][EMCO Automation

Turn-keySolutions from a Complete Service Provider

The EMCO swing loader.The integrated solution.

Tailor-made solutions. What would highly flexible universal lathes be without the features afforded by modern automation technology? EMCO has a range of bespoke solutions for unmanned or minimally staffed manufacturing. For pre-formed blanks and parts with a diameter larger than the spindle capacity, we offer an integrated swing loader for fully automatic loading. This has been conceived to work together with the machine as one harmonious unit and is characterized by uninterrupted operation and very short loading times. It is activated using the control unit.

Gear wheel (Hard machining/steel)

Ball stud(Steel)

Connector housing(Aluminum)

[Chain feeding system]

[Swing loader] [Finished parts conveyor]

The EMCO swing loader is a universal loading device for all types of preformed blanks. It can be highly customized in line with individual customer requirements. Numerous gripper and handling systems are available. How we do it: We standardize the components and customize the solution. This results in a custom-tailored machine for the same price as a standard unit.

Feeding systems for blanksFeed systems specific to particular blanks allow preformed workpieces to be loaded into the main spindle in the correct orien-tation, which enables economical unmanned operation.

Chain feeding system for oriented loading of blanks with a large storage capacity.

Multiple infeed chutes for rotationally-symmetrical blanks; the length of the blanks determines the number of infeed chutes.

Chain feeding system with V-supports for preformed shaft parts of various shapes

Multiple infeed chutes for loading rotationally sym-metrical blanks. A sensor monitors the availability of blank parts for each infeed chute.

Shaft gripper for automatically loading pre-formed shafts

Fully automatic shaft loading. Feed-in via a chain feeding system. Removal via the finished parts coll-ection device.

Customization:A wide range of gripper and handling systems are available.

2-finger gripper with 180° rotary module for loading vertically fed blanks

2-finger toggle lever gripper for loading shaft parts

Parallel grippers with 180° turning module for loading shaft parts (1st and 2nd clamping cycle)

Maximum output -minimum space.

[Chain feeding system] [Swing loader] [Finished parts conveyor]

The EMCO gantry loader.The universal solution. The perfect combination. Decades of experience, constant innovation and ongoing refinement have made the EMCO gantry loader one of the fastest and most flexible handling systems on the market. The machine and gantry are constructed by EMCO to match each other perfectly. This results in precise, rapid integration of all units and uninterrupted processes. Our gantry enables the automatic loading of both preformed flanged parts and shaft parts. Manufacturing time can also be reduced signi-ficantly through the use of additional features such as a measurement station, marking station, filtering tank, or even mounting assemblies – a sure-fire route to economical manufacturing, even in high-wage countries.

[Pallet magazine (20 station)]

[Gantry loader]

Water fitting(Brass)

Sprocket wheel adapter(Aluminum)

Sprocket wheel(Steel)

Profile: EMCO gantry loaders significantly reduce the time required for manufacturing processes and enable a large increase in efficiency. They are optimally aligned to the individual machine, resulting in an integrated, highly productive system.

Technical data

Traverse speed Workpiece dimensions for 4 x 3 jaw gripper

Horizontal 120 m/min Max. diameter 120 mm

Vertical 60 m/min Max. length 100 mm

Max. weight 5 kg

Workpiece dimensions for 2 x 3 jaw gripper Workpiece dimensions for 2 x 2 jaw gripper

Max. diameter 220 mm Max. diameter 100 mm

Max. length 100 mm Max. length 300 mm

Max. weight 10 kg Max. weight 10 kg

Gripper heads Pallet attachments

4-station pallet attachment for valve caps

2x3-jawdouble-gripper head

4x3 jaw gripper head Shaft gripper head

6-station pallet attachment for articulated brackets

20-station pallet magazine with customer-specific pallets

20-station pallet magazine with customer-specific pallets

The gantry loader offers maximum flexibility.Tailor-made solutions. EMCO has a range of bespoke solutions for unmanned or minimally staffed manufacturing. For preshaped blanks and parts with diameters larger than the spindle clearance, EMCO offers a high-performance loading gantry for fully automated loading and unloading. Designed as a compact unit, the machine and gantry loader guarantee uninterrupted operation and very short loading times. It is activated using the control unit. A short-bar loader and a 3-meter bar loader can be used to produce serial workpieces from bar stock.

