1. travel

[
That’s
E[M]CONOMY:
]
X Large - for all demands.
EMCO MAXXTURN 110
Universal CNC turning center for machining
shafts and chuck parts
EMCO MAXXTURN 110
[ Control ]
[ Work area ]
[ Y axis ]
- Ergonomically designed
- Plenty of open space
- Travel -80 / +100 mm (– 3.1 / +9.4")
- Siemens or Fanuc
- Optimal chip flow
- 90° implemented in the
- LCD color monitor, including
- Easily accessible
machine construction
- Large distance between guides
ShopTurn or ManualGuide i
- Stable and compact construction,
- Optionally available with Teleservice,
without restrictions
Ethernet connection and PC keyboard
- Control panel pivot and slides
horizontally
[ Hydraulic unit ]
- Ergonomic operation
- Automatic adjustment of
the pressure switch
- Low noise generation
[Steady rest system ]
[ Machine bed ]
- Widely spaced guide ways
- Large dimensioned Roller-type guide ways
- Highest solidity
- Tag along steady rest in various sizes
- Optional: NC steady rest or tandem steady rest
- Manual pressure setting
- Optional: Programmable pressure setting
- Maximum pre-load guarantees rigidity in
several cutting load directions
Machine with optional equipment
The EMCO MAXXTURN 110 takes care of the most demanding turning and milling operations just as perfectly as the machining of
precision parts with the highest-quality surfaces. We make sure of this with a high-precision C axis and a very stiff Y axis with large
travel. On top of this come the very high rapid-motion speeds and the optimum performance. Your choice of Fanuc or Siemens
control unit. The EMCO MAXXTURN 110: Quite a piece of work.
[ Workpiece]
[ Chip conveyor ]
- Slat band conveyor with ejection height
of 1150 mm (45.3")
- Suitable for: Long steel chips, swarf balls,
wooly swarf, dry and wet machining
- With integrated coolant apparatus
- Easy to remove, easy to clean
- Optional: High-pressure pumps
[ Tailstock ]
[ Machine cover ]
- Tag-along tailstock
- All-round protection against chips
- Optional: NC tailstock
- 100% coolant retention
- Integrated bearings for MT5 centering tip
- Large safety glass window in door
- Quill diameter ø 150 mm (5.9")
- Clear view into the work area
- Quill travel 150 mm (5.9")
- Incl. position and pressure monitoring
Crankshaft
(Tempered steel)
[Engineering ]
Tool turret. Axial tool turret VDI 50 with additional tool
holders on the perimeter (block tool). Speed, stability
and flexibility – all characteristics which come as standards in our tool turrets.
Y axis. The machine base at a 90° offset with widely positioned, preloaded guide rails ensure short
projections and therefore the greatest stability for
complete machining.
■ Glass scales in X/Y/Z axes
■ Automatic tool measuring
■ Programming and simulation system
ESPRIT CAM
Main spindle. There are two spindle versions available.
An integrated motor spindle drive with A2-8 spindle nose
for mainly shaft machining and a belt-driven spindle with
very high torque for flange type part machining - spindle
nose A2-11.
Large work area. Supporting long shafts with tailstock and two CNC controlled steady-rests.
■ Programmable clamping pressure
■ EMCO tool breakage and
■ Automatic door system
■ High pressure coolant system
■ Extremely robust construction
■ Top machining precision
■ High rapid motion speeds
■ Stable Y-axis with large travel (–80 / +100 mm (–3.1 / +3.9"))
■ Optional: NC steady rest or tailstock
■ Hydraulic spindle break
■ State-of-the-art control technology from Siemens or Fanuc
■ Driven tools, with C axis
■ Simple, dialogue-supported programming
■ Made in the Heart of Europe
Tailstock. Integrated, large bedding for holding MT5
centering tips (optional MT6). The positioning occurs
via the Z-slides as standard and optionally as a controlled NC axis.
Options
wear monitoring
Highlights
Area of application
■
■
■
■
■
■
■
Hydraulic/pneumatic components
Motors and vehicle parts
Machine components
Medical engineering
Friction and roller bearing parts
Materials handling equipment
Fixing systems and much, much more
Uncompromising quality
for top precision.
