In line with the purpose of replacing workpiece travel with process integration, the VLC series' existing 500, 630, 800, and 1200 machine tools have reduced the waiting time and transportation time of the workpieces between the single processes, and at the same time reduced the time and area for replacement. area. Because with this series of machine tools, the required number of machine tools is reduced, so that the area needed for the workpiece buffer and workpiece preparation is also reduced accordingly. Due to its high flexibility and process reliability, the VLC series is particularly suitable for machining large, medium, or small batches of workpieces.
Process integration:
Cars, drills, boring, milling, grinding and hobbing - all in one machine.
The VLC 1200 machine uses a sturdy turning platform. The self-loading work spindle is equipped with a directly driven synchronous motor (without drive spindle), high power (110 kW) and high torque (11 000 Nm). Due to the direct drive, it is possible to integrate on the machine platform a process that requires high control and synchronization performance (eg grinding or hobbing processes). By integrating the A-axis and the B-axis, the helical beveling and grinding bevel machining can be realized separately. In addition, this series of machines can achieve excellent surface finish and low machining errors (such as high precision of drill hole) through a directly driven spindle. This is a great advantage compared to drive spindles. Because of the use of transmission spindles, balancing elements are required to reduce vibration during transmission.
In order to maximize the flexibility of the VLC 1200 machine tool, EMAG offers users a tool magazine with 160 tools. The tool holder in the machine tool is integrated in the B axis as a single position system.
A milling spindle is installed in the opposed tool holder, so a Y-axis can be expanded to fit a number of different tools if needed.
“With a traditional 6-position or 8-position turret, large workpieces are often subject to interference because the workpiece and adjacent tools often interfere.
EMAG can configure an automatic lathe tool holder, a milling spindle and a tool changer as required. Drills, grinding wheels, milling cutters and turning tools removed from the magazine can be directly exchanged into different tool holders. According to Stefan Anders, project manager of the VLC 1200 model, another advantage of the machine is that the main machining and tool change are performed simultaneously.
When the workpiece is still machined in the machine, the operator can change the tool for machining the next workpiece into the magazine.
The maximum weight of a single tool that can be stored in the magazine is 60 kg. Heavy tools can be placed directly into the magazine by means of a tool changer.
Reduced takt time by 80%
When processing large workpieces, the entire cycle time from start to finish plays an important role.
“When processing large workpieces, the cost of purchasing a blank part costs several thousands of euros, so the entire processing time is 170 hours or 35 hours. The use of VLC 1200 machine tools and the integration of different processing technologies can be used for this type of work. The total cycle time of large parts is reduced by 80%, so the investment return cycle is very short.†Mr. Stefan Anders is proud to introduce the advantages of process integration. The total cycle time of the workpiece is greatly shortened compared to traditional production equipment. For those workpieces that originally required multiple machine tools, the intermediate idle time was greatly reduced. “When machining the drive elements of a track-type tractor on a VLC 1200 machine, the idle time of the workpiece is reduced by 80% compared to conventional machine tooling,†explained Stefan Anders.
Another advantage of combining machining on a machine tool is that it can reduce the warehouse area. A 1 meter diameter workpiece requires a European standard bracket for storage. When machining these kinds of workpieces with different machine tools, the semi-finished parts of each machine tool have to be temporarily stored, so each machine tool must occupy a pallet storage location. Occasionally, temporary storage of workpieces is often two to three times the area of ​​all machine tools installed. This is a cost factor that is often overlooked! This is not the case when using the VLC 1200 machine tool because many workpieces can be assembled and assembled in a single setup. In addition, this processing method greatly simplifies the logistics of materials. In traditional machining methods, workpieces are transported from one machine to the next, and then clamped. When using the VLC 1200 machine tool, only one set-up process is required to complete the combination. This, of course, has also had a beneficial effect on the time to change. When machining with VLC machine tools, it is not necessary to reload 3 or 4 machine tools, but only one machine tool. "The smaller the batch size, the greater the effect of the replacement time. When there are only 10 workpieces in a batch, it is a matter of changing the three or three machines, or just changing one machine. †explains Stefan Anders.
A hoist is a device used for lifting or lowering a load by means of a drum or lift-wheel around which rope or chain wraps. It may be manually operated, electrically or pneumatically driven and may use chain, fiber or wire rope as its lifting medium.
The basic hoist has two important characteristics to define it: Lifting medium and power type. The lifting medium is either wire rope, wrapped around a drum, or load-chain, raised by a pulley with a special profile to engage the chain. The power can be provided by different means. Common means are hydraulics, electrical and air driven motors. Both the wire rope hoist and chain hoist have been in common use since the 1800s, however mass production of an electric hoist did not start until the early 1900s and was first adapted by Germany. A hoist can be built as one integral-package unit, designed for cost-effective purchasing and moderate use, or it can be built as a built-up custom unit, designed for durability and performance. The built-up hoist will be much more expensive, but will also be easier to repair and more durable. Package units were once regarded as being designed for light to moderate usage, but since the 60s this has changed. Built-up units are designed for heavy to severe service, but over the years that market has decreased in size since the advent of the more durable packaged hoist. A machine shop or fabricating shop will use an integral-package hoist, while a Steel Mill or NASA would use a built-up unit to meet durability, performance, and repairability requirements. NASA has also seen a change in the use of package hoists. The NASA Astronaut training pool, for example, utilizes cranes with packaged hoists.
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Eurocrane (China) Co., Ltd. , https://www.craneparts.pl