Everything from a single source.

Drive shaft(Steel/C45)

The EMCO loading gantry solution provides maximum flexibility in terms of weight and machine size. It allows the integration of various automated systems such as a shaft conveyor, circulating magazine, robot, or measurement station. This enables various combinations of minimally staffed complete solutions to be implemented in line with customer requirements.

[Tool turret]- 12-position VDI 40- 12 tool adapters with coolant feed

(block tool)- Synchronized thread cutting and

polygonal turning as standard

[Control]- Ergonomically placed and pivotable- Multi-channel for machining and

parts handling- Siemens 840D-sl incl. ShopTurn- Color LCD monitor- USB interface- Ethernet connection

[Hydraulic unit]- Ergonomic operation- Automatic pressure monitoring- Compact and low-maintenance

[Blank conveyor / finished parts conveyor]- Shaft conveyor (shown)- Circulating magazine

[Gantry axes]- Robust mechanism- Safety brake- Central lubrication system- Optional: H-loader, machine connection

[Gantry]- Electric shaft gripper- Adjustable gripping force- Position monitoring via NC axis- No compressed air required

[Chip conveyor]- Slat band conveyor- Ejection height 1200 mm- 350-liter coolant volume - Included in the basic model

[Y axis]- Travel +80/-60 mm- 90° implemented in the machine

construction- Large distance between guide rails- Stable and compact construction

Gantry loader offers maximum flexibility:For Maxxturn 95 and 110, Hyperturn 110

Technical data:

Traverse speed

Horizontal 80 m/min Vertical 40 m/min

Application example: Maxxturn 95

Workpiece dimensions for flanged parts Workpiece dimensions for shaft parts

Max. diameter 250 mm Max. diameter 180 mm

Max. length 100 mm Max. length 800 mm

Max. weight 25 kg Max. weight 150 kg

■ Large number of individual applications■ For fully automated loading and unloading■ Complete solution for uninterrupted operation■ Short loading times

The benefits

The user saves costs and programming time involved with automation equipment thanks to the integrated pick-up system that loads the chuck with parts up to a diameter of 160 mm. Short cycle times and the ample parts storage guarantee short chip-to-chip times of up to 5.5 s for two-track loading. The various flexible feeding systems facilitate the integration into production lines: pallet, drag frame or chain conveyor belts.

Flexible and change-over friendly autoEMCO Vertical Turn machines.

■ Flexible automation: for both heavy and light parts, ample and low parts storage

■ Individual customer requests, such as pallets, drag frames, conveyor belts, and the integration of feed

systems can be implemented easily

■ Short travels allow short loading times

The benefits

Perfect Automation and integration are parts of the performance offered by the new vertical lathe VT 400 (for chuck parts with up to 400 mm clamping diameters). The automation concept enables customer-specific solutions. Since the pick-up system removes the need for additional loading systems for workpieces, machine linkage and technical adaptation are easily made to fit any customer’s individual needs.

omation solutions for

■ Quick loading through direct pick-up for high productivity

■ Simple automation solutions for maximum flexibility

■ Small footprint of machine and automation

■ Access to automation: easy to change over and maintain

The EMCO Compact Loads.Perfect teamwork. Low price. Strong performance. "Design to cost" was the primary aim when developing the EMCO E-series. These loaders intentionally do not include a dedicated control unit and are instead controlled directly by the machine control system. This results in an unbeatably low price for the entire package - including parts catchers, alarm lamp, and interface. Of course, we also provide tailored bar loader packages for our EMCOTURN E25, E45 and E65.

