More power to your elbow

17/09/2004

With a strong reputation for educational machines, Emco doesn’t always get the full recognition that it so rightly deserves for the full breadth and range of its industrial turning machines or its wide experience in automation systems.

Well established in the training and standard machine sector, the Salzburg-based machine tool manufacturer Emco demonstrated its new generation of Hyperturn lathes at last year’s EMO exhibition. For industrial purposes, the modular design provides a backbone for various system configurations and for a variety of applications for incorporation in existing or new production lines.

The Hyperturn product line up offers two basic types, the 645 and 665 model series (45 and 65mm bar diameters respectively), and the 690 for bar sizes up to 105mm or a swing diameter of 500mm. Each of these basic types is available in five different versions; the Hyperturn 645/665 series starts out as a four-axis machine with an upper and lower turret, the Quickmill version for small milling operations adds a Y-axis and a B-axis on the upper turret.

Next stage is the Power Mill design with a milling axis and an extra turret as an option. With reduction of idle times as a primary objective, the powered tools can be changed in less than 0.2 seconds.

The Hyperturn 690 is designed for heavy duty cutting processes. The basic type comes with a counter spindle with an upper turret and the enhanced version with a Y-axis on the upper turret. Power Mill versions are equipped with an upper milling spindle and available with optional, extra lower turret, counter spindle or tailstock.

The 690 is a powerful machine when it comes to the milling of turned parts. With a 54kW main spindle, power output and a maximum torque of 688Nm, the Hyperturn 690 can turn extremely difficult materials as required, for example, in the aerospace, medical or chemical plant industries. The FEM-optimised damping of the machine base - a polymer concrete filled steel fabrication - and machine components facilitate quiet operation and allow roller bearings to be used to achieve higher rapid traverse rates. A liquid-cooled, hollow shaft motor drives the 21.5kW milling spindle that can be tilted by 210 degrees (X, Y, Z and B-axis).

Delivered with a standard toolholding capacity for 30 tools, for complex workpieces and to offer a comprehensive range of machining options, the 690 can be upgraded to 48 or 80 toolholding positions so that even the most difficult workpieces can be machined in a single set-up. A probe from the magazine can measure the workpiece automatically by means of a variety of measuring cycles.

As both spindles can be used in both directions simultaneously, high machining speeds can be achieved and the use of long tools in the second direction copes with difficult machining passes. The 690 can be operated using both toolholders, with the milling spindle and the VDI toolholder, or as a multi-axis lathe, inserting a multiple turning toolholder in the milling spindle to eliminate lengthy milling toolchange times. Also, the bearings are relieved for the turning application of the cutter head with the clamped spindle.

The second workholder can be used to process the same workpiece, making it possible to rough and finish in a single operation. The diagonal base design optimises swarf disposal, while telescopic guideway covers and shielded rollers provide ample protection.

An important consideration when contemplating the purchase of any turning/milling machine is a practical and functional control system. Emco has entered into an agreement with CAD/CAM company DP Technology to jointly develop the Esprit programming system. In fact, Emco opted for the Esprit product from DP Technology as it provides complete support for Emco’s full line of products including the new Hyperturn Quickmill and Power Mill Series. Maximum customer benefits, through easy operation and system compatibility, were prime reasons for this co-operation. Also decisive for Esprit was the 100% Windows operation plus full dealer network coverage throughout Europe and Emco’s overseas export markets.

Production of Hyperturn began in earnest in June 2002 and by the year end 30 had been delivered, initially with machines going to the home markets of Austria and Germany. With machines on order for the UK Spain, Sweden and the Netherlands, Emco is starting to meet the requirements of the major European markets while looking to expand this important part of its business worldwide.

The Hyperturn business also represents a strategic move for Emco. With standard machines the market tends to think more about price and then the technology. However, each machine within the Hyperturn range is sold as part of an overall project with everything done by Emco, from the initial concept through to supplying the complete package including all the necessary automation aspects of the installation. What the customer expects to see is Emco’s technical solution for the application, including time studies and so on.

Meanwhile, Emco has seen some major changes at its main manufacturing site near Salzburg. Most prominent is a new assembly hall, currently dedicated to flow line production of the standard ranges of CNC lathes made by Emco. Machines are built, from the ground up, on rail mounted carriages that flow through the assembly hall, station by station, finishing at the despatch bay.

Emco likes to keep control over what it produces with all key components made in house, and that includes all sheet metal production for the cabinets, and it even has its own electric powder paint plant.

As far as the UK is concerned, HK Technologies is the initial contact, although HK does encourage direct communications between the customer and Emco specialist staff. So whether it is educational machines, CNC turning machines or the new Hyperturn ranges, HK Technologies has the necessary in depth technical know how to assist customers.

When it comes to a special project, such as that involving a Hyperturn machine, Nigel Bunt, managing director of HK Technologies, likes to consider the customer relationship as an equilateral triangle with the customer, Emco and HK each having an equal input in the partnership. More importantly, he is keen to get the message across that Emco has a far greater range of products than people might envisage - and Hyperturn is helping to refresh the image.