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■ emcoNNecT 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 emcoNNECT

■ Main spindle and counter-spindle: high-perfor-mance machining with vibration-damped boring bar, including a special magazine (option) with the same drive concept and identical perfor-mance data

■ Automatic tool default settings and workpiece measuring 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.

0

100

200

300

400

500

max. 800

0 1000 2000 30000

5

10

15

20

25

30

max. 33

35

700

900

600

max.3500400

MAIN SPINDLE

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

� emcoNNECT allows for easy and quick configuration and updating

Highlights

Your “Control Center” for the entire production flow

emcoNNECT‘s hardware basis is a 22" industrial 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 theemcoNNecT Apps and the control at any time. All it takes to do so is a click on the emcoNNecT logo. To improve the work processes on the machine the control can, as shown in the picture, be operated in full 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

220

max. 180200

60

200

043 .xam - 08 . ni

m

062=2X

180220

1300/2000/2900

Z2=1300/2000/2900

Z1=1500/2200/3100 100 Y1=420

210 210

110°110°

502

400

250

min.80 - m

ax.340SW

380 - BMT65

(SW340 - VDI40)

max. Ø750Ø720

max.Ø800no lower turrent!!

max.Ø580

BMT65 with

special

toolholder

120555

45°

1700/2400/3300

Z3=1300/2000/2900

20

Steady rest K5.1

8"11"m

ax. Ø

410

min. Ø 100

8"11"

20

100

015.xam

087=1X

052

067

2010

040

120

220 m

ax. 1

8020

0 60

200

043 . xa m - 08 . ni m

062=2X

180

220

1300

/200

0/29

00

Z2=

1300

/200

0/29

00

Z1=

1500

/220

0/31

0010

0Y1

=42

0

210

210

110°

110°

502

400

250

min.80 - m

ax.340

SW 380 - B

MT65

(SW340 - V

DI40)

max

. Ø75

0Ø

720

max

.Ø80

0no

lower

turre

nt!!

max

.Ø58

0

BMT6

5 with

spec

ial

toolhold

er

120

555

45°

1700

/240

0/33

00

Z3=

1300

/200

0/29

00

20

Stea

dy re

st K

5.1

8"

11"

max

. Ø 410

min

. Ø 1

00

8"

11"

20

100

015. xa m

087=1X

052

067

Work Area Work Area

indications in millimetres

installation plans

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 - counter spindle

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

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

max. spindle speed (11" with transmission) 3500 // 2500 rpm

max. drive power, main spindle 33 // 53 kw

max. torque (11" with transmission) 800//4400 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 daN

Feed force Z1 / Z2 1640 daN

counter-spindle 1640 daN

Millingspindle - Powermill

Speed range 0 – 12000 rpm

max. Torque 165 Nm

max. drive power 33,8 kw

Tool holder HSK-T63

B-Achse

Travel range 240°

detend torque of clamp 6000 Nm

drive torque interpolated 880 Nm

Driven Tools (BMT 65P – VDI 40)

Speed range 6000 rpm

Torque 62 Nm

drive power (max.) 21 kw

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

coolant pressure (max.) 80 bar

Flushing system in the work area 2x7 bar

cooling tank capacity from 600 l

Power consumption

connected load (max.) 117 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

*

* Bl2400

emco GmbH Salzburger Str. 80 . 5400 Hallein-Taxach . AustriaT +43 6245 891-0 . F +43 6245 86965 . info@emco.at . www.emco-world.com

EN

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issi

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ZERTIFIZIERT

TÜV AUSTRIA CERT GMBH

EN ISO 9001

ZERTIFIKAT NR. 20 100 20419