The modular machine structure. The heart of the machine is the 60° slanted machine base made of top-quality
HYDROPOL®, a composite material consisting of special concrete and steel that provides numerous advantages
over conventional materials. Compact monoblock construction for extreme stiffness and a stable base for the rest of
the machine. The results are outstanding surface qualities, more narrow production tolerances and longer machine
lifetimes. This means that the high drive performance of the work spindle can be used without restriction.
Main spindle A2-11
- Belt drive with two-speed transmission
- Maximum drive power: 42 kW (56.3 hp)
- Maximum torque: 2,000 Nm (1474 ft/lbs)
- Maximum speed: 2500 rpm.
- Partial hollow clamping:
ø 110 x 1000 mm (4.3 x 39.37”)
Tool slide without
Y axis
Tool slide with Y axis
(–80/+100) integrated as an
extremely rigid element into the
machine structure
Retractable
C axis including
hydraulic spindle brake
Main spindle A2-8
- Water-cooled spindle motor (ISM)
- Maximum drive power:
33 kW (44.2 hp)
- Maximum torque:
800 Nm (589.6 ft/lbs)
- Maximum speed: 3500 rpm.
- Bar capacity: ø 95 mm (3.7”)
A large distance between
the guideways ensures
greatest stability
Linear
roller guides
on all axes
Ball screws in all axes
enable high drive forces
Machine base in monoblock construction
for the MAXXTURN 110 x 1500 / 2500 /
3500
Tag along steady rest,
NC drive optional
Versions EMCO MAXXTURN 110
MT 110 with tailstock
MT 110 M with driven tools
MT 110 MY with driven tools and Y axis
Large tailstock with quill
and integrated bearings for
stable shaft machining
Everything from a single source.
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.
[ Control ]
- Ergonomically placed and pivotable
- Multi-channel for machining and
[ Gantry axes ]
parts handling
- Siemens 840D-sl incl. ShopTurn
- Robust mechanism
- Color LCD monitor
- Safety brake
- USB interface
- Central lubrication system
- Ethernet connection
- Optional: H-loader, machine connection
[ Blank conveyor / finished parts conveyor]
- Shaft conveyor (shown)
- Circulating magazine
[ Gantry ]
[ Hydraulic unit ]
- Electric shaft gripper
- Ergonomic operation
- Adjustable gripping force
- Automatic pressure monitoring
- Position monitoring via NC axis
- Compact and low-maintenance
- No compressed air required
Gantry loader offers
maximum flexibility:
For Maxxturn 95/110 and Hyperturn 95/110
The benefits
■
■
■
■
Large number of individual applications
For fully automated loading and unloading
Complete solution for uninterrupted operation
Short loading times
[ Chip conveyor ]
- Slat band conveyor
- Ejection height 1200 mm
- 350-liter coolant volume
- Included in the basic model
[ STABLE MACHINE CONSTRUCTION = PRODUCTIVITY ]
Material: 16 Mn Cr 5
Unit
1st case
2nd case
Turning diameter
mm
434
294
Cutting speed
m/min
170
170
Spindle speed
rpm
125
184
Cutting depth
mm
7.0
10.5
Feed
mm/r
0.5
0.6
Specific cutting force acc. to table
N/mm2
2300
2300
Cutting thickness
mm
0.5
0.5
Main cutting force
N
6930
10400
Efficiency
Factor
0.95
0.95
Power requirement
kW
24
36
Torque
Nm
1750
2130
Material removal rate
cm3/min
587
860
Gear milling
Gears can be produced with the gear hobbing method. Therefore the milling spindle needs
to be precisely synchronized with the main spindle. To increase the tool life, the gear hobbing cutter can be shifted.
Customized solution
Available with tandem steady rest, custom painting, 16-station tool turret VDI40, workpiece
measurement and automatic door system..
Tool measuring arm
The tool measuring arm installed in the MAXXTURN 110’s work area enables precise repetition
of tool measurements within the machine. User-friendly input masks support the user and
enable short set-up times.
