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O I L F I E L D T E C H N O L O G Y A N D
V E H I C U L A R H Y D R A U L I C S
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C O M P L E T E M A N U F A C T U R I N G S Y S T E M S
EMAG can look back on many years of exper ience in the machin ing of o i l f ie ld components (O i l Country Tabular Goods [OCTG] ) . In fact , the company began to bu i ld NC manufactur ing systems for the o i l f ie ld indust ry as ear ly as 1976. Even then, customers were look ing for a so lut ion in complete manufactur ing systems for cou-p l ing s leeves , wi th operat ions inc lud ing sawing, heat t reatment , turn ing , threading, gauging and washing – everyth ing fu l ly in ter l inked and fu l ly automated. Th is paved the way to a new technology.
. . . f o r t h e m a c h i n i n g o f t u b e s , c o u p l i n g s l e e v e s a n d c a p s
Besides machines for the manufacture of coupl ing s leeves , EMAG also developed machines and manufactur ing systems for tube ends . Today, EMAG suppl ies whole product ion l ines for the complete-machi -n ing of tubes and coupl ing s leeves inc lu-d ing caps .
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T U R N K E Y S Y S T E M S
Today, product ion l ines for the machin ing of tubes , coupl ing s leeves and caps cover a var iety of manufactur ing processes .Apart f rom CNC machines for threading work , there are automat ic c i rcu lar saws, hydraul ic presses produc ing raw par ts for thread protectors and n ipp les , washing machines for coupl ing s leeves , loading p i ts for tube bundles , mandre l test fac i l i t ies , co l lect ion p i ts for tube re jects , tube storage l ines , s tat ions for v isual thread inspect ion , non-dest ruct ive tests , coupl ing s leeve assembly l ines , s tat ions for the
Many manufactur ing sectors combined
fi tment of thread protectors and n ipp les , automat ic test presses , coat ing machines , dry beds , length measur ing systems, weig-h ing s tat ions , emboss ing s tat ions , r ing mark ing dev ices , s tack ing and bundl ing fac i l i t ies and last , but by no means least , the cent ra l cont ro l system for the whole process .
Complete-machining of tubes
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W E H A V E T H E R I G H T S O L U T I O N F O R T H E M A C H I N I N G O F . . .
. . . tube ends
. . . coup l ing s leeves and too l jo in ts
. . . rock b i t cones
. . . pump components
. . . veh icu la r hydrau l i cs components
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EMAG machines of fer these advantages :
◆ Modular des ign
◆ Very s turdy, v ibrat ion- res is tant machine base in h igh qual i ty MINERALIT ® polymer grani te
◆ Powerfu l , d i rect -dr iven sp ind le motors
◆ D i rect - index ing too l ing systems
◆ H igh-prec is ion , pre loaded l inear ro l le r gu ides for maximum prec is ion and great dynamic
◆ Absolute measur ing systems for constant ly mainta ined accuracy
◆ F lu id-cooled, temperature-cont ro l led main assembl ies – inc lud ing sp ind le motor, too l ing system and e lect r ica l cabinet – as the bas is for h ighest workp iece qual i ty
◆ Safe , no-wear, maintenance f ree machin ing area envelope
◆ Ideal ch ip f low condi t ions , wi th the ch ips fa l l ing to the bot tom
This is the ideal p lat form for mul t i - funct ional manufactur ing
so lut ions – whether s ing le- or mul t i -sp ind le – up to and
inc lud ing fu l ly automated product ion systems.
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M A C H I N I N G T U B E E N D S W I T H . . .
Many years o f exper ience in the mach in ing o f o i l f ie ld components
The new USC ser ies of fers a l l the advan-tages of a modern machine too l for the machin ing of a l l th readed connectors in the OCTG sector.
u API thread on an ascending tube,
machined ona USC 11
The machines – of fered in three s i zes : USC 11, USC 21 and USC 31 – represent a ta i lo r-made so lut ion for the machin ing of tube ends ( tubes , cas ings ) .
