Diversification and safeguard of know-how and jobs
Regarding the reasons for the purchase of EMCO, CEO Günter Kuhn says: "EMCO is really the jewel of the ATEC Group and we are pleased that we were able to take it over and to continue its success and its history as a family company. EMCO is a division which we have searched carefully and deliberately chosen. It will be our third strong pillar and a diversification into a very promising market. We are a family owned company and not an investor. We want to safeguard jobs and know-how in Hallein“.

Günter Kuhn started the company in 1973 in Salzburg and grew it into one of the biggest construction equipment dealer in Europe. Today the Kuhn Group has 14 subsidiaries across 10 European countries and is one of the biggest dealer in Europe for the world renowned brand of Komatsu. In Austria Kuhn sells and servics Palfinger cranes.
EMCO will become the 3rd business unit for the holding besides the construction and lifting/loading equipment. With its 700 employees the Kuhn Group achieved more than 440 Mio. Euro in sales last year. Since 2000, both of his twin-sons Stefan and Andreas are part of the company.

There will be no intervention into the operational side of the business – synergies will have to grow first. For example with the market expansion into Eastern Europe the help of the new owner will be very helpful. “Kuhn’s sales expertise in Eastern Europe is very strong. We want to follow what the Kuhn Group already achieved in those markets“, said Stefan Hansch, CEO EMCO Group.
Besides Hansch wants to send EMCO on a global growth trip. Markets like Brazil, Russia and China are on his radar.
„EMCO did its homework, the new structure is in place and the order books are full. We reached the safe harbor. This surely is a great Christmas gift for all of us at EMCO”, said Hansch.

Das automatische Spindelkopfwechselsystem gestattet ihm, für die Schruppbearbeitung auch auf HPC-Spindelköpfe mit bis zu 330 Nm (ED 100 % = Dauerbetrieb) und 6.000 min-1 zu wechseln. Ein Platz in der Spindelkopfablage für einen dritten Spindelkopf steht zur Verfügung. Die Ablagestation ist außerhalb des Bearbeitungsbereiches sicher geschützt vor Kühlmittel und Spänen angeordnet. Um die Trennstelle an den Spindelköpfen vor schädigenden Einflüssen in rauer Industrie-Umgebung zu schützen, ist die Spindelkopfablage zusätzlich automatisch abgedeckt.

Zusatzeinrichtungen wie innere Kühlmittelzufuhr, Öl-Luft-Kühlsysteme, Werkzeugwechselsysteme mit bis zu 40 Ablageplätzen, Vorschubkraftüberwachung, verschiedene Messtaster, Video-Überwachung der Bearbeitung, druckluftbeaufschlagte Führungsbahnabdeckung, Absauganlagen oder die Ausstattung für Ferndiagnose generieren weiteres Nutzenpotenzial bei den Anwendern.
Bilder zum Download

 
Horizontale und vertikale Fräs-BAZ bilden den Programmschwerpunkt. Die längs verfahrbaren Horizontalfräs- und -Bohrwerke beginnen bei 4.000 mm Verfahrweg in der X-Achse. Die Vertikal-Fräs-BAZ in Portalbauweise starten mit X-Achsen von 2.500 mm, die Y-Achse kann bis 5.000 mm und die Z-Achse bis 2.000 mm betragen. Gängig sind Fräsköpfe mit Leistungen zwischen 30 und 55 kW sowie Drehmomenten zwischen 330 und 1000 Nm. Eine große Auswahl von Fräsköpfen, auch mit Elektrospindel und kontinuierlichen Achsen, bietet dem Anwender seine individuell passende Lösung.

 

 

Benefits of all versions
Both versions include the basic benefits. Due to its cylindrical design, the machine stand forms a self-contained compact system with an extremely small footprint. In contrast, there is extra large spacing between the rails and as a result the guiding carriage is selected along the X-axis. In combination with the long guide shoes, this results in very stable guidance. The thermo-symmetrically designed headstock ensures long term overall stability and thus also precision of operation. The passive work space covering leads to lasting low maintenance.  The accompanying system has no moving telescopic parts, thus eliminating the wear and tear on them. The control panel and the control cabinet are an example of user-, maintenance-, and service-friendly ergonomics.  Both can be swiveled so as to allow the service personnel easy access. Production planners and operators also profit from the lasting benefit provided by the exemplary Siemens 828D controls system. New features of the user interface "Operate" and the ideal solution for one-channel machines will convince during actual operation. A chip conveyor with integrated coolant system is provided as a standard feature to complete the vertical turning machine.