Performance and torque diagram
Nm
kW
50
max. 2000
45
40
1750
max. 42
35
1500
30
1250
25
1000
20
750
15
500
10
250
5
0
0
0
200
400
600
800
1000
1500
2000
2500
min-1
M-41
M-42
Main spindle A2-11
Nm
kW
35
900
max.33
max. 800
30
700
25
600
20
500
400
15
300
10
200
5
100
0
0
0
400
10 0 0
2000
3000
ma x.3 5 0 0
min-1
Main spindle A2-8
Nm
kW
120
12
11
100
10
9
80
8
70
7
60
6
5
4
40
3
20
2
0
0
1
0
400 800 1200 1600 2000 2400 2800 3200 3600 4000
min-1
Driven tools
Indications in millimeters
The Esprit CAM system offers high flexibility and process security, a comprehensive selection of machining cycles, maximum tool control, and cross-machine technology for your
entire production facility.
[CAD]
Direct CAD data import
- AutoCAD (DWG)
- Parasolid®
- Solid Edge ®
- Solid Works ®
- ACIS® (SAT)
- Optional interfaces: CATIA®,
Pro/ENGINEER®, STEP, STL,...
[CAD]
[CAM]
-
2-22 axis turning
2-5 axis milling
Multi-tasking of turning and milling
3D machine space simulation
Certified post-processors
The Virtual Machine
A 1:1 mapping of the real machine for defining and testing processes, optimizing machining
sequences, and training new operators.
[Process chain]
[CPS]
-
1:1 simulation with collision detection
Direct connection to CAM ESPRIT
Process optimization
Reverse simulation of existing NC codes
Reduction in scrap rates
Training on the virtual machine
Simulation of loading systems
(e.g. EMCO gantry loader)
[CAM] [CPS] [Production]
[Production]
- Reduction in set-up costs
- Reduction in downtimes
- Reduction in repair costs
OPTIMUM MACHINE UTILIZATION
[ Installation plans]
Machine layout MAXXTURN 110 with gantry loader
3
2
2
0
431
664
3381
16140
10640
9850
9300
3202
3502
0
4590
0
6115
3200
2780
2523
1260
750
0
Details in millimeters
ø315 BH–D
Work area ASA 8" / ASA 11"
136
30
95
(3.7
“)
ASA 8"
32(1.3“)
45
(1.8“) 95
(3.7“)
0
Ø 42 )
“
(16.5
-80
(-3.1“)
SW 520
+100
(+3.9“)
10
Ø 3 .2“)
(12
32x32
35
VDI 50
Ø 50 (2
“)
55
Ø2
“)
(10
Ø 550 (21.7“) SWING OVER CROSS SLIDE
Ø 610 (24“) MAX. SWING DIAMETER
Ø 840 (33.1“) MAX. SWING OVER BASE
MAX. 610 (24“) - MIN. 200 (7.9“)
TRAVEL = 410 (16.1“)
Machine layout
B.L ASA–11
1500
2500
3500
A
6680
7680
9140
B
4780
5780
7200
C
560
600
B.L ASA–8
1500
2500
3500
A
6120
7120
9140
B
4780
5780
7200
C
560
600
Details in millimeters
Quality components
[Machine bases and slides]
When matching components, we
place great value on high stability,
good damping characteristics, and a
thermoneutral design. We achieve high
stability through a shorter force flow,
thermal stability through symmetry,
and dampening through the materials
and interfaces selected.
www.emco-magdeburg.de
[Tool turret]
[Clamping cylinder / chuck]
Hydraulically activated clamping
cylinders and chucks guarantee the
precise, safe clamping of work pieces.
Programmable sensors are used for
stroke monitoring. There is no need
for time-consuming adjustments of
contactless limit switches.
[Tool holder]
Innovative, fully developed tool holder systems form the basis for costeffective machining. High changeover
accuracy and stability result in short
setup and cycle times.
Rapid-indexing turrets with adjustable
swivel speeds and milling drives represent the current state of the art. The
backlash-free milling drive is not only
ideal for milling and drilling, but also for
rigid tapping, hobbing, and polygonal
turning.
www.roehm.biz
www.wto.de
www.sauter-feinmechanik.com
[Chip conveyor]
[Coolant pumps]
Slat band conveyors allow for flexible
implementation and the safe removal
of chips. A monitored overload clutch
prevents damage from improper use.