Range of appl icat ion :
◆ Tube d iameters f rom 40 to 508 mm (1 .66“ to 20“ )
◆ Tube lengths of up to 18 m
◆ A l l common threads to in ternat ional s tandards , a lso to propr ietary s tandards such as API , GOST, VAM, BDS and others
◆ Complete-machin ing of the tube ends , wi th automat ic tube t ranspor t systems that do not requi re reset t ing
u Casings with external
thread machined on USC 21
D i rect -dr iven motor sp ind les wi th
◆ a power rat ing of up to 180 kW
◆ a torque of up to 12 ,000 Nm
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The par t icu lar advantages of th is ser ies of machines are :
◆ Main sp ind le wi th a max capac i ty of 550 mm
◆ 2 compound s l ides wi th 4-stat ion f la t -bed tur ret ; a l l too l ing systems can be accommodated
◆ A l ternat ive ly : 12-stat ion d isc- type tur ret to VDI 40 or VDI 50
◆ Tru ing at tachment for tube ends
◆ Use of f ront and rear end chucks for opt imal c lamping – hydraul ica l ly, pneumat ica l ly or mechanica l ly operated
◆ H igh motor power and h igh torque rat ing on the main sp ind le
◆ Dur ing machin ing , the ins ide of the tube is sealed against the ingress of ch ips and coolant
◆ H igh degree of operator- f r iendly, low-maintenance automat ion
◆ Maximum stabi l i ty
Mach in ing both ends o f a tube
. . . M A C H I N E S O F T H E U S C S E R I E S
u Truing of
the tube end
t USC21with machine-specific tube handling system
u The tube end is sealedagainst the ingress of
chips and coolantduring machining
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M A C H I N I N G C O U P L I N G S L E E V E S A N D . . .
Bespoke so lut ions for every requi rement , wi th machine des igns – such as center dr ive machines of the USC ser ies , o r VSC and VLC ver t ica l turn ing machines – and f rame s i zes for a l l commonly found cou-p l ing s leeves in today ‘s o i l f ie lds .
A l w a y s t h e m o s t e c o n o m i c a l s o l u t i o n
p Machining of coupling sleeves – both ends simultaneously –on a USC 27
◆ Reduced machin ing t imes through s imul taneous complete machin ing of both ends of the workpiece
◆ H ighest prec is ion and concentr ic i ty o f the s imul taneously machined threads
◆ Fu l ly automated workhandl ing min imises id le t imes
◆ Wide range of appl icat ions : Coupl ing s leeve d iameters 40 - 508 mm Workpiece lengths 80 - 1270 mm
◆ D i rect -dr iven motor sp ind les wi th speeds of max 1 ,000 rpm Power rat ing up to 120 kW
The advantages of work ing with center dr ive machines are :
The USC 17, USC 27 and USC 37 center dr ive machines s tand for ef f ic iency in the s imul taneous machin ing of both s ides of coupl ing s leeves and too l jo ints wi th threads to API , GOST, VAM, BDS and other company-spec i f ic s tandards .
The principle of machining coupling sleeves on USC 17/27/37
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. . . T O O L J O I N T S O N U S C , V S C A N D V L C
The machin ing of coupl ing s leeves and too l jo ints on the VSC – s ing le- or twin-sp ind le vers ion – and the VLC a lso of fers these wel l -establ ished advantages :
◆ The machine loads i tse l f through the p ick-up sp ind le
◆ Shor test t rave ls , resu l t ing in shor test loading/unloading t imes
◆ Ideal ch ip f low condi t ions
◆ Workpieces measured outs ide the machin ing area as par t o f the same set -up
◆ Reduced footpr int
q The VSC series for the machining of smaller and medium size coupling sleeves
p VLC 800, used to machine
the larger coupling sleeves
q USC 27, for the machining of coupling sleeves
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C O M P L E T E - M A C H I N I N G O F R O C K B I T C O N E S . . .
Tai lor-made des igns and f rame s i zes f rom the VSC, VLC and BA ser ies of machines are a lso avai lab le for the machin ing of rock b i t cones .
F rom raw par t to f in ish-machined component – a l l operat ions inc luded
q Internal machining of the bearing journals on a VSC 400 (machine shown in pick-up position)
t Carbide tipped rock bit cone
q BA 400-2 for the drilling of stud holes in rock bit cones
The rock b i t cones are pre-machined inter-na l ly and external ly in two set -ups on machines of the VSC ser ies .