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 130 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. The multi-function table facilitates the execution of frequently recurring machining operations, accommodating fixed drilling tools, special tools, separate milling heads and the workpiece measuring sensors; it also simplifies the exchange of spindles and chucks. Users who opt for the version with the Y-axis benefit from the fact that they are separately provided in the tool turret. The separation from the X-Y carriage system results in a short power train and thus ensures stability.

Naturally, the EMCO commitment of ‘Made in the Heart of Europe’ also applies to the new vertical turning machine VT 160. The machines are completely developed and produced in central Europe in cooperation with European brand manufacturers that meet the highest standards in terms of quality, productivity and efficiency.

Hyperturn 45 - High-performance universal turning center with loading gantry

Hyperturn 95 - Multitasking-machine for the highest levels of productivity and flexibility

Hyperturn 65 TT - High-performance turn/mill center with 3 tool turrets

Vertical VT 160 - Vertical lathe VT 160 with integrated automation

etc.

Halle 27 / D45

MMV 2000 - Floor-type machining center for 3- to 5-axis machining

Maxxmill 500 - Vertical milling center for 5-axis machining 

From enquiry to contract
Probably the largest manufacturer of construction machinery in Asia issued the enquiry for a total of 21 machine tools, including 13 turning and turning milling centers complete with automated tool change, parts storage and handling loading and unloading for parts weighing up to 150 kg. With this equipment at its Changshu site in south-eastern China, the location of its headquarters, Sany intends to process precision parts: drive shafts, splined shafts, flanges and similar precision components. On the basis of workpiece drawings, bidders were asked to compile proposals for the various machine tools and all the necessary documentation. The boundary conditions specified by the Chinese company were an availability rate of 98% in 24-hour operation, 7 days/week. 
EMCO recognized the opportunity to bundle together its own competencies and to profile the program: “We are now using not only our relevant production know-how, but also our know-how in automation technology for our whole portfolio of lathes and turning centers,” is how engineer Dr. Stefan Hansch, CEO of EMCO Maier, describes the strategy of the Hallein company. He explains: “This creates the foundation which will enable us in future to automate our largest turning centers on the workpiece side independently and comprehensively, thereby increasing the percentage of our own added value.” In only 5 working days, the EMCO project managers drew up the concept and layout for the automation solution including a guideline offer. Both the quick response and the solution, which included technical as well as production organizational factors, and the price/performance ratio convinced Sany’s production experts. Helmut Huber, Head of Automation at EMCO, adds: “For Sany the decisive factor was that EMCO was prepared to take responsibility for the whole 6 million-Euro project, namely for 19 turning centers and workpiece-side automation including full engineering.”
The positive reference given by Mitsubishi in China, as well as the shaft clamping chuck introduced in the country by Emco also served to inspire confidence at the outset.
Qualitatively as well as quantitatively, the company is launching itself in new directions. Instead of relying on external providers of engineering services, the company is gaining the competence needed to be able in future to automate even the largest processing centers on the workpiece side using its own program. In terms of order of magnitude, this decision means a leap from a workpiece weight of 10 kg to 150 kg; accordingly, parts with diameters of 60 to 200 mm and up to 2,000 mm in length. Helmut Huber is certain that: “Apart from EMCO, I know of no other machine tool manufacturer which can offer such an integrated portal solution for workpiece handling for its whole program from one source.”
Following the award of the contract, the Austrian machine tool experts gave a detailed presentation of these technical solutions to their new customer at a design meeting held at the Changshu headquarters. They presented time studies, tools lists, layouts and data of the partners’ shares. The first high-performance turning milling centers were ready for acceptance only twelve weeks after the order.

An integrated concept
The user receives a complete turn-key solution. This contains all hardware and software components from the automated takeover of the parts to be processed through their processing in the machine tool up to handover of the finished part.  All the high-tech turning, milling and turning milling centers for industrial applications are available from EMCO as processing centers. They process workpieces up to 1050 mm in diameter and offer a travel range up to 580 mm for workpieces weighing between 1 and 400 kg, or even more on request. The loading and unloading equipment is orientated to the type and size of machine, the geometry of the base material and the finished workpiece: swivel or portal loaders with unfinished and finished part belts or supply lines. Also integrated in the systems are the workpiece grippers, pallet tops, tool changers (eg in revolving design), measurement stations, signaling stations, cleaning containers and even conveyors for chips, cooling and preparation plants for the cooling lubricants. All working processes and peripheral functions are controlled by the central machine control system. For special applications, EMCO Robo Load 10 is available as a system solution with robot handling. If the customer requests it, the software can also include already completed programs for the actual workpieces to be produced. For the application of the 13 machine tools at Sany, a solution with portal loaders is suitable for technical and commercial reasons. This guarantees the highest degree of flexibility.