The technology. The loaders in our E-series can be used immediately as a "plug-and-play" solution. Their extremely small footprint enables processes to be automated even if space is tight. All loaders offer comprehensive cycle support and are perfectly aligned to the spindle lengths in the individual machines. Changing over to different bar diameters requires only minimum effort and the loaders can also be used to load individual workpieces.

The EMCOTURN E25 with EMCO COMPACT LOAD E25The most compact machine design for fully automatic processing of bar material up to ø 25 (51) mm.

The EMCOTURN E65 with EMCO COMPACT LOAD E65A clever "plug-and-play" solution with comprehensive cycle support

Technical data COMPACT LOAD E25 COMPACT LOAD E45/E65

Bar diameter Ø 25 (51) mm Ø 8 – 65 mm

Max. bar length 800 mm 1100 mm

Min. bar length 100 mm 150 mm

Material support approx. 550 mm approx. 550 mm

Feed rate 0 – 60 m/min 0 – 60 m/min

Bar change time approx. 10 sec. approx. 12 sec.

Dimensions (L x W) 1200 x 1100 mm 1700 x 1100 mm

Weight approx. 330 kg approx. 535 kg

■ Smaller footprint■ Easy to use■ Short feed times■ Fast, straightforward changeover■ Option to load individual workpieces■ Central diameter adjustment■ Ergonomic EMCO design

The benefits

25

The EMCO short bar loaders.Universal, high-performance. Short and to the point. Faced by ever-increasing pressure on floorspace for machines, EMCO has developed the most compact short loaders on the market: The EMCO LM800 and EMCO LM1200/1500 are the perfect solution for automatic feeding and loading of cut-to-length bars. The key advantages are a small footprint and rapid loading times resulting from shorter strokes.

The technology. The loaders in our LM series can be used immediately as a "plug-and-play" solution. Their extremely small footprint enables processes to be automated even if space is tight. In contrast to the EMCO COMPACT LOADs, the loaders in the LM series are fitted with their own control units, which also enables the loaders to be used together with other machines. The controls are perfectly coordinated with the machine interfaces, which are identical on all three models. All loaders offer comprehensive cycle support and are optimally aligned to the spindle lengths in the individual machines. Changing over to different bar diameters requires only minimum effort and the loaders can also be used to load individual workpieces.

EMCO LM800For use with MAXXTURN 25/45.

EMCO LM1200Compatible with the machines EMCOTURN E65-BB, MAXXTURN 65, HYPERTURN 45, HYPERTURN 65.

Infeed of profile bar stock using a chain feeding system (option)

■ Smaller footprint■ Easy to use■ Short feed times■ Fast, straightforward changeover■ Option to load individual workpieces■ Central diameter adjustment■ Dedicated control■ Ergonomic EMCO design

The benefits

Technical data LM800 LM1200 LM1500

Bar diameter Ø 6 – 52 mm Ø 8 – 65 mm Ø 16 – 95 mm

Max. bar length 800 mm 1200 mm 1500 mm

Min. bar length 100 mm 150 mm 150 mm

Material support approx. 550 mm approx. 550 mm approx. 550 mm

Feed rate 0 – 60 m/min 0 – 60 m/min 0 – 60 m/min

Bar change time approx. 10 sec. approx. 12 sec. approx. 14 sec.

Dimensions (L x W) 1200 x 1100 mm 1700 x 1100 mm 2000 x 1100 mm

Weight approx. 330 kg approx. 535 kg approx. 550 kg

EMCO TOP LOAD.The premium class. Quality by the meter. The EMCO TOP LOAD series was designed to automatically load 3-meter long bar stock into EMCO machines. Loaders are available for diameters of 4 - 25 mm, 8 - 42 mm, and 10 - 65 mm. The oil-coolant-fed loading channel, lined with plastic shells, reduces vibrations to a minimum, even at high speeds. Bar stock is fed in via a servo motor which controls both the speed and feed force. A patented guidance system with several guide rests guarantees optimum feed quality. Time-consuming conversions and channel changes are a thing of the past. The bar loader can be switched from one diameter to another within one or two minutes.