The appl icat ion of c lever ly thought-out loading concepts ensures that the machi -nes can be quick ly reset to accommodate a var iety of workp iece s i zes .
Machin ing centers f rom EMAG SW machine the prec is ion s tud holes and mi l l the pre-forged cut t ing teeth .
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. . . O N V S C , V S C D S , V L C A N D B A
The bear ing journals of the rock b i t cones are hard- turned on VSC machines and/or ground on machines of the VSC DS ser ies . Rapid loading and unloading is accom-pl ished by the p ick-up sp ind le equipped with a spec ia l ax ia l (pot ) chuck . Even var iat ions in the external contour can thus be secure ly c lamped, guaranteeing h ighest prec is ion of the internal contour.
Internal machining of bearing journals on a VSC 250 or VSC 400 p
p An external view of rock bit cones and a view of the finish-machined internal bearing journal
The VLC ser ies is used to machine rock b i t cones and rock b i t head seg-ments qu ick ly and economical ly. The use of a Y-ax is in conjunct ion with dr i l l ing/mi l l ing at tachments and gr in-d ing sp ind les prov ides for cost -ef fec-t ive combinat ion- and complete-machin ing .
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VSC DUO – the h igh ly f lex ib le twin-sp ind le automat ic for a var iety of operat ions .
The DUO features two separate machin ing areas and independent ly programmable overhead s l ides . Both sp ind les can car ry out the same machin ing cyc les s imul ta-neously or d i f ferent ones independent ly.
M A C H I N I N G O F P U M P C O M P O N E N T S O N V L , V S CA N D V S C D U O . . .
Pump components such as impel lers , hous ings and ta i l p ieces in d i f ferent s i zes are complete-machined on f lex ib le s ing le or in ter l inked mul t ip les of machines .
The d is t inguish ing features of the VL 3 and VL 5 , the p ick-up turn ing machines for chucked components of 30 to 220 mm diameter, a re :
◆ H igh output rates
◆ Constant ly mainta ined accuracy and operat ional re l iab i l i ty
◆ Automat ic workpiece changeover in the shor test poss ib le t ime
◆ In tegrated automat ion
◆ H igh degree of ava i lab i l i ty
◆ Very shor t ch ip- to-ch ip t imes
◆ Smal l footpr int
O u t s t a n d i n g l y o p e r a t o r a n d m a i n t e n a n c e f r i e n d l y
t 2 machines of the VL 3 series, connected by a transfer station
u Pump impeller and
pump housing
p VSC 400 DUO for the simultaneous execution of OP 10 and OP 20
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. . . A N D V E H I C U L A R H Y D R A U L I C S C O M P O N E N T S O N T H E U S C
F l e x i b l e m a n u f a c t u r i n g s y s t e m f o r a v a r i e t y o f d i a m e t e r s
The wel l -establ ished machine des igns USC 11, USC 21 and USC 31 produce hydraul ic cy l inders and p is tons of the h ighest qual i -ty, wi th hard ly any need for reset t ing and at excel lent product iv i ty rates f rom as few as a batch s i ze of 1 .
Dependent on requi rements , f lex ib le work-p iece loading can be fu l ly automated. The t ranspor t system adapts to the task in hand without hav ing to be reset . Se l f -cent r ing s teadies pos i t ion the work-p iece at speeds of up to 1 ,800 rpm.