Concrete solution for Sany: 21 automated turning and turning milling centers
The part-contract for automated machine tools placed on EMCO comprised 13 systems. These include 8 high-performance CNC turning centers Maxxturn, 5 high-performance CNC turning and milling centers Hyperturn, and also 4*MT45 aund 4*MT65 with bar feeders. For each of the 13 machine tool systems, the Hallein project engineers work on the layout and all hardware components including mounting, tool holders and tools. The scope of the contract also includes the processing and sequence programs, including time studies for each of 5 different workpieces for the turning centers or 3 for the turning milling centers (details of the processing centers and workpieces are given in the summary tables).
All electrical shaft grippers on the 8 turning centers are provided by Sommer automatic, Ettlingen/Germany. These ensure that the parts, which can weigh up to 150 kg, are gripped safely. They in fact use the electrical impulses for self-locking of the worm gears. This technology also has the advantage of ensuring that the position on the gripper is queried via the C-axis. Compressed air is therefore completely unnecessary. For the 5 turning milling centers, EMCO uses its tried and trusted 3-jaw pneumatic grab heads. Every machine has 2 each of these.
For the large portal systems, the Hallein team works with Güdel, Langenthal/Switzerland. This specialist in modular portals has an impressive level of technical competency and short delivery times. It achieves this with an unusual depth of in-house production: from basic units through guide mechanisms and racks to gears, the Swiss company manufactures everything itself. With its qualified 24 hour/7 days a week service in China, it offers just the right addition to EMCO’s customer service as its local partner. The smaller 2-axis portals, the 3 Maxxturn 65 MY and the 5 Hyperturn 665 MC plus Y are manufactured by EMCO.
As the Main Contractor, EMCO also takes responsibility for the tools and tool-holders. Its partners include Algra, Sandvik and WTO, and as a specialist in the special milling machine for manufacturing gearing, the Swiss company Schnyder.
The control system has a further practical use. All processing centers including the relevant peripherals work with identical control hardware and software: Sinumerik 840D/powerline 840D-sl with PCU 50.

Outlook
The project for Sany started in Hallein during calendar week 40 (the start of October) in 2010. Commissioning and training of Sany employees started as early as Week 26 (the end of July) in the Changshu headquarters. Training and induction will take around 3 months. After this, Sany will be able to fully exploit the automation solution. Helmut Huber summarizes the outlook: “The integrated design and obtaining everything complete from one source will bring our customer Sany the greatest possible benefit. On average we expect a thirty percent reduction in personnel costs, significantly higher productivity and reliability in the process compared with conventional solutions”.

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The issue is current and is regarded as urgent by the entire industry: where will we find the specialized personnel of the future? Years with low birth rates, only a very limited willingness on the part of girls to choose technical training and a rather low age of retirement are just a few of the starting points that are the focus of discussions.

With the creation of the Center of Excellence, an exclusive selection of EMCO centers of excellence, EMCO and Festo Didactic together provide a platform for the continuous improvement and development of industry-standard CNC training: up-to-date, industry-related and comprehensive, that's what the perfect training should be like.

How can EMCO and Festo Didactic assist the Center of Excellence with this?

• Proximity to industry as an everyday lived experience rather than as a catch phrase - the ongoing exchange with and between all Center of Excellence partners, such as at the annual meeting in the EMCO center in Hallein,
• the ongoing involvement in product development processes, 
• regular training in the EMCO technology center or on-site,
• teaching and learning materials for the everyday classroom experience such as the new
EMCO campus,
• technical advice in accordance with didactic aspects and technical support on site,
• and assistance with the planning and preparation of the Center of Excellence rooms

are just some examples of the package of measures planned for EMCO Center of Excellence.

A New Center of Excellence Partner:
The vocational school in Göppingen is yet another partner we have been able to gain in the heart of Germany's mechanical engineering region. The goals and plans reflected in the decision for a vertical milling center for 5-axis machining are thus correspondingly ambitious. Approximately 500 trainees in metal manufacturing trades (e.g., cutting machine operators, industrial mechanics and toolmakers) and another 50 participants from the technical school as well as approximately 250 students of the technical high school will find ideal training conditions here – highly motivated teachers familiar with the industry requirements, industry-standard machinery and the most modern teaching and learning materials. http://www.gs.gp.bw.schule.de/

The training provided using interchangeable controls on EMCO Concept machines has now been expanded to include the new programming system EMCO WinNC for Siemens Operate, making it ideally suited to meet these requirements. EMCO WinNC for Siemens Operate is control-specific software which is installed on a conventional PC. Its interface and functions are the same as the original Sinumerik Operate controls.