Low-maintenance immersion pumps
for pressures of up to 25 bar and flow
rates of up to 1500 l/min provide optimum conditions for machining and
enable reliable chip transportation.
www.knollmb.de
www.grundfos.at
[Headstocks]
The design and manufacture of
headstocks are two of EMCO‘s core
competencies. During engineering,
the focus is on precision, robustness,
high rigidity, precise rotational characteristics, and a long service life.
www.emco-magdeburg.de
[Hydraulic systems]
Compact dimensions, quiet operation,
ation,
and high energy efficiency - just some
of the advantages of the hydraulic
raulic
assemblies used by EMCO. Monitored
tored
pressure switches prevent the need
for time-consuming manual pressure
ssure
adjustments.
[Ball screws and roller guides]
Highly precise and generously dimensioned guide rails and ball screws with
optimal pretensioning form the basis
for the machining of precision parts.
www.hawe.de
www.boschrexroth.com
Minimum use of resources
for maximum profit.
E[M]CO
COLOGY
OLOG
Designed for Efficiency
At EMCO, we take a consistent, responsible approach to the use of resources in machine tools in order
to safeguard long-term investments. From the development of our machines through to their construction
and manufacture, we place a strong focus on the sensible and sparing use of raw materials and energy.
This enables us to achieve parallel savings in two areas:
1. Reduction in the basic power consumption of machine tools, e.g.
assemblies are switched on and off as required and the installed
connected loads are kept to a minimum.
2. Reduction in variable consumption: This can be seen in the lighter axes,
energy recovery system, increased rate of good parts, and the shorter process chain enabled by complete
machining.
Through these measures, which are constantly being refined and further optimized, EMCO truly demonstrates that its slogan of „Designed for your Profit“ is not just an empty promise: EMCO products help save
the environment and provide intelligent customer savings without compromising on quality and flexibility.
[Regenerative drive system]
[Compact hydraulics unit with pressure accumulator]
[Roller guides]
Kinetic energy is converted into electrical energy and
fed back into the grid.
Savings of up to 10%
Thanks to its accumulator charging system, the pump
only runs when required. If the pressure accumulator is
full, the pump switches over to closed loop circulation.
Savings of up to 90%
Extremely low friction losses thanks to rolling friction.
Highly dynamic performance with minimal lubricant
consumption.
Savings of up to 50%
10
0
90
0
50
0
5 10
0 15 20
0 25 30 35 40 45 50 55 60
0 65 70 75
5 80 85 90 95
5 10
00%
%
5 10
0 15 20
0 25 30 35 40 45 50 55 60
0 65 70 75
5 80 85
5 90
09
95
5 10
00%
%
5 10
0 15 20
0 25 30 35 40 45
5 50
0 55
5 60
0 65 70 75
5 80 85 90 95
5 10
00%
%
[Structurally optimized mechanics]
[Highly efficient motors]
[Synchronized chip conveyor]
FEM analysis is used to optimize the relevant components in terms of their rigidity while simultaneously
reducing their weight.
Savings of up to 10%
The use of energy-efficient motors (IE2) in the coolant
preparation area guarantee highly cost-effective
operation.
Savings of up to 10%
Programmable interval times enable optimal use of
the chip conveyor independently of of the machining
process.
Savings of up to 95%
10
0
10
0
95
5
5 10
0 15 20
0 25 30 35 40 45 50 55 60
0 65 70 75
5 80 85 90 95
5 100%
%
5 10
0 15 20
0 25 30 35 40 45 50 55 60
0 65 70 75
5 80 85 90 95
5 10
00%
%
5 10
0 15 20
0 25 30 35 40 45 50 55 60
0 65 70 75
5 80 85 90
0 95
5 100%
%
[Intelligent standby concepts]
[Virtual machine]
[Intelligent energy management]
Reduced consumption by automatically switching off
ancillary units and machine space/screen illumination
after a defined period of inactivity on the control panel.
Savings of up to 50%
Significant reduction in the setup and running-in times
on the machine through the use of highly developed
simulation and programming software.
Savings of up to 85%
Intuitive data entry screens for activating the individual
energy-saving functions.