u Hydraulic cylinder
t Piston rod
p USC 21 for the machining of vehicular hydraulics components
t Host computers ensure the automation system resets itself
EMAG Salach Maschinenfabrik GmbHAustrasse 24D-73084 SalachTel.: +49(0)7162/17-0 Fax: +49(0)7162/17-270E-mail: [email protected]
EMAG Maschinenfabrik GmbHVertrieb + ServiceNiederlassung KölnRobert-Perthel-Strasse 79D-50739 KölnTel.: +49(0)221/126 152-0Fax: +49(0)221/126 152-19E-mail: [email protected]
EMAG Maschinenfabrik GmbHVertrieb + ServiceNiederlassung FrankfurtOrber Strasse 8D-60386 Frankfurt/MainTel.: +49(0)69/40802-0Fax: +49(0)69/40802-412E-mail: [email protected]
EMAG Leipzig Maschinenfabrik GmbHPittlerstrasse 26D-04159 LeipzigTel.: +49(0)341/46 66-0Fax: +49(0)341/46 66-114E-mail: [email protected]
EMAG-Werkzeugmaschinen Vertrieb GmbHHerringhauser Strasse 39D-32051 HerfordTel.: +49(0)52 21/93 33-0Fax: +49(0)52 21/93 33-25E-mail: [email protected]
NODIER EMAG INDUSTRIE S.A.Service commercial:38, rue André Lebourblanc - B.P. 26F-78592 Noisy le Roi cedexTel.: +33(0)1/30.80.47.70Fax: +33(0)1/30.80.47.69E-mail: [email protected]
EMAG MAQUINAS HERRAMIENTA S.L.Pasaje Arrahona, No. 18Centro Industrial SantigaE-08210 Barberà del Vallès (Barcelona) Tel.: +34(0)93 719 50-80Fax: +34(0)93 729 71-07E-mail: [email protected]
ZETA EMAG SpAViale Longarone 41/bI-20080 Zibido S.Giacomo (MI)Tel.: +39 02-905942-1Fax: +39 02-905942-21E-mail: [email protected]
EMAG (UK) Ltd.Chestnut House, Kingswood Business ParkHolyhead RoadAlbrightonGB-Wolverhampton WV7 3AUTel.: +44(0)1902/376090Fax: +44(0)1902/376091E-mail: [email protected]
EMAG Salach Maschinenfabrik GmbHVertrieb und ServiceNiederlassung ÖsterreichDorfstrasse 343A-5423 St. KolomanTel: +43(0)664/4101063Fax: +43(0)6241/640E-mail: [email protected]
EMAG Salach Maschinenfabrik GmbHVejle KontorHorsvangen 31DK-7120 Vejle ØTel.: +45 75 854 854Fax: +45 75 81 62 76E-mail: [email protected]
KP-EMAGul.Butlerova 17RU-117342 MoskauTel.: +007/495/3302574Fax: +007/495/3302574E-mail: [email protected]
EMAG L.L.C.38800 Grand River AvenueFarmington Hills, MI 48335, USATel.: +1(248) 477-7440Fax: +1(248) 477-7784E-mail: [email protected]
EMAG MEXICOColina de la Umbria #1053140 Boulevares Naucalpan Edo. de MèxicoTel.: +52 55 5 3742665Fax: +52 55 5 3742664E-mail: [email protected]
EMAG DO BRASIL Ltda.Rua Felix Guilhem, 107205069000- Tel.: +55(0)11 3906 9238Fax: +55(0)11 3906 9238E-mail: [email protected]
EMAG SOUTH AFRICAP.O. Box 2900Kempton Park 1620Tel.: +27(0)11/3935070Fax: +27(0)11/3935064E-mail: [email protected]
EMAG Machine Tool (Taicang) Co., Ltd.Room 2315, B Far east International Plaza,No. 317 Xianxia Rd.Shanghai 200051, ChinaTel.: +86(0)21 62 35 15-20/21/22/23 Fax: +86(0)21 62 35 01 18E-mail: [email protected]
EMAG INDIA Pvt. Ltd.#12, 12th Main Street, 17th CrossMalleswaramBangalore - 560 055, IndiaTel.: +91(0)80 2344 7498 / 41281692Fax: +91(0)80 2344 7498E-mail: [email protected]
EMAG KOREA Ltd.Rm806, Lotte IT Castle 1st B/D550-1, Kasan-dongKumchun-guKOR-153-803 Seoul/KoreaTel.: +82-2-2026-7660Fax: +82-2-2026-7670E-mail: [email protected]
TAKAMAZ EMAG Co., Ltd.1-8 Asahigaoka Hakusan Ishikawa 924-0004 JapanTel.: +81(0)76-274-1409Fax: +81(0)76-274-8530E-mail: [email protected]
EMAG Holding GmbHAustrasse 24D-73084 SalachTel.: +49(0)7162/17-0 Fax: +49(0)7162/17-170E-mail: [email protected]
www.emag.com
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T H E EMAG G R O U P – W O R L D - W I D E PA R T N E R I N F O R WA R D L O O K I N G P R O D U C T I O N T E C H N I Q U E S
