[ E[M]CONOMY means: ] Outstanding Performances, again and again. HYPERTURN 665 High-performance turning/milling center with Y and B axes for complete machining of complex workpieces in one operation HYPERTURN 665 [ Upper tool turret ] - [ Main spindle ] 12-station tool turret VDI30 (VDI40) quick-change system 12 driven tool positions Servo-controlled Rigid tapping Polygonal turning, etc. - Integrated spindle motor (ISM) in synchronous technology – water-cooled - High drive power - High torque - Wide speed range - Highly dynamic - Bar capacity ø 65 mm (76,2) [ Control ] - Ergonomically placed 90° pivot Siemens Sinumerik 840D-sl LCD color monitor [ Lower tool turret ] - 12-station tool turret VDI30 (VDI40) quick-change system 12 driven tool stations Servo-controlled Rigid tapping Polygonal turning, etc. Machine with optional equipment The new HYPERTURN Series 3. A brilliant fusion of state-of-the art turning and milling technology – for highly productive, complete machining in a new dimension. The aim: to increase productivity when machining complex workpieces. The equipment: stateof-the-art, extremely dynamic, water-cooled spindle motors, with Y and B axes and the latest control and drive technology. [ Workpieces ] [ Y axis ] - Travel +/- 50 mm Stable, compact construction Wide guide clearances Tapered carriage system Sprocket-wheel (Steel Ck45) [ Counter spindle ] - Integrated spindle motor (ISM) in synchronous technology – water-cooled - High drive power - High torque - Wide speed range (max. 7000 rpm) [ Chip conveyor ] - Hinged type conveyor Ejection height 1200 mm Integrated coolant tank 300 l Turret pumps: 2 x 14 bar Flushing pumps: 2 x 3.7 bar Bonnet flange (Brass) Sensor housing (Stainless steel) [ Work area ] - Generous design Straight chip fall Optimum accessibility Guideways 100 % covered [ Finished part container ] - Easy access - Universal - Extendable with finished part conveyor as an option Knee (Steel 16Mn Cr 5)) I.D. roller burnishing Undercut Form E/F Tapping O.D. roller burnishing Face and O.D. turning I.D. deburring I.D. gear/slot shaping I.D. turning Drilling Reaming Milling slant slots Turn-milling of eccentrical diameter Knurling Hyper-Flexibility Machine flexibility is often sacrificed for the sake of productivity. Not with the HYPERTURN: with its high-performance and exceptionally mobile milling spindle and an almost inexhaustible tool magazine, the HYPERTURN can do nearly anything - and very quickly. Gear machining (gear hobbing) Thread milling Circular spitgot milling Slot milling Deep-hole drilling Wobble broaching HEXAGON I.D. threading I.D. boring I.D. undercutting I.D. grooving Engraving Contour milling (elliptical) Hole patterns centering, drilling, tapping Multifunctional workpiece [Engineering ] Highlights Q High dynamics due to state-of-the-art spindle motor technology Q All spindles liquid-cooled for optimum thermostability Q High productivity due to short tool change times Q Both tool turrets can be used on both spindles Q Hydropol bed design for maximum stability and oscillation damping Q Excellent repeatability due to linear guides Q Short set-up times due to ease of access to work area Pivoting control unit. The Sinumerik 840D SolutionLine control is on the left of the machine on the HYPERTURN Series 3 and pivotable. This enables ergonomic operation of the machine and shortens setup times. Most modern machining cycles supported with animated graphics, 3D simulation of the machining process and Ethernet connectivity simplify the programming and the daily operation of the machine. Part pick-up device. To ensure the gentle removal of finished parts, the HYPERTURN 665 is fitted with a part pick-up device as standard equipment. The finished parts are deposited in the standard parts holder or on an optional backup conveyor. NC tailstock. The HYPERTURN with this tailstock version is particularly suitable for machining shaft parts in large batches. The tailstock is completely NC controlled and can be positioned using a recirculating ball spindle. This also enables interpolation with other axes, saving machining time. The machine design. Finite element analysis has been used to optimize the machine components for