The new energy vehicle market is highly competitive and has put forward disruptive requirements for the production of auto parts, including lightweight, rigidity, precision and production rhythm. At the same time, processing production lines are also facing severe challenges in terms of automation and flexibility.
As a professional enterprise with turning, grinding, gear hobbing, gear grinding, laser welding, hot-fit assembly, precision electrolysis and other technologies, EMAG is one of the few suppliers in the world that can provide one-stop full industry chain solutions. First, help companies related to the automotive industry to easily cope with the multiple challenges brought about by the tremendous changes in the automotive industry and plan for the future.
At the upcoming CCMT 2024 China CNC Machine Tool Exhibition, EMAG will showcase a number of innovative products and technologies. At that time, a variety of typical parts will be processed on site. Everyone is welcome to visit the booth! We have a sneak peek at some of the highlights!
CCMT 2024 China CNC Machine Tool Exhibition
Time: 2024.4.8-2024.4.12
Location: Shanghai New International Expo Center
EMAG Booth: No. A201, Hall W5
01
differential housing
Compared with traditional bolting or riveting, laser welding technology provides more possibilities for the development of the automotive industry. The welded automobile differential housing has multiple advantages such as lightweight, high quality, and low cost.
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EMAG ELC 6 laser welding machine is an efficient solution for connecting differential cases and gears. It has a double turntable workstation structure, and loading and unloading and welding are performed simultaneously. It is equipped with standard welding head CNC axis, welding process monitoring, etc. It has high flexibility and good stability, and is very suitable for mass production.
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EMAG ELC 6 laser welding machine
02
Planetary gear
You must know that the actual grinding of typical workpieces such as planetary gears only takes about ten seconds. The difference in changeover time is the key to determining the efficiency of mass production of parts.
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The G160 high-precision gear grinding machine has two parallel worktables that can alternately move the workpiece at high speed (with the help of low-wear linear motors). When one spindle is processing gears, the loading manipulator will put the blank into the other spindle, and the spindle switching time is only 1.6 seconds, while the fastest changeover time for a traditional flip-type double-table machine tool is 5 seconds.
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EMAG G160 high-precision gear grinding machine
03
main reduction gear
In the new energy vehicle industry, in the face of higher requirements for lightweight, efficiency and reliability of electric drive systems, the processing technology of main reducer gears also needs to be optimized and upgraded.
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Using two VL 6 inverted CNC lathes as the main body, EMAG has launched a "fully automated processing solution" for the main reduction gear, including an online measuring instrument, AGV trolley and stacking unit, which can achieve 3 processes and a 60-second cycle time. High processing efficiency.
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EMAG fully automated processing solution for main reduction gears
VL 6 is a lathe used to process heavy workpieces with a maximum diameter of 300mm. It has a unique inverted structure that can prevent chip accumulation and improve processing quality. Through the cooperation of the lower loading spindle and the workpiece storage belt, automatic loading and unloading can be realized, significantly shortening the processing preparation time.
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EMAG VL 6 inverted CNC lathe
04
cam ring
The picture below is a cam ring part with a non-circular profile.
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As a universal equipment platform, VL 200 GT can not only realize internal and external cylindrical compound grinding, but also perform non-circular contour grinding. The wave generator in the harmonic reducer robot industry can be clamped once, and the grinding of the outer contour and the processing of the inner hole and end face can be integrated into one piece of equipment.
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EMAG VL 200 GT vertical turning and grinding machining center
What EMAG is demonstrating at this exhibition is the typical grinding process of the cam outer contour on the VL 200 GT; VL 200 GT using different process combinations can realize grinding, hard turning and other processes in one piece of equipment. Minimize processing time. In addition, the VL 200 GT adopts a spindle loading and unloading concept and can be connected to a shuttle feeder or a circular circulation feeder to easily realize automated production.
05
Motor shaft
Due to the successful promotion of new energy vehicles, the demand for rotor shaft production is also increasing. Facing the dual challenges of high output and high precision requirements for new energy vehicle motor shafts, a flexible solution is needed.
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The VT 200 is a vertical turning center for shaft machining, which can meet the requirements of large production batches and extremely high quality requirements.
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EMAG VT 200 vertical turning center
In addition to the single-machine processing demonstration, EMAG also displayed an automatic production unit for new energy vehicle motor shafts at this CCMT. It connects a VT 200 vertical turning center with the MRC robot modular unit independently developed by EMAG, thereby realizing the motor shaft from blank frame loading, camera recognition, robot grabbing, to processing. After cleaning, measuring, finished parts are returned to fully automated production.