Users benefit from the unique interchangeable control concept , which enables them to be trained in all current industrial controls on just one machine. Changing to a different control system is a simple matter of calling up the relevant software and swapping out the control-specific keyboard module. This currently enables up to nine different CNC controls to be used on just one machine.

All EMCO Concept machines with ACC machine technology can be upgraded to use WinNC Siemens Operate, as can external programming systems. The system can be installed on XP or higher. The initial version for milling operations covers the following areas:
       Machine status page
       (machine, parameters, programs, program manager, diagnostics)
       Cycles: ISO, ShopMill
       Simulations: 3D, 2D
       Editors for tools, contours, etc.

The external programming system is available as a single workstation license or as a multi-user/site license. The expansion for Concept lathes will be released in time for the EMO 2011 in Hanover. Through this release, EMCO is once again demonstrating its expertise in industry-focused CNC training.

Application engineers, the product management team and the development team are available to answer your enquiries.
Should you be interested in visiting us on the occasion of the Open House, we would be pleased to see you. Also gladly by appointment at: info@emco.at

The courses - Basic Principles, Machining Technology, Quality and CNC - can all be completed independently of each other. As long as they have the requisite basic understanding, students can start any of the courses at any time. For newcomers to the field, the "Basic Principles" course provides a particularly good starting point.
Gerhard Meisl, EMCO Senior Product Manager, and his coworker, Monika Mayr, a mechatronics trainee at EMCO, accompany both tutors and students on their journey through the campus. They explain how the E[MCO] Campus is structured, provide support, and give helpful advice.
In addition to the courses, the "Further Reading" section provides an overview of the supplementary literature available on the topic of machining.

Interactive learning, customizable for different target groups and ability levels: An authoring tool enables tutors to create customized courses with dedicated content and tailored tests. They can also communicate with their classes via the E[MCO] Campus.
All students also have an individual user account that provides up-to-date information on their progress through the course.

The MAXXTURN family comprises five members: the MAXXTURN 25, 45, 65, 95 and 110. While the smaller three high-performance universal lathes with their counter spindle represent the perfect solution for the economic complete machining of barstock and chuck parts, the MAXXTURN 95 and 110 concentrate on the machining of shafts and flange parts. Fitted with a Y axis, driven tools, a high-precision C axis and very high rapid-motion speeds, the MAXXTURN series offers everything the customer desires, to not only manufacture complex machined parts in high quality, but also cost-effectively – true to the EMCO maxim: Design to Cost. 
One of the characteristics which distinguishes the entire MAXXTURN line is that the Y axis is integrated in the body of the machine. This ensures maximum stability, as well as utmost precision of all parts manufactured. The extremely wide distances between the guides make for stable turning and offer the operator additional possibilities for complete machining.
The compact counter spindle is an additional highlight, taking over workpieces position-oriented and with utmost precision for machining the reverse side. This avoids having to clamp workpieces a second time, thereby avoiding wait time, which in turn increases productivity and makes for shorter part delivery periods.
The tool turret with single-motor engineering offers space for 12 VDI30 tool holders. Each station can accept driven tools. A servo motor powers the driven tools and the swivel movement, respectively. The tool holders, equipped with EMCO joggling plates, allow easy tool insertion with repeatable accuracy without the need for time-consuming adjustments.In the course of modular assembly customers can choose between a SIEMENS (incl. ShopTurn dialogue interface) and a FANUC control interface (incl. Manual-Guide-i control interface).

Tailored automation
A swing loader is included for automatic loading and feeding out of the machined parts. This extremely compact and integrated loader is controlled via the machine control. Two linear axes with high feed rates and an additional B axis in the swivel head, guarantee short loading times and fast setup. As a result, preformed raw parts can also be inserted position-oriented into the clamping device. The gantry loader transports the finished workpieces from the machine and places them on an accumulating conveyor.  
EMCO has two different versions of bar loaders on offer for bar work: a classic 3-meter loader (EMCO TOP LOAD 8-65/3300) and the EMCO short bar loader LM1200 for limited floor space. 
Depending on the make, the MAXXTURN 65 forms the basis for efficient machining of precision and machined parts. The range of manufactured workpieces ranges from hydraulic / pneumatic components, to machines as well as engine and automotive parts, all the way to components from the field of biomedical engineering or the fields of materials and bulk material handling. Friction and antifriction bearing parts are just a few more examples of the nearly endless possibilities.