Savings of up to 70%
50
0
5 10
0 15 20
0 25 30 35 40 45
5 50
05
55 60
0 65 70 75
5 80 85 90 95
5 10
00%
%
85
5
5 10
0 15 20
0 25 30 35 40 45 50 55 60
0 65 70 75
5 80
0 85
85 9
90 95
5 10
00%
%
70
0
5 10
0 15 20
0 25 30 35 40 45 50 55 60
0 65 70 75
5 80 85 90
0 95
5 100%
%
[ Technical data]
EMCO MAXXTURN 110
Max. turning diameter
Max. part length
Maximum chuck diameter
Travel
Travel in X
Travel in Z
Travel in Y
Main spindle with spindle nose A2-8
Speed range
Maximum power
Maximum torque
Spindle nose DIN 55026
Spindle bore
Spindle diameter at front bearing
C axis for spindle A2-8
Resolution
Main spindle with spindle nose A2-11
Speed range
Maximum power
Maximum torque
Spindle nose DIN 55026
Spindle bore
Spindle diameter at front bearing
Maximum chuck diameter
C axis for spindle A2-11
(indexing/gear-driven servo drive)
Maximum torque
Resolution
Tool turret
Number of tool stations (all driven)
VDI shaft DIN 69880
Tool cross-section for square tools
Shank diameter for boring bars
820 mm (33.1")
550 mm (21.7")
1660 / 2660 / 3660 mm
(65.4 / 104.7 / 144.1")
610 mm (24.0")
1500 / 2500 / 3500 mm
(59.1 / 98.4 / 137.8")
315 mm (12.4")
410 mm (16.1")
1560 / 2560 / 3560 mm
(61.4 / 100.7 / 140.2")
–80 / +100 mm (– 3.1 / +9.4")
0 – 3500 rpm
33 kW (44.2 hp)
800 Nm (589.6 ft/lbs)
A2-8
106 mm (4.2")
160 mm (6.3")
0.001°
0 – 2500 rpm
42 kW (56.3 hp)
2.000 Nm (1474 ft/lbs)
A2-11
125 mm (4.9")
190 mm (7.5")
400 (500) mm (15.7 (19.7)")
2000 Nm (1474 ft/lbs)
0.001°
12
50 mm (2.0")
32 x 32 mm (1.3 x 1.3")
50 mm (2.0”)
Tool turret
Additional tools (block tool)
Speed range
Max. power
Max. torque
Feed drives
Rapid motion speed in X / Z / Y
12
0 – 4000 rpm
max. 10 kW (13.4 hp)
max. 70 Nm (51.6 ft/lbs)
24 / 30 / 12 m/min
(944.9 / 1181.1 / 472.4 ipm)
17000 N (3821.6 lbs)
20000 N (4496 lbs)
17000 N (3821.6 lbs)
Feed force in X axis
Feed force in Z axis
Feed force in Y axis
Tailstock with quill
Quill travel
Quill diameter
Maximum application force
Internal taper of quill
Coolant system
Tank capacity BL 1/2/3
150 mm (5.9")
150 mm (5.9")
22200 N (4990.6 lbs)
MT 5
Pump power 7 bar (option 14 bar)
Power consumption
Connected load (spindle A2-8 / A2-11)
Dimensions
Height of centers above floor
Total height
Dimensions W x D
(without chip conveyor)
Total weight BL 1/2/3
450 / 520 / 650 liters
(119 / 137.4 / 171.7 gal)
1.15 (2.2) kW (1.8 (3.0) hp)
46 / 70 kVA
1260 mm (49.6")
2530 mm (99.6")
5550 / 6650 / 7850 x 2470 mm
(218.5 / 261.8 / 309.1 x 97.2")
approx. 14 / 16 / 18 t
(30684.7 / 35273.9 / 39683.2 lb)
GANTRY LOADER
Technical data:
Traverse speed Horizontal
Traverse speed Vertical
Application example: Maxxturn 110
Workpiece dimensions for
Max. diameter
Max. length
Max. weight
80 m/min (3150 ipm)
40 m/min (1575 ipm)
flanged / shaft parts
250 / 180 mm (9.8 / 7.1")
300 / 2000 mm (11.8 / 78.7")
35 / 350 kg (77.2 / 771.6 lb)
www.emco-world.com
EMCO MAIER Ges.m.b.H.
Salzburger Str. 80 . 5400 Hallein-Taxach . Austria
Phone +43 6245 891-0 . Fax +43 6245 86965 . [email protected]
EN4332 . 01/13 . Subject to change due to technical progress. Errors and omissions excepted.
Work area
Swing over bed
Swing over cross slide (at Y = 0)
Distance between spindle noses