GHM edia
B usiness
|Article|
The optional measuring stations are installed between
the machining area and the pick-up stations. Measuring
is performed on the way to loading/unloading achieving
considerable time savings.
manufacturing of cam parts, flanges,
sleeves, and roller bearing rings at
every level.
(3 inches).”
due to its two pick-
up spindles and also
ensures dynamics as
well as repeatability
and
long-term
accuracy with its direct
distance
measuring
systems in the X-axis,
size 45 recirculating
roller
guide
rails,
and innovative linear
motor. It is the perfect
solution for turned
parts with diameters
of up to 75 millimeters
Minimizing Cycle Times
“Quantity and quality” are shaping
The possibilities made possible by
transmission manufacturing more
this approach become clear from a
than ever: Considering the increasing
simple description of the production
number of gears in transmissions, the
sequence: A simultaneous process
quantity of gears and other toothed
(OP10/OP10) is performed on two
components produced is undeniably
on the rise. At
Short cycle times as a result of
the same time,
simultaneous machining: Planetary Gear
the quality of the
Example: 12 second cycle times for a
total machining time of 24 seconds (two
components must
working spindles are used).
also increase in
order to achieve
the
power
density required
in
modern
t ra n s m i s s i o n s .
The performance
features expected
of transmissions,
such as a long
service life with
optimal dynamic
response,
also
still apply. Is it
at all possible
to
reconcile
growing quality
and productivity
requirements
with
generally
increasing pressure on costs? “That was
identical workpieces, quickly, within
precisely our goal,” says Björn Svatek,
the machine. Both components are
Sales & Marketing Director Modular
picked up from the conveyor belt by
Solutions at EMAG. “We have developed
the two pick-up spindles (9.9 kW/136
a low-cost machine, that enables high
Nm at 40% duty cycle), transported
output volumes with short lead times
to the machining area, and machined
13 | may-june 2019
Global
MDA
Journal
in a single clamping operation—the
diameter and length (X/Z directions) of
the two components can be adjusted
independently, since the movement of
the spindles is entirely autonomous.
The linear motor in the X-axis combined
with the direct distance measuring
system also increase the speed in
the simultaneous sequence. What
cycle times are possible with these
features? “It obviously depends on the
component and process,” says Björn
Svatek. “Generally, the average chip-to-
chip time is just under five seconds.
VL 1 TWIN Line
EMAG uses the productive twin
approach for advanced manufacturing
solutions. For example with the VL 1
TWIN Line:two VL 1 TWIN machines are
linked together using the TrackMotion
automation system. Machining is then
performed simultaneously on two sides
of two components
in OP10 and OP20.
This allows for cycle
times of less than
20 seconds to be
achieved for the entire
OP10/OP10 and OP20/
OP20 sequence—an
incredibly low figure,
ensuring significantly
lower unit costs for
the soft machining of
planetary gears. The
system is also equipped
with an extensive
parts storage area
for raw and finished
parts. The use of space
optimizedstacker
pallets allows for
a large number of
components to be
accommodated
in
a very small space.
Doing so, by stacking
the parts as the name already implies.
With the TrackMotion automation
system linking machines, EMAG is able
to deliver multi-technology production
lines. Let’s take gearwheels as an
example: After machining two sides
Global MDA Journal