Teach-in control simplifies lathe operation

A teach-in control system for electronic lathes brings simplicity and ease of programming and/or operation in combination with high-performance operating software.

Users of the Emcomat E160 electronic lathe designed with a new control will benefit from enormous ease in operation, HK Technologies has informed Manufacturingtalk.

HK said that the customer benefits from an unrivalled price-performance ratio according to the design-to-cost Emco philosophy.

Cycle-controlled lathes by Emco offer an economic alternative where conventional machines reach their limits and CNC machines are too expensive.

Whether single or small series production, simple or complex workpieces, Emco cycle machines offer high machining performance and utmost precision.

CNC know-how is not required.

A user guide and graphic workpiece simulation is used in programming in a user-friendly fashion.

The Emcomat E160 electronic lathe with 'Easy Cycle' control was developed for lathes with a height above centres of up to 160mm and a distance between centres of up to 1000mm.

It is suited very well for small-scale and industrial production of single parts as well as for model construction and mould making.

Also small series requiring repetitive accuracy can be produced efficiently with the E 160.

In comparable products on the market the customer is offered some functions that are scarcely used, whereas the 'Easy Cycle' is configured according to customer needs.

This is reflected by the significantly lower complexity for the customer according to the slogan 'The customers buy what they really need'.

The extremely clear structure of the cycle control provides a major contribution in this respect.

Due to the high-performance Teach-In control, programming becomes 'child's play' even for programming beginners or users lacking routine.

* 'Easy Cycle' teach-in control - the simplicity and ease of programming and/or operation of the Emcomat-E series is ensured by using the new 'Easy Cycle' Teach-In control in combination with high-performance operating software.

The 'Easy Cycle' offers three operating modes as an option for the customer: manual operation, teach-in mode and the program sequence.

* Manual operation - during manual operation the slide can be moved manually via an intermediate switch or with electronic handwheels.

Entry and processing of cycles is supported graphically in direct exchange with manual machine operation.

* teach-in operation - during teach-in mode, operating cycles can be arranged in sequence.

A graphic simulation of the sequence is carried out directly after data entry.

The cycles are processed immediately after entry.

The operating cycles can be stored and recalled.

The program sequence offers the possibility to have cycle or DIN programs processed in single or sequential block operation.

During programming the 'Easy Cycle' allows programming of a cycle is carried out interactively and with graphic support.

Thus, the customer benefits from user-friendly operation which is clearly understandable due to its clearness for beginners and users lacking routine, said HK Technologies.

A large number of processing cycles that can be freely combined into a programme are available to the customer, as follows.

* Cycles for single and multiple-threaded axially parallel and tapering threads.

* Longitudinal turning and facing cycles.

* Cut-in/cut-off cycles.

* Threading cycles with automatic repetition, multiple threads.

* Radius/taper cycles.

* Drilling and screw-tapping cycle.

* Free contour cycle.

* Contour editor with graphic support with the help of which the entire surface and composition of the workpiece to be machined can be determined.

* Automatic insertion of chamfers and radii - sharp edges can thus be chamfered and rounded.

* Naturally, the cycles can be stored - time-consuming reprogramming is eliminated.

* Any number of cycles can be arranged one after the other in one program.

Additionally, the cycles can be combined with ISO programming.

Thus, the workpiece can be finished completely.

With interactive contour programming, the contour of the workpieces can be defined with linear and circular contour elements.

Entered contour elements are displayed immediately and lacking coordinates are calculated on the spot.

When several solutions are possible, all of them are displayed graphically, and the user makes the selection.

Chamfers, radii's and form elements can be entered during contour creation and overlaid later on.

Programming is regulated according to DIN standard; DIN programs can be created directly.

The nominal positions are indicated in Cartesian coordinates in absolute dimensions.

Entry and display refer to mm or inch.

The user is offered a large range of tool corrections, as follows.

* The tool tip position in the X/Z level can be corrected.

The fine correction of the tools is carried out via handwheel by taking over the correction values in the tool table.

Furthermore, the 'Easy Cycle' is equipped with a cutter and miller radius compensation.

* Any number of tools together with a tool description can be entered into the tool table.

Tool entry is carried out with graphic support.

* Within the framework of test graphics individual cycles or the cycle or DIN programs created can be simulated graphically.

This is facilitated by the two-dimensional line graphics with zoom function for enlargement and/or reduction of sections - to create a timetable for the production of small series, the customer can have the processing time analyzed and have the production time calculated.

* Data exchange is carried out via an integrated USB interface.

Presently, the following dialogue languages are available: German, English, French, Italian, Spanish, Dutch and Czech.

* Operating panel - all relevant data such as X and Z position, spindle speed, tool memory, feeds and constant cutting speed are shown clearly on the 12.1in TFT-active matrix colour screen.

All functions for manual and automatic machine operation are arranged on the swivelable operating panel of ergonomic design.

Two electronic handwheels for the X and Z axis are used for manual processing.

* ISO programming - ISO programming is carried out via G and M commands.

The speed can be adjusted via an S command.

Zero point shifts can be programmed.

Cycle and ISO programming can be combined with each other.

* Teach-in operation - the intelligent control is able to store and take over values.

Tools - the tool memory offers space for 999 tools.

Thus, the customer has a large range of machining possibilities to produce the workpiece.

Program memory + interface details are as follows.

* 256MB program memory.

* USB interface.

Technical details/machine concept - Emcomat-E 160 widens the very successful Emcomat series, the range of multiply proven EMCO lathes by providing 160mm height above centres and 1000mm distance between centres in the work area.

* Machine base - the robust cast design features heavy ribs for low-vibration machining.

This consequently leads to higher precision.

The high-quality machine and the axis drives are reflected in hardened (HRC 50) and ground guides.

* The counter guides are provided with a high quality Turcite coating which provides increased protection against wear.

* Axis movement is carried out via ground circulating ballscrews, due to which the customer achieves maximum precision via increased positioning accuracy.

The circulating ball spindles are driven by AC motors with digital drives.

* Electronic hand wheels are available for manual axes operation.

* The main spindle is equipped with a Camlock support (size 5) featuring a quick-lock device according to DIN 55029.

* The highly precise spindle bearings are lubricated for life with special grease.

The AC main motor offers a constant output of 7.5kW of 40-4000 rev/min without intermediate gearing.

* The constant cutting speed adjusts the speed to the current turning diameter of the workpiece to be machined.

* The Emcomat E-160 complies with top safety regulations.

* All pinching hazards are eliminated by covers.

The chip protection cover of the working zone is equipped with movable chip guard doors.

The control circuit voltage is 24V (DC).

* An EMERGENCY-OFF key is installed.

Mechanics and electrics are in accordance with the currently valid European safety standards (CE).

* Lubrication - an all-automatic lubrication of X and Z guides and the circulating ball spindles optimize the use of lubricants.

* The hardened and ground guides HB>380 as well as the main spindle bearings are lubricated for life.

Range of accessories - the range of accessories contains a number of features which facilitate the machining of the workpiece for the customer and offer a whole range of different machining possibilities.

This range includes stationary supports, different tool holding fixture systems, driving centres, chucks, face plates, etc.

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