static and dynamic rigidity. The core element here is the machine base made of HYDROPOL®, a composite material consisting of special concrete and steel which offers far-reaching advantages over conventional materials. The results are improved surface finish, closer manufacturing tolerances and longer tool life. Integrated spindle motor (ISM). The latest synchronous technology guarantees the highest dynamics and exceptional torque in a compact design. Liquid cooling in conjunction with automatic temperature control maintains a constant temperature for all spindle motors. High-precision Y axis. The HYPERTURN’s Y axis is designed to divide the cutting forces over two guide planes. The result is outstanding rigidity for all turning and milling operations. The +/– 50 mm travel permits off-center milling and drilling. HSK-Multi-tool HYPERTURN PowerMill. In this design, the upper turret is replaced by a 14.5 kW milling spindle and direct drive (hollow-shaft motor). The B axis travels 210°. And the tool carrier is a 24-station tool magazine with HSK-T63 or CAPTO C4 holders (48 tool stations optional). These features make this machine the perfect balance of turning and milling technology. Its great flexibility and high metal-cutting performance makes it especially suitable for complete machining of complex workpieces with high milling content. 24-tool station magazine. HSK-T63 or CAPTO C4 (48 tool stations optional) for tool management. Easy access for inspection and manual magazine loading. Integrated into the machine casing for excellent space-saving. CAPTO Multikopf HSK-Multi-tool. Triple slot toolholder for standard tools. Ensures shorter downtimes and more flexibility. CAPTO Multihead. A tool for roughing, finishing, threading, grooving and milling. Saves tool changing time frees up space in the tool magazine. HYPERTURN PowerMill with powerful milling spindle and 24-slot tool magazin within the basic version. A 12 station tool turret with up to 12 driven tools can be implemented below the spindle centre line. This allows to machine simultaneously on both main and counter spindles. EMCO HYPERTURN 665 versions HT 665 is the basic version with main and counter spindles, two tool turrets with or without driven tool stations HT665 with Y axis in upper slide system HT665 with Y and B axes as milling spindle (PowerMill) with tool magazine HT 665 with Y and B axes as milling spindle, without lower tool turret; for complete machining of small batch sizes 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 Automatic Return on Investment Even in the design stage of the HYPERTURN, the EMCO development engineers were already aware that a highly productive industrial machine such as the EMCO HYPERTURN would need high-performance automation periphery. Which is why the HYPERTURN gantry loader was immediately included in the HYPERTURN concept and design, which produced a particularly homogenous solution. Workpiece magazine Blank-specific pallet attachments enable oriented loading of blanks into the machine and increase the parts stock for unmanned production. Changeover times are reduced or eliminated thanks to the perfect adjustment to the customer‘s parts. 4-station pallet attachment for tees 6-station pallet attachment for articulated brackets 4-station pallet attachment for valve caps 20-station pallet magazine with customer-specific pallets Multi-pallet attachment for a family of parts Customizing options: The HYPERTURN gantry loader is a universal loading and unloading device for all models in the HYPERTURN Series. EMCO Automation can equip it to your individual needs with numerous gripper and handling systems. How we do it: we standardize the components and customize the solution. The goal: a custom-tailored machine for the same price as a standard unit. 2x3-jaw double gripper head 4x3-jaw gripper head Shaft gripper head Pivoting B axis The special feature of the HYPERTURN gantry loader is the integrated B axis as swivel unit. It enables blanks to be loaded into devices at an angle and simultaneous pivoting and positioning. This means not only almost unlimited flexibility in loading and unloading, it also dramatically reduces cycle times. Measuring system