hyperturn 100 powermill - decca · hyperturn 100 powermill main spindle and counter-spindle...

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  • Turning and Milling Centre for the Complete Machining of Complex Workpieces

    HYPERTURN 100 Powermill

    TURNINGEMCO-WORLD.COM

  • Multifunctional Profit CentreThe Hyperturn 100 is a powerful multitasking machine for the machining of complex workpieces with a maximum turning diameter of 720 mm and a maximum turning length of 3100 mm (between the points). The 40 or 100 tool stations available allow for machining with high flexibility.

    TOOL MAGAZINE Perfect accessibility for tool setup and inspection Up to 100 tool stations 3 additional stations for boring bars and tools featuring large dimensions

    4

    4

    CONTROL Sinumerik 840D sl with 22“ colour screen USB interface Swivel-mounted, movable control panel EMCO technology cycles AURIGA process assistant

    5

    5

    MILLING SPINDLE Travelling column principle for high rigidity Integrated B-axis Excellent technical data: 165 Nm, 33.8 kW, 12000 rpm

    With integrated torque motor Large swivel range

    6

    6

    TAILSTOCK Hydraulic quill Integrated bearing Off-centre quill setting for easier machining Positioning with NC-axis 100% programmable and monitored Powerful counter-spindle, identical to the main spindle

    7

    7

    MACHINE DESIGN Optimum use of space Innovative protection system against flying chips and coolant

    Large work area Ergonomic access Chip flushing system in the work area (standard)

    3X-, Z-, Y-AXES All axes equipped with Heidenhain glass scales High feed forces NC-controlled tailstock and steady rest High and stable dimensioning for all axes

    2

    2

    MAIN SPINDLE Dual drive motor for a zero-play C-axis (A2-11") Integrated spindle motor with C-axis (A2-8“) Impressive performance values (A2-8"/A2-11"):33/53 kW - 800/3500 Nm - 2500/3500 rpm

    Liquid cooling with automatic temperature regulation

    1

    1

    Machine with optional equipment

    3

  • Milling spindle. The standard version comes with 12000 rpm and is suitable for all turning, drilling and milling operations and technologies. The water-cooled ISM (integrated spindle motor) can be delivered with up to 33,8 kW and a maximum torque of 165 Nm as well as with HSK-T 63 or PSC63 (Capto C6). Coolant inside and outside (up to 80 bar), which allows for the efficient production of turned and milled parts.

    42

    35

    28

    21

    14

    7

    0

    P [kW]M [Nm]

    0 2000 4000 6000 8000 10000 120000

    300

    60

    90

    120

    150

    180

    n [min-1]

    170

    34

    26

    127

    1950

    M (S1-100%)

    M (S3-40%)

    P (S1-100%)

    P (S3-40%)

    Work area. The spacious work area has been designed for workpieces featuring a turning diameter of up to 720 mm. The complete machining of complex workpieces in one setup is possible when using an NC steady rest and a counter-spindle.

    Very large work area for the complete machining of large workpieces featuring a turning diameter of up to 720 mm and a maximum length of 3100 mm

    Powerful main spindle and counter-spindle (A2-8", A2-11"), 33/53 kW and 800/3500 Nm

    Dynamic and precise B-axis with direct drive as well as high torque and performance

    Multitasking and multi-technology: Sinumerik 840D sl with Auriga process assistant

    Main spindle and counter-spindle: high-performance machining with vibration-damped boring bar, inclu-ding a special magazine (option) with the same drive concept and identical performance data

    Automatic tool default settings and workpiece mea-suring probes

    One or several NC steady rests

    40 / 100 tool magazine stations

    Flexible milling spindle with 12,000 rpm

    Boring bar pick-up system

    Simultaneous 5-axis machining

    Maximum coolant pressure: 80 bar

    Virtual machine – collision monitoring

    EMCO teleservice/network service

    Tool breakage monitoring

    Made in the Heart of Europe

    Highlights

    Hyperflexibility. The Hyperturn 100 machine concept enables a wide range of machining operations in one setup, including off-centre turning and milling, bore levelling, gear milling, contour milling, 5-axis machining and much more.

