to the combined turning, milling and drilling technologies and intelligent machine design. The highly accessible machining area and workpiece spindle fitted at the bottom ensure short tooling times and maximum flexibility in the production of workpieces in small series.

    The VM 9 vertical turning center is designed for the manufacture of individual parts and small production runs with a wide variety of parts. The heavy-duty foundation of the machine is made of a MINERALIT® polymer concrete column. The particularly good damping properties of MINERALIT®, combined with the compound slide with the X- and Z-axes ensure excellent machining quality, high speed processes and short idle times. The main spindle provides the necessary power with a 83 kW rating and a torque of 990 Nm.

    Flexibility for turning

    Part of the large family of EMAG modular machines, the VM 9 is designed as a vertical turning center, combining a reliable design with an extensive range of equipment.  Designed to machine chucked components with a maximum diameter up to 450 mm, it features a tool turret which can be fitted with up to twelve tool positions, depending on the tool interface (BMT or VDI). The turret can, of course, be equipped with driven tools to carry out drilling or milling operations, for example. The integrated probe delivers absolute process reliability by ensuring continuous quality control of the workpieces. Thus, the VM 9 is thus extremely well equipped for a wide variety of production tasks, enabling it to produce a wide range of workpiece formats.

    Ergonomic maintenance and loading

    But the VM 9 does not just deliver excellent machining quality. The ergonomic design of the machines is perfect evidence of the decades of experience EMAG has with vertical turning machines. Both the machining area and all maintenance components are easy to access. “This is the really positive aspect of the VM 9 for our customers,” explains Peter Loetzner, CEO EMAG L.L.C. “It is a major advantage for customers who have to machine many different workpieces or various part families.”

    With the VM 9, EMAG offers a new machine system for chucked parts suited to the production of a wide variety of workpieces in many different manufacturing scenarios thanks to its flexibility. Whether components for trucks, construction and agricultural machines or for mechanical and plant engineering, the VM 9 is ideal for practically every sector. The excellent accessibility to the machining area makes the machines an all-round solution for turned parts.

    Technical features of the DM 9

    Chuck diameter

    450 mm

    Parts Weight, max.

    300 kg

    Swing diameter over base

    650 mm

    Turning diameter, max.

    450 mm

    X-axis/Z-axis travel

    330/500 mm

    Main spindle

    » Spindle flange to ISO 702-1: 2009

    » Spindle bearing

    Size 8

    140/160 mm

    Main drive unit

    » Synchronous motor (40% duty cycle)

    » Synchronous motor (100% duty cycle)

    » Full performance from spindle speed of 800 rpm

    » Torque (40% duty cycle)

    » Torque (100% duty cycle)

    » Speed 3,000 / 2,400 rpm, max.

    49 / 83 kW

    32 / 54 kW

    800 rpm

    585 / 990 Nm

    380 / 650 Nm

    3,000 / 2,400 rpm

    Feed drive

    » Rapid-traverse rate X / Z

    » Feed pressure X/Z

    30 / 30 m/min

    4 / 8 kN

    Disk-type turret

    » Turret interfaces  

    » Turret tool positions

    » Torque of driven tools, 40% / 100%

    » Speed of driven tools

    VDI 40 / BMT 65

    12 / 12

    24 / 15 Nm

    6,000 rpm

    Benefits of the VM 9 at a glance:

    • Dynamic axes for short idle times and fast machining processes
    • All the service units are easy to reach
    • Axis monitoring by rotary, indirect absolute encoders. All axes with fully encapsulated linear glass scale (optional).
    • Generously dimensioned main spindle, maintenance-free spindle motors and rigid guideways
    • Machine body made of MINERALIT®, 6 to 8 times better damping properties than gray cast iron
  • When EMAG launched the new TrackMotion automation system in 2015, it quickly became apparent that it not only focused on transporting parts, but on the perfect combination of machine tool, raw parts storage facility and a standard automation solution to create a highly efficient production line.

    The consistent adjustment of the automation to the modular machines from its internal production makes it possible to create manufacturing systems using a modular kit.