An integrated measuring unit allows serial production of high precision components with minimum man-power. Tool offset changes are done fully automatically. Each workpiece is loaded into the measuring system via the gantry loader and measured using the feeler. Good parts are pushed into the storage box and bad parts are separated into a special chute. Short and to the point In view of the ever-increasing pressure on floorspace for machines, EMCO has developed the most compact short loader on the market: the EMCO LM1200. Custom-made for the HYPERTURN – and the perfect solution for automatic feeding and loading of cut-to-length bars. EMCO TOP LOAD A bar-loader which automatically reloads 3-meter bar stock. The loader is exceptionally reliable and has a patented guidance system that allows you to switch to a different bar stock diameter in just a minute or two. If required, the loader can also be extended by adding several material storage strips and can therefore be operated automatically for even longer periods. Unloading through the counter spindle Long, thin workpieces can be removed from the machine using the counter spindle. Long parts can be stored in different ways. Finished parts can simply be allowed to roll away via a sloping surface or can be gathered to the side for storage using a timed belt. [ Options ] Individualize your HYPERTURN with our wide range of options. Amongst others, with a steady rest fitted to the lower turret to support long, thin workpieces. This can be swung in as required instead of metal-cutting tools. A live centre can also be included to support shaft parts in one turret position. Tool eye The tool measurement sensor mounted in the working area of the HYPERTURN makes it possible to measure tools in both the upper and lower turret within the machine Finished part conveyor The finished-part pick-up device places the parts on an accumulating conveyor. The conveyor is timed to prevent the parts, some of which are very complex, from falling on top of each other. EMCO tool monitoring system The tool status is monitored by evaluating the load on the various axis drive motors. Excessive loads point to tool wear or breakage. Too low a load indicates a tool is missing. Band filter system with high-pressure coolant pumps A coolant pressure of 25/40/60/80 bar can be set as needed. This enables coolant-fed drilling and milling tools to be used to their best advantage. Rotary window The ingenious rotating glass disc provides a perfect view into the work area of the machine. So the machining can be observed even when the coolant system is switched on. Power and torque diagram M (Nm) P (kW) 300 M (Nm) 30 P (S6-40 % D.C.) P (kW) 150 25 P (S6-40 % D.C.) 250 25 200 20 P (S1-100 % D.C.) P (S1-100 % D.C.) 200 20 150 15 100 10 15 100 10 50 M (S6-40 % D.C.) 50 150 M (S6-40 % D.C.) 5 M (S1-100 % D.C.) 5 M (S1-100 % D.C.) 0 0 0 1000 2000 3000 4000 5000 0 0 0 1000 2000 3000 HYPERTURN 665 main spindle HYPERTURN 665 counter spindle HYPERTURN 665 with bar loader LM1200 6524 (256.85”) 4789 (188.5”) 1503 (59.2”) 240 (9.4”) 4103 (161.5”) 2168 (85.4”) (18.3”) Lag – Bolt hole distances to secure the machine to the floor. 1200 (47.2”) 442 (17.4”) 1027 (40.4”) 2531 (99.6”) Lag – Bolt hole distances to secure the machine to the floor. 826 (32.5”) 915,5 (36”) 4170 (164.2”) 870 (34.25”) 595 (23.4”) 1045 (41.1”) 2264 (89.1”) 1588 (62.5”) 1080 (42.5”) 3376 (132.9”) 50 (2”) 5000 6000 7000 n (rpm) 6000 n (rpm) 465 4000 1705 (67.1”) Work area layout and turret clearance HYPERTURN 665 with Y axis Power and torque diagram M [Nm] M [Nm] P [kW] P [kW] 15 14 PS6 M (S6-25%D.C.) 25 13 6,7 12 6 11 PS1 20 10 5 9 40 8 MS6 15 4 7 30 6 3 10 5 20 4 MS1 2 0 0 2 P (S6-25%D.C.) 3 10 5 1 0 1000 2000 3000 3500 1 4000 5000 6000 S1=100% S6=40% (bei 1 min. ED) HYPERTURN 665 PowerMill milling spindle 7000 8000 0 0 9000 10000 0 -1] [rpm] nn[min 1000 2000 3000 4000 5000 n [rpm] Tool changer driven tools Work area layout and turret clearance HYPERTURN 665 with tailstock Work area layout and turret clearance 665 PowerMill [ Technical data] Work area Swing over bed Swing over slide Distance between spindle noses Max. turning diameter Max. part length Max. bar-stock diameter Travel