Sometimes it's the projects where everything is under time pressure that are the most challenging. This was the case when our team was called to the north of Germany to overhaul the 5.5-ton X-axis slide of an EMAG VLC 800 machining center. At first glance, the job seemed clear-cut, but as soon as we arrived it became clear that this was not going to be an easy task.
The challenge begins:
Even the removal was a challenge that required all our skills. With only 0.2 meters of remaining ceiling height, we had to lower the massive sled safely from a height of 4.5 meters. Every centimeter counted, and precision was the top priority. Fortunately, the Pfaff company was on hand with a special electric vehicle that helped us to safely dismantle the carriage and transport it to our assembly center in 34311 Naumburg.
But that was just the beginning. A list of challenging tasks awaited us in Naumburg: replacing the 3,700 mm long INA linear guide, repairing the ball screw of the X-axis and replacing the Z-axis ball screw and linear guide. And all under immense time pressure – because the machine had to be up and running again within 18 days. There was no room for delays.
You are currently viewing a placeholder content from YouTube. To access the actual content, click the button below. Please note that doing so will share data with third-party providers.
The race against time:
In addition to the repair work, the procurement of spare parts and logistics were also major challenges. Some parts were difficult to obtain and we had to improvise. In some cases, we even resorted to 3D printing to produce spare parts in time. However, as is usual with such projects, we encountered unexpected problems: The local hydraulic supplier installed the wrong lines, which led to significant problems in the hydraulic kinematics.
Teamwork and determination:
Despite these setbacks, our team was not deterred. Thanks to close cooperation with our suppliers such as INA and Bosch Rexroth Service, as well as the flexibility and determination of our team, we were able to solve the problems in good time.
Our project manager Alexander Greb recalls:
“It was one of the most challenging projects we have had in recent times. The time pressure was enormous and the logistical hurdles, especially with the hydraulic lines, were not easy to overcome. But thanks to the great cooperation and tireless efforts of the team, we managed to complete everything on time.”
The result:
After 21 days, the machine was ready for use again. The test run and trial part machining confirmed that the machine was working at full power and precision again – a moment we are all proud of.
Fazit:
This project was a real tour de force that showed that we can achieve great things together, even under extreme pressure. We will continue to support our customer and ensure that the machine runs reliably in the long term.
Would you like to find out more about us or our EMAG service?
Contact us at: emag@egin-heinisch.de
Your SPINDELDOCTOR team – successful together, in every situation!
Alexander Greb Erdem Akin
Emag vertical turning machines:
402282 Emag HG 204 horizontal grinding
402216 Emag HSC 800 vertical turning
400626 Emag VL 3 vertical turning
401098 Emag VL 5 vertical turning
402890 Emag VL 6 vertical turning
402828 Emag VLC 100 GT vertical turning
401147 Emag VLC 800 vertical turning
402202 Emag VMC 300 MT vertical turning
400257 Emag VSC 200 vertical turning
400630 Emag VSC 200 TRIO vertical turning
401111 Emag VSC 250 vertical turning
402167 Emag VSC 250 DUO vertical turning
402249 Emag VSC 315 vertical turning
402461 Emag VSC 315 KBS vertical turning
401810 Emag VSC 350 DUO vertical turning
400279 Emag VSC 400 DD vertical turning
401948 Emag VSC 7 vertical turning
Everything you always wanted to know about EMAG Maschinenfabrik:
EMAG was founded in 1867 and developed from a small forging company into one of the world's leading manufacturers of machine tools. With the introduction of vertical turning technology in 1992, EMAG revolutionised metalworking. The company offers a wide range of products such as vertical turning machines, grinding machines, milling machines, drilling machines and laser machines. Machine types include the VSC Series (vertical turning machines), VL Series (pick-up turning machines), VT Series (vertical turning machines for shafts) and the EMAG Modular Series (multifunctional production machines).
Technological advantages:
EMAG offers maximum precision, space-saving design and the integration of several machining steps in one machine. The machines are ideal for automated series production and can be integrated into Industry 4.0 solutions. EMAG focuses on energy-efficient and sustainable manufacturing technologies, especially for the production of components for electromobility.
Number of employees:
EMAG employs over 3,500 people worldwide and is one of the most important employers in the machine tool industry.
Companies belonging to the EMAG Group:
The EMAG Group comprises several specialised subsidiaries, including:
EMAG ECM (Electrochemical Metal Machining),
EMAG Eldec (induction technology),
EMAG Salach Maschinenfabrik GmbH (headquarters),
EMAG Leipzig Maschinenfabrik GmbH (machining solutions for large workpieces),
EMAG Automation GmbH (automation solutions).
Turnover:
EMAG has an annual turnover of over 500 million euros, making it one of the companies with the highest turnover in the industry.
Ownership structure:
EMAG is a privately managed company. The majority of the shares are held by the Stoll family, the descendants of the founders. However, there are also management shareholdings that involve the management team and ensure close ties to the company's objectives. This ownership structure enables EMAG to plan independently and for the long term, which contributes to the company's innovative strength and flexibility.