EMCO TOP LOAD 8-42/3200in the SINGLE LEVEL version. Pieces of bar stock are laid on a slanted feed track (350 mm) and fall into the guide channel one by one.

EMCO TOP LOAD 10-65/3300in the MULTI-LEVEL version. Multiple material supports enable even longer unmanned operation.

EMCO TOP LOAD 4-25/3300in the SINGLE LEVEL version. Pieces of bar stock are laid on a slanted feed track (350 mm) and fall into the guide channel one by one.

Standard guide rests (8-42 and 10-65)Integrated and automatic travelling guide rests center the bar stock at several points and enable to material to be fed through in the optimal manner. A patented system with great results: High rotational speeds, economical cutting data, and excellent productivity.

Standard guide rest (4-25)When machining smaller items of bar stock, the integrated guide rest ensures improved centering and reduces vibrations.

Accessories

Steel feed gripper for

ejection of oddments

to the rear.

Steel-Vulkollan feed grip-

per is milled according to

the bar diameter (1 item

provided in the basic

configuration)

Taper adapter for

forward ejection of

oddments (basic confi-

guration)

The feed grippers are placed in the loader to match the bar width. A quick-change system ensures that the system can be changed over quickly and without the need for tools.

■ Optimized length through use of a releasable feeder■ Programmable diameter adjustment on the control panel■ Servo-controlled feed motor (programmable)■ Oddments ejected to the front or rear■ Longitudinal sliding unit (approx. 800 mm)■ Quick-change systems result in lower changeover effort■ Extremely short setup time of just 1 to 2 minutes■ No changeover sets required thanks to the patented guidance system ■ Includes installation accessories

The benefits[Technology]

Technical data TOP LOAD 4-25/3300 TOP LOAD 8-42/3200 TOP LOAD 10-65/3300

Bar diameter Ø 4 – 25 mm Ø 8 – 42 mm Ø 10 – 65 mm

Max. bar length 3300 mm 3200 mm 3300 mm

Min. bar length 1500 mm 1500 mm 1500 mm

Material support approx. 350 mm approx. 200 mm approx. 350 mm

Feed rate 0 – 100 m/min 0 – 30 m/min 0 – 30 m/min

Bar change time approx. 30 sec. approx. 70 sec. approx. 75 sec.

Dimensions (L x W) 4390 x 867 mm 4310 x 790 mm 4410 x 1090 mm

Weight approx. 1100 kg approx. 1200 kg approx. 2200 kg

MAXXTURN 45 with unloading through the counter spindle Workpieces measuring up to 1,000 mm in length and up to a maximum of 32 mm in dia-meter may be unloaded through the counter spindle. Short parts measuring up to 120 mm in length are unloaded through the parts catcher. This system may also be installed on the HYPERTURN 45 (up to ø 45 mm).

MAXXTURN 65 with unloading through the counter spindle Workpieces measuring up to 1200 mm in length and up to a maximum of 54 mm in dia-meter may be unloaded through the counter spindle. Short parts measuring up to 175 mm in length are unloaded through the parts catcher. This system can also be installed on the HYPERTURN 665.

Unloading through the counter spindleThe length of the workpieces determines the distance between the centers on the lathe. The "unloading through the counter spindle" option enables long workpieces to be manufactured using compact machines with short dimensions. Machined parts, whether round or contoured, are transported onward easily through the counter spindle. Long parts are stored on a sloping surface or on a chain feeding system. This enables the extremely efficient manufacturing of typical shaft parts such as piston rods, cylinder tubes, drills, drive shafts, shock absorbers, and many more. On machines without counter spindles, long workpieces may also be unloaded using modified tailstock slides.