Travel in X/X2 Travel in Z/Z2/Z3 Travel in Y Main spindle Speed range (infinitely variable) Maximum torque Spindle nose DIN 55026 Spindle diameter at front bearing Spindle bore (excluding draw pipe) Counter spindle Speed range (infinitely variable) Maximum torque Spindle nose DIN 55026 Spindle diameter at front bearing C axes Resolution Rapid traverse Drive power Main spindle (AC hollow-spindle motor) Counter spindle (AC hollow-spindle motor) Tool turret top and bottom Number of tool stations VDI shaft (DIN 69880) Tool cross-section for square tools Shank diameter for boring bars Turret indexing time Driven tools Speed range Max. torque Drive power Number of driven tools Tailstock Tailstock travel Tailstock thrust Inside taper for live centre Max. traveling speed B-PowerMill (with milling spindle) Travel range (with interpolation) Holding torque of indexing (5°)/positioning (0.001°) Number of tools Tool holder Maximum torque Drive power Speed range Tool changing time (tool to tool) Feed drives Rapid motion speed in X/Z/Y/Z3 (counter spindle) Feed force in X/Z/Z3 (counter spindle) Coolant system Tank capacity Pump power Power consumption Connected load Compressed air Dimensions Height of center above floor Total height Footprint (excluding chip conveyor) W x B Total weight Safety devices 600 mm (23.6“) 500 mm (19.7“) 975 mm (38.4“) 430 mm (16.6“) 744 mm (29.3“) 65 (76,2) mm (2.6“ (3“)) 280 / 205 mm (11 / 8.1“) 900 / 750 / 750 mm (35.4 / 29.5 / 29.5“) 100 (+/–50) mm (3.9 ( +/–2)“) 0 – 5000 (4000) rpm 250 Nm (184.3 ft/lbs) A2-6 (A2-8) 105 (130) mm (4.1“ (5.1“)) Ø 73 (86) mm (2.9“ (3.4“)) 0 – 7000 rpm 130 Nm (95.8 ft/lbs) A2-6 Ø 73 (86) mm (2.9“ (3.4“)) 0,001° 1000 rpm 29 kW (38.9 hp) 22 kW (29.5 hp) 2x12 30 (40) mm (1.2“ (1.6“)) 20 x 20 (25 x 25) mm (0.8 x 0.8“ (1 x 1“)) 32 mm (1.3“) 0,2 sec 0 – 5000 (4500) rpm 25 Nm (18.4 ft/lbs) 6,7 kW (9 hp) 2 x 12 750 mm (29.5”) 1000-10000N (224-2240 lb) MT4 15 m/min (590ipm) 210° 3600 / 1300 Nm (2 653/958 ft/lbs) 24 / 48 HSK-T63 (Capto C4) 40 Nm (29.5 ft/lbs) 14,5 kW (19.4 hp) 0 – 10000 rpm 1,3 sec 24 / 30 / 10 / 30 m/min (945 / 1 181 / 394 / 1 181 ipm) 5000/8000/9000 N (1 124/1 798/2 023 lbs) 300 l (79 gal) 2 x 2.2 kW (2.7 x 3 hp) 46 kVA 6 bar (87 PSI) 1200 mm (47.2“) 2300 mm (90.6“) 3400 x 2550 (133.9 x 100.4”) approx. 9500 kg (15 432 lb) to CE Quality components [Machine bases and slides] [Tool turret] 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. [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. 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. [Tool holder] www.emco-magdeburg.de www.emco-magdeburg.de www.sauter-feinmechanik.com www.wto.de [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 Innovative, fully developed tool holder systems form the basis for costeffective machining. High changeover accuracy and stability result in short setup and cycle times. [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. www.roehm.biz [Hydraulic systems] Compact dimensions, quiet operation, and high energy efficiency - just some of the advantages of the hydraulic assemblies used by EMCO. Monitored pressure switches prevent the need for time-consuming manual pressure 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]C 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 25 30 35 40 45 5 50 0 55 60 65 70 75 80 85 90 95 100% 5 10 0 15 5 20 25 30 35 5 40 45 5 50 0 55 60 65 70 75 80 85 5 90 09 95 100% 5 10 0 15 5 20 25 30 35 5 40 45 5 50 0 55 5 60 65 70 75 80 85 90 95 100% [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 25 30 35 40 45 5 50 0 55 60 65 70 75 80 85 90 95 100% 5 10 01 15 5 20 25 30 35 40 45 5 50 55 60 65 70 75 80 85 90 95 100% 5 10 0 15 5 20 25 30 35 5 40 45 5 50 0 55 60 65 70 75 80 85 90 0 95 51 100% [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 5 20 25 30 35 40 45 5 50 05 55 60 65 70 75 80 85 90 95 100% 85 5 5 10 0 15 5 20 25 30 35 40 45 5 50 55 60 65 70 75 80 85 85 9 90 95 100% 70 0 5 10 0 15 5 20 25 30 35 5 40 45 5 50 0 55 60 65 70 75 80 85 90 0 95 51 100% EN4350 . 08/12 . Subject to change due to technical progress. Errors and omissions excepted. 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]
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