Mass production components always present challenges: planning the machine installation site, linking machines and coordinating cycle times all to achieve the perfect combination of quality and cost efficiency. The larger the workpiece the more demanding the planning process for the manufacturing set-up. However, optimizing the production of such parts, for example by reducing expensive automation components or reducing the process chain to just a few machines, can drastically cut costs. EMAG's VLC 800 vertical turning center for chucked parts up to 800mm is a production system that combines all these benefits in a single machine thanks to its integrated automation systems.

A customizable machine, as the "C" in the name indicates, the VLC 800 vertical turning center can be configured for a wide range of applications. Combining multiple modules to choose from and the time-tested EMAG modular design means that the VLC's machining area can be configured for a wide range of machining tasks. For example, the machine can be fitted with two tool turrets equipped with driven tools and, as an option, can travel on an additional X-axis. Furthermore, drilling and milling spindles with tool magazines can be mounted on a Y-B-axis unit. As a result of the machines' high strength and precision, they can also tackle grinding and hard machining. The VLC 800 can be used for almost any type of machining on large workpieces.

The sturdy main spindle with a drive rating of up to 74 kW, 4400 Nm of torque and speeds up to 500 rpm ensures that machining processes are completed quickly. The Mineralit polymer concrete machine base is made using a cold casting process for particularly good vibration damping, which in turn minimizes tool wear and delivers excellent surface quality. The spindle motor, main spindle, tool turret, electrical cabinet and machine body are liquid-cooled. A dual-circuit cooling unit readjusts the machine temperature to the ambient temperature within close tolerances. Consequently, VLC turning centers produce even large components with accuracies in the range of a hundredth of a millimeter. For optimal quality control, however, an optional probe can be installed outside the machining area to verify dimensions. Not only is the probe protected from chips, but the measurement is carried out just before the loading or unloading process, saving time.

Naturally, the VLC 800 also features the typical EMAG pick-up system consisting of an included parts storage facility and pick-up spindle. Raw parts are placed on the integrated conveyor belt for transport in and out of the machine either by hand or using additional automation components. The spindle picks up the workpiece from the conveyor and guides it to the various stations in the machining area. The short distances from the conveyor belt to the machining areas and back minimize the chip-to-chip times and ensure excellent efficiency. The integrated automation system also simplifies the structure of production lines since there is no need for complicated automation systems to load the machines. All that is required is a part transport system between the conveyor belts, easily achievable with simple automation components such as additional conveyors, pick-and-place units or changers. Using as few components as feasible also reduces possible fault sources.

Excellent accessibility to all relevant machine zones is ensured by the vertical design, as convenient access to the machining area ensures very short tooling times with perfect ergonomics for the set-up technician. All the service units are also laid out for ease of accessibility to make machine maintenance convenient and efficient.

EMAG's VLC 800 vertical turning center is designed for large workpieces and can be used for a wide range of applications due to the great flexibility of its equipment features. The VLC 800 also allows the complete machining of large chucked parts in a single clamping cycle. The integration of different processes and technologies ensures a drastic reduction in process chains and thus creates optimized production processes. One of the most flexible and productive manufacturing systems for large components on the market, the VLC 800 offers manufacturing engineers a wide range of possible uses.