Today’s manufacturing environment is more challenging than ever. Global competition is intense, price pressures are constant, and customers demand higher quality, shorter lead times, and maximum flexibility. Leveraging its global technological expertise, EMAG provides tailored solutions for a wide range of manufacturing challenges. “Whether delivering a single machine, a multi-technology system, a complete production cell, or a fully integrated line, the goal remains the same. Mr. Hartmut von Fugler, Managing Director of EMAG System GmbH (Thailand), emphasized that this core objective is to engineer the optimal solution for each customer’s specific application.”
To that end, EMAG hosted a technology seminar at its Chonburi office in late March, drawing technology enthusiasts from across Thailand’s metalworking industry. EMAG showcased a series of compelling processing examples across various technologies, followed by in-depth discussions on customer-specific challenges. The event was held in a relaxed and welcoming atmosphere, fostering an environment where participants could network and exchange ideas while enjoying curated food and beverages
A major highlight of the event was the showcase of three distinctive EMAG technologies—innovations that remain unmatched in the global market for their precision and efficiency.
ELC 6i – Empowering Industrial Manufacturing with Next-Generation Laser Welding
Leveraging over 20 years of expertise in laser welding for powertrain components, EMAG has developed a standardized system tailored for optimized process sequences and individual automation. The ELC 6i integrates up to six process steps into a single compact machine, featuring parallel processing that minimizes non-productive time to achieve cycle times of less than 20 seconds.
Key Advantages:
- Optimized Footprint: Significantly reduces floor space requirements compared to standalone units, maximizing factory layout efficiency.
- Streamlined Control: Features a centralized CNC system that simplifies programming and drastically reduces software complexity for easier operation.
- Enhanced Cost Efficiency: Delivers high-performance production with lower initial investment costs (CAPEX) and improved long-term ROI.
A prime example of the high-productivity ELC 6i system is the laser welding of differential housings to ring gears. To reduce weight, streamline manufacturing, and enhance quality—while ultimately driving down costs—laser welding is increasingly replacing traditional bolting methods for these components.
The illustration shows the complete process chain of the ELC 6i – from laser cleaning to joining and laser welding. Preheating and testing processes as well as laser marking for component identification can be integrated as an option. All steps are automated within the system.
VLC350GT – High precision complete machining: in one single setup
The machining of thin-walled, hardened, and tempered workpieces—with round or even elliptical geometries—presents several manufacturing challenges. These include deformation caused by clamping forces, process-related heat generation, and geometric complexity, all of which are further compounded by the process chain, such as sequential machining in multiple setups.
- The “Complete Machining” Advantage: By integrating turning, milling, and grinding into a single machine tool, EMAG delivers pivotal manufacturing benefits:
- Unrivaled Precision & Integrity: Eliminates re-clamping errors and minimizes tolerance chains by enabling the simultaneous production of reference surfaces and complex functional geometries.
- Maximum Process Efficiency: Significantly reduces workpiece lead times by streamlining the production flow and eliminating redundant handling and setup procedures.
- Superior Accuracy: The VLC 350 GT’s vertical machine concept integrates diverse technologies in a single setup, ensuring uncompromising shape and dimensional accuracy for even the most complex workpieces.
View into the work area of the VLC 350 GT. The machine combines turning, milling and grinding in a single setup and guarantees maximum shape and dimensional accuracy for complex workpieces.
GP500H : Precision and efficiency in grinding double helical gears
The EMAG GP 500 H was developed for the precision grinding of internal and external gears. For aerospace, helicopter and general gear manufacturing, it guarantees the highest quality, especially for components that have many interfering contours due to their design. The compact design and 5-axis technology guarantee precise results.
Double helical gears are specialized components featuring two helical gears arranged in a mirrored configuration on the shaft. This design is capable of sustaining high loads and proves significantly more cost-effective to manufacture than continuous herringbone profiles.
Production requires highly flexible machine tools, as interfering contours often preclude the use of large grinding wheels. The GP 500 H from EMAG SU provides an ideal solution, accommodating various wheel sizes for both internal and external grinding. Furthermore, its rapid changeover times make it exceptionally well-suited for the aerospace industry.
Beyond advanced technology, the GP 500 H delivers high operational efficiency. Fast changeovers and integrated workpiece inspection—via a swivel-out measuring probe—significantly reduce overhead costs. In small-batch production, these savings often surpass the cost of the finishing operation itself.”
Work area of the GP 500 H 5-axis grinding machine for machining double helical gears. Especially developed for complex helicopter gearboxes with the highest reliability requirements. Compact design enables high torque transmission with minimum installation space.
Navigating the Future of Manufacturing: Reflections on Innovation and Partnership
Participants were introduced to innovative, state-of-the-art manufacturing methods and advanced machinery spanning diverse technological areas, including turning, milling, grinding, gear machining, laser welding, and electrochemical machining.
Following the presentations, attendees engaged in dynamic discussions—sharing experiences, exchanging ideas, and finding inspiration for new approaches to modern manufacturing challenges. With its extensive technological portfolio and decades of expertise, EMAG stands as the ideal partner for the precision machining of components in series production. Mr Hartmut concluded with a warm smile to build confidence among the customers.
Article by: MEGATech Thailand & EMAG Systems GmbH (Thailand) << Click here