    Main spindle and counter-spindle (A2-8"). The A2-8" spindle version with dynamic direct drive and a maximum of 3500 rpm and 33 kW is available as an alternative. The standard spindle brake allows for additional stability during high-performance milling. Identical performance data are offered by the movable counter-spindle, which helps achieve a secure automated machining process.

    Technical HighlightsHyperturn 100 Powermill

    Main spindle and counter-spindle (A2-11"). Featuring performance data that enable all types of machining without any compromises. The Emco spindle concept comes with two servomotors that also act as a C-axis. The motors work synchronously, guarantee the compensation of plays and enable the achievement of the outputs and torques shown in the diagram. What is more, the main spindle and the counter-spindle are equipped with a special EMCO cooling system that optimises the temperature stability and guarantees maximum precision regardless of the machining duration.

    200 400 600 800 1000 1500 2000 25000

    0

    5

    10

    15

    20

    25

    30

    35

    40

    45

    50

    55

    P [kW]

    n [min-1]

    2000

    1000

    3000

    4000

    5000

    5500

    500

    0

    M [Nm]

    M42M41 RANGE N°1

    RANGE N°2

    575

    625

    143

    34

    664

    53

    880

    2656

    3520

    M (S1-100%)

    M (S6-40%)

    P (S1-100%)

    P (S6-40%)

    0

    100

    200

    300

    400

    500

    max. 800

    0 1000 2000 3000

    0

    5

    10

    15

    20

    25

    30

    max. 33

    35

    700

    900

    600

    max.3500400

    min-1

    kWNm

  • ■ Direct interaction between EMCO Apps and the control

    ■ Intuitive user interface optimized for touch control

    ■ Range of available applications is continuously being expanded

    ■ Customised and project-specific applications

    ■ Optimized for the EMCO machine range

    ■ auriga allows for easy and quick configuration and updating

    Highlights

    Your „Control Center“ for the entire production flow

    auriga‘s hardware basis is a 22" industri-al touch control panel combined with an industrial PC (IPC).

    DASHBOARD – For a Quick Overview of the Machine StatusClear and compact processing of all relevant machine and NC data depending on the configuration of the machine (number of tool systems, spindles, ...) and the active operating mode (JOG, MDA, AUTO). Know at a glance whether everything is OK or whether the machine operator will be required to interact.

    SINUMERIK - the Control and the Machine‘s CenterpieceThanks to the App Launcher operators may switch between theauriga Apps and the control at any time. All it takes to do so isa click on the auriga logo. To improve the work processes on themachine the control can, as shown in the picture, be operated infull screen mode or in interaction with practical apps (sidebar).

    MACHINE DATA – All Data related to Productivity at a Glance

    Operating data collection to inform the user about the current production status and OEE (Overall Equipment

    Effectiveness) values full screen or sidebar.

    DOCUMENTS – A Digital and Expandable Document Collection Customised to Suit Your Individual NeedsTo display PDF documents such as machine documentations,programming instructions, process descriptions …Including favourites management - full screen or sidebar

  • Direct CAD data import AutoCAD (DWG) Parasolid®

    Solid Edge®

    Solid Works®

    ACIS® (SAT) Optional interfaces: CATIA®, Pro/ENGINEER®, STEP, STL,...

    CAD

    Reduction in set-up costs Reduction in downtimes Reduction in repair costs Optimum machine utilization

    Production

    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. EMCO CPS Pilot provides a true 1:1 mapping of the real machine for defining and testing processes, optimising machining sequences and training new specialist workers.

    The Virtual Machine

    Virtual Workflow. Real Benefits.