1955

1234

0

2141

1710

377

0

4493

1918

0

Machine layout MAXXTURN 45 and HYPERTURN 45 with unloading via the counter spindle

Details in millimeters

[Installation plans]

Machine layout MAXXTURN 45 with swing loader

Machine layout HYPERTURN 45 with swing loader

Details in millimeters

Pos. Zeichn.Nr. Z

S4Z30001

S4Y62002

S4Y60003

R2Y64104

A71193-5

A7074346

R7Z0307

2152768

9

10

A71013-11

A71260-12

A71260-13

A71260-14

A71260-15

A71260-16

A71260-17

A71260-18

A71260-19

A71260-20

A71261-21

F1Z200322

A71246-23

2322

2322

1817

165

4

3

3

1513

1513

1420

21

21

12

632

3179

4282

2991

2587

14800

929

32853203

22442385

1745

1541

0

1171

0

8

11

7

n120

937

4282

3382

2587

30180

1200

1653

18521958

2861

0

Machine layout HYPERTURN 65 - POWERMILL with gantry loader

Machine layout MAXXTURN 65 with gantry loader

Details in millimeters

[Installation plans]

620

970

3759

1252

1650

4633

4944

5539

6094

78930

983

37593572

29452945

21151874

1234

0

installation space for chip conveyor

1800

1085

3779

2524

2231

0

1197

1650

0

_

_Rohteil-Nr:

Masse:

Name

Für diese Zeichnung

Datum

Norm gepr.

Geprüft

Gezeichnet 19.11.2010hoellbam

_

_1:30

Blatt:

Werkstoff:

Zeichnungs Nr.:Teil-Benennung:

Maßstab

Änd.Nr.NameDatumÄ n d e r u n gNr.

Oberflächenschutz :

Untolerierte Maße nach DIN / ISO

79 Unterstrichene Maße nicht maßstäbl. gez.

FF

FFD0,40,8

3,212,5

schlichten

feinschlichten schleifen

roh schruppen

Prototyp

ZV: Datumsstempel / Unterschrift

2768mK / 6930 / 8570BF

[Installation plans]

Machine layout MAXXTURN 95 with gantry loader

Details in millimeters

3131

1288

8

8888

8060

7460

0

200

6070

2400

0

0

750

1135

21302400

2820

5545

Machine layout MAXXTURN 110 with gantry loader

3202

1614

0

1064

0

9850

9300

35020

664431

4590

3381

0

750

3200

6115

2780

2523

1260

0

[Installation plans]

1200

1583

163 1420

1103

1684

2950

1522

1025

45,3

715

1266

250

1812

1123

1130

1812

1323

Machine layout EMCOTURN E25 with EMCO COMPACT LOAD

1115 -

11

60

~1080

201

383,5

220

19

0

1198

545 327,5

157

349

Machine layout EMCO LM800

Maschinenachse

450

964

- 12

50

405515

1012

210

176105

645

2005

1040352

235

40500

453

546

- 83

2

594

418

1334

Machine layout EMCO LM1500

964

- 12

50

405515

1012

210

176105

645

285

40500

304

546

- 83

2

594

418

1334

1705

1040348

331

262

Maschinenachse

Machine layout EMCO LM1200

Details in millimeters

Machine layout EMCO COMPACT LOAD E45/E65

[Installation plans]

Machine layout EMCO TOP LOAD 4-25/3300

318.5 739 616 1767

4395

726 547

857

900-

1250

1300

-165

0

523 675.5

4410

510.57861652786

929

980-

1350

1420

-179

0

Machine layout EMCO TOP LOAD 10-65/3300

1420

-179

0

1156.5

980-

1350

523

Multi-Level

Details in millimeters

Machine layout EMCO TOP LOAD 8-42/3200

950-

1300

1340

-170

0354.5

987

Multi-Level

4386

486 3200 700

426 362

98

0-13

50

12

93-1

66322

7

540

EN

4570

. 08

/13

. Tec

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al m

odifi

catio

ns re

serv

ed. E

rror

s an

d om

issi

ons

exce

pted

.

www.emco-world.com

EMCO MAIER Ges.m.b.H. Salzburger Str. 80 . 5400 Hallein-Taxach . AustriaPhone +43 6245 891-0 . Fax +43 6245 86965 . info@emco.at