    So it will come as no surprise that EMAG is now unveiling another world first, a direct development of the modular machines in combination with the TrackMotion automation system the VL 3 DUO.

    When you first see the machine, you’ll immediately notice how compact it is. “We need just 13 m² (140 sq ft) to install the complete VL 3 DUO,” explains Peter Loetzner, CEO at EMAG L.L.C. “For a twin-spindle vertical pick-up turning machine, that is a fantastic size. Even if the machine is combined with a raw parts storage facility and the TrackMotion automation system, the dimensions for a complete manufacturing system for chucked parts up to 150 mm (2 in.)  is almost laughably small. That makes the VL 3 DUO one of the most compact and efficient systems available from EMAG,” says Peter Loetzner, glowing with pride.

    Gearbox Parts at a Glance

    With its parts ranging up to 150 mm (2 in.) in diameter, the VL 3 DUO is ideal for the manufacturing of gearbox components, for example, machining blanks for gear wheel production. “Gearbox components such as gear wheels must be manufactured in very large quantities. The standard production process is always the same: in OP 10 and OP 20, both sides of the gear wheel blank are machined by a turning process and the surfaces are prepared; the gear cutting process follows in OP 30 and deburring takes place in OP 40,” explains Peter. “The VL 3 DUO is, of course, primarily focused on the first process in this machining chain, in other words OP 10 and OP 20, which can be implemented perfectly with our system.” What the Product Manager is saying becomes apparent when we look at the VL 3 DUO in detail.

    TrackMotion Modern Part Management in the Manufacturing Process

    The VL 3 DUO can be fitted with EMAG’s TrackMotion automation system as an option. The automation system consists of three central parts, the track (i.e. the rails) on which the TransLift NC gripper runs and the raw parts storage facility. The entire system is very compact and runs directly behind the machining areas of the VL 3 DUO. The TrackMotion always focuses on the individual component. Each transport process only moves a single component which allows for significant benefits for component management. The increased mobility of the TransLift, including the Z-axis, means that stackable pallets can be used on the raw parts storage facility, making it possible for the raw and finished parts to be stacked with minimal space requirements. In addition, the TransLift is also used as a changer between the two machining operations. This means that the TrackMotion automation system provides everything required for compact manufacturing on the VL 3 DUO: an extensive parts storage area that accommodates up to 400 parts and a fast, flexible parts transport system between the various manufacturing stations.

    Modular Machine with Two Machining Areas

    Like every modular machine, the VL 3 DUO has its own parts buffer and a pick-up spindle in each machining area. The TrackMotion automation system loads the individual part pallets on the parts buffer as they shuttle between the loading position near the machining area and the rear section of the machine. From there, the working spindle takes the raw part, transports it into the relevant machining area and places the part back onto the appropriate pallet after it has been machined. Immediately next to it, the subsequent part is waiting to be picked up by the spindle, so that only a few seconds pass until the next part is being machined.

    The machining areas are arranged in a mirror constellation and each has its own working spindle which, with a rating of up to 18.1 kW and torque of up to 142 Nm, has plenty of power for high speed, precision machining.

    In addition, each machining area has a tool turret with twelve tool positions which can be fitted with turning tools or driven tools. “The turrets can also be fitted with an additional Y-axis to extend the range of uses of the machine even further,” explains Peter.

    Ideal Supplement to the Modular Series

    The VL 3 DUO adds a highly productive, compact manufacturing system for large-scale production to EMAG’s modular machine family.

    “Its real strength can be seen when it is connected to other machines in the modular machine family,” continues Peter. “Let’s look at the example of gear wheel production mentioned above. If we supplement the VL 3 DUO with the VL 4 H, the modular gear hobbing machine from EMAG, and a VLC 100 CC or VLC 100 RC, the vertical chamfering and deburring machines, we create a manufacturing system for gear wheels which is completely linked using the TrackMotion automation system, with a very small footprint. The whole thing is made possible by the standard structure of the modular machines, the integrated automation system and the fact that the transfer height between the machines is always identical – it’s simply brilliant! In other words, almost as simple as using building blocks,” says Peter Loetzner in conclusion.