    2-22 axis turning 2-5 axis milling Multi-tasking of turning and milling 3D machine space simulation Certified post-processors

    CAM

    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)

    CPS

  • Indications in millimetres Indications in millimetres

    20100

    40120

    max. 180200

    60

    200

    043 .xam - 0 8 . n i

    m

    0 62=2 X

    180220

    1300/2000/2900

    Z2=1300/2000/2900

    2010

    040

    120

    220

    043 . xa m - 08 . ni m

    062=2X

    180

    220

    Z2=

    1300

    /200

    0/29

    00

    Z1=

    1500

    /220

    0/31

    0010

    0Y1

    =42

    0

    210

    210

    110°

    110°

    400

    250

    min.

    80 - m

    ax.34

    0SW

    380 -

    BMT6

    5

    (SW34

    0 - VD

    I40)

    max

    . Ø75

    720

    max

    .Ø80

    0no

    lowe

    r tur

    rent

    !!

    max

    .Ø58

    0

    BMT6

    5 with

    spec

    ial

    toolh

    older

    120

    555

    45°

    1700

    /240

    0/33

    00

    Z3=

    1300

    /200

    0/29

    00

    20

    8"

    11"

    8"

    11"

    20

    100

    015. xa m

    087=1X

    052

    067

    Work Area Work Area

  • Indications in millimetres

    Installation plans(м

    ин. т

    ранс

    порт

    иров

    очны

    й ра

    змер

    )

    (мин. транспортировочный размер)

    Working area

    Swing over bed 750 mm

    Max. turning diameter 720 mm

    Length between spindle and centre 1700 / 2400 / 3300 mm

    X1-axis 750 mm

    Y-axis 420 mm

    Z1-axis 1500 / 2200 / 3100 mm

    Main spindle

    Spindle connection (DIN 55026) A2-8" // A2-11"

    Power chuck diameter 315 / 630 // 400 / 630 mm

    Max. spindle speed (with transmission) 400 / 3500 // 143 / 2500 rpm

    Max. drive power, main spindle 33 / 53 kW

    Max. torque (S1/S6 40% DC) 580 / 800 // 2600 / 3500 Nm

    Max. weight incl. chuck 350 // 500 kg

    Max. weight between the centres incl. chuck 800 // 1500 kg

    Tailstock with quill MK 5

    Travel distance (without steady rest) 1300 / 2000 / 2800 mm

    Travel distance, quill 150 mm

    Quill diameter 150 mm

    Max. contact pressure 2500 – 22200 N

    Movement speed, tailstock 15 m/min

    X-, Z-, Y-axes

    X1-X2_Z2 / Z1 and counter-spindle 30 / 40 / 20 m/min

    Feed force X1 / X2 1640 N

    Feed force Z1 / Z2 1640 N

    Counter-spindle 1640 N

    Driven Tools (BMT 65P – VDI 40)

    Speed range 6000 rpm

    Torque 62 Nm

    Max. drive power (max.) 21 kW

    Max. number of driven tools (max.) 12

    Tool magazine

    Tool magazine stations 40 / 100

    Max. tool length 500 mm

    Max. tool diameter 90 mm

    Max. turning tool weight 12 kg

    Coolant system

    Max. coolant pressure (max.) 80 bar

    Flushing system in the work area 2x7 bar

    Cooling tank capacity from 600 l

    Power consumption

    Max. connected load (max.) 86 kVA

    Compressed air connection 6 bar

    Dimensions

    Height above floor 1450 mm

    Total length including chip conveyor 8100 / 8800 / 9600 mm

    Height 3000 mm

    Width / with control panel 2900 mm

    Weight (depending on the type and accessories) 18000 – 22000 kg

    Technical DataHYPERTURN 100 Powermill

  • EMCO GmbH Salzburger Str. 80 . 5400 Hallein-Taxach . AustriaT +43 6245 891-0 . F +43 6245 86965 . [email protected] . www.emco-world.com

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