Commercial vehicle production: designed to reduce component costs

The commercial vehicle market is booming, for example, in emerging economies, in order to achieve the expected growth in construction and agricultural development, new technologies are urgently needed to produce large trucks or agricultural machinery. And as competition is heating up, as emerging manufacturers from China intensify the price war, production planners will face tremendous pressure to compete with the current background. Commercial vehicles produced in the future must be faster, more energy efficient and more flexible. EMAG's turning experts are very familiar with this situation. Their vertical inverted lathe VL 8 can process workpieces up to 400 mm in diameter, providing an efficient solution for the production of commercial vehicle components.

The production of large vehicles is actually the production of large components, which is the simplest description of the production of commercial vehicles. However, the manufacture of very large or heavy components (such as large trucks, heavy dozers or bus power systems) faces a number of problems. How to process a large part economically and accurately? Will the laborious loading and unloading of the workpiece lead to an infinite extension of the construction period? The EMA 8 machine manufacturer's vertical inverted lathe VL 8 gives the answer. They directly transform all the advantages of the VL series into a machine that specializes in large components: a wide range of turning and milling operations in a single closed-loop production process; integrated automation provides the required speed and vertical layout Eliminate the problem of chip removal and ensure the integrity of the production process. The effectiveness of this design is evident, with extremely short machine downtimes, quality components and ever-decreasing unit costs that benefit subcontractors and component suppliers. In the production of commercial vehicles, VL 8 is quickly becoming a real "cost killer."

The basic structure that has been tested repeatedly: the best price/performance ratio

The basic design of the VL 8 follows the successful design of the VL series. These machines feature a rugged mechanical construction, a powerful power shaft and simple, flexible operation. They also follow the new machining concept, combined with a variety of soft and hard processing technology to achieve the best cost performance. The VL series lathes guarantee the high efficiency of the following main components during processing:

·The machine base is the core structure of the machine. It is made of cast mineral material, which can ensure the shock absorption performance of the machine, prolong the life of the tool and improve the processing quality.

· There is a double slide on the front of the machine base to drive the powerful vertical spindle to perform linear motion of the X and Z axes.

• The spindle has a chuck diameter of 500 mm and can process workpieces up to 400 mm in diameter.

• The process uses a 60 kW spindle with a torque of up to 1220 Nm and a speed of 2850 rpm.

· The turret can accommodate 12 turning tools or 12 power drilling and milling tools.

• The workpiece is loaded into the diamond cabinet of the conveyor and positioned by the CNC axis.

The spindle grabs the part from the transverse conveyor and places it in the processing area. It is precisely because the distance from the processing to the loading and unloading position is short, the extremely short chip-to-chip time is guaranteed. The process is highly flexible and can be used with a wide range of tools. It is also possible to connect two machine tools and one workpiece turnover unit into a single flexible production unit – for example, the first and second sides of a part can be machined in one cycle. In addition, by integrating the Y-axis on the turret, it is possible to perform "eccentric" machining for more complex geometries.

Built-in precision

Other characteristics of the machine guarantee the accuracy of the machining process. For those bearings that are close to each other, high-precision detachable bearings are used in series, and support bearings with length compensation are used at the end of the spindle, which makes the construction very strong and provides important basic conditions for turning to the micron. . In addition, by integrating the inspection process into the production steps, the precision is once again guaranteed – the probe is mounted outside the machining area and is inspected while the workpiece is still being clamped. Any correction data will be sent to the CNC center and the process will be adjusted accordingly. This ensures that the machine has a constant high precision when it is running automatically. This lathe also makes it easy to produce additional parts for commercial vehicles. Since the operator is only 400 mm from the turret, all service components are within easy reach and tool change is very convenient.

As a lathe manufacturer, EMAG is convinced that its products are trustworthy and that tested parts are generally considered to be the standard in the manufacturing sector. Therefore, EMAG is fully assured that VL 8 will be available in a few weeks and is very cost effective. In short, VL 8 combines all the factors that can reduce component costs in commercial vehicle production: low investment costs, flexible production processes and robust mechanical construction.

About EMAG

The innovative processing technology of reverse thinking has created EMAG's industry leading position. In 1992, EMAG was uniquely crafted, and it was a great success for the first time to introduce a cleverly inverted inverted lathe. Since then, EMAG has continued to develop a new inverted multi-function production center. Today, EMAG has become a world-famous manufacturer of inverted machine tools.

Headquartered in Salah, Germany, EMAG Group has a long tradition and is experienced in machine tool manufacturing. Its process technology is comprehensive and perfect, and it can provide users with machine tools and production systems for processing disc parts, shaft parts and box parts. Whether it's a lathe, a grinding machine, a gear hobbing machine, a laser welding machine or a machining center – the EMAG Group offers the best production solution for almost any application.

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