Getting into gear with a retrofitted VSC 400 DDS

The VSC 400 DDS EMAG retrofitted machine at EWS Weigele with tool shuttle for external tool preparation - the basis for reliable hard machining of gears

EMAG, has modernised a VSC 400 DDS and adapted it to its individual production requirements. This has created a manufacturing solution that is at least on a par with a new investment in terms of process reliability, availability and cost-effectiveness. The decisive difference — the retrofit was not chosen out of necessity, but as a deliberate strategy.

EWS Weigele manufactures high-precision tool holder systems with an in-house production depth of 90-95% — from the raw material to the assembled product. An essential part of this production chain is the manufacture of bevel gears and spur gears for driven tool units. The typical batch size structure is two to five workpieces per order.

With this high level of vertical integration, any machine downtime has a direct impact on delivery capability. When the existing gear production had to be modernised, the central question was not only ‘Which technology?’, but above all ‘How fast?’.

The decision to retrofit the VSC 400 DDS was based on a clear calculation — the delivery time for a comparable new machine would have been eight to 12 months, plus several weeks for commissioning and process qualification. The retrofit made it possible to resume production after just a few weeks. The basic mechanical structure of the machine was intact and the employees were familiar with the machine concept — ideal conditions for a quick modernisation.

Up-to-date CNC system
The retrofit included the complete technological modernisation while retaining the basic mechanical structure: Control technology — replacement with an up-to-date CNC system with extended functions and interfaces for production data acquisition. The new control system enables direct integration into the digital production management system.

Pictured left: Bevel gears on workpiece carriers in the rotary indexing conveyor of the VSC 400 DDS - the pick-up spindle removes the workpiece with precision and reproducibility for hard machining at EWS

Automation interfaces — adaptation of the machine-side interfaces to the Varia quick-change system used at the factory and the workpiece feed via a rotary indexing conveyor belt.he capital investments were around 70% of a comparable new machine — with full technological performance.

Pick-up principle — process stability through mechanical guidance. The VSC 400 DDS is based on the concept of a vertical pick-up turning machine with a pick-up spindle. The workpiece is not inserted into a chuck manually or by a robot, but is picked up from a defined position by the work spindle itself. The gears are located on a workpiece carrier in the rotary indexing conveyor system. The work spindle grips the workpiece from the pick-up station and transports it into the work area.

This process eliminates insertion inaccuracies. The repeat accuracy of the workpiece pick-up is in the range of a few micrometers, as the positioning is mechanically defined by the workpiece carrier geometry. In contrast to robot systems with grippers, insertion errors due to contamination, workpiece mix-ups or recognition errors are ruled out by design.

Process stability
The process stability is demonstrated in practice: At EWS, the complete hard machining of the gears is carried out on the VSC 400 DDS - hard turning with PCD or CBN tools, grinding of defined functional surfaces and final finishing. Batches of several dozen workpieces are produced without intermediate measurement. The required tolerances are maintained over the entire batch.

With batches of two to five workpieces and processing times of 4 to 7min per component, the pure processing time per batch is between 20 and 100min — conventional set-up times of 2hr would destroy the economic efficiency.

EWS uses its own Varia quick-change system, available in three standard sizes — VX3, VX4, V5. The system is based on a bayonet lock with a defined tightening torque. The repeat accuracy is in the range of a few micrometers. Both static and driven tools can be accommodated.

The tool change takes place according to a well thought-out sequence — while the machine is running, the tools for the next job are installed in Varia holders outside the machine, measured and inserted into a tool shuttle. The tool data is transferred to the control system. CAM programming is carried out with digital twins of the tools so that collision checks are carried out before the physical changeover.

Pictured right: Tools in the Varia quick-change system - externally set up and measured for fast tool changes and minimal machine downtimes

Once the current job is complete, the tools are removed from the tool shuttle and inserted into the turret positions via the bayonet lock. The mechanical changing process takes a few seconds per tool. The machine downtime for job changes is reduced to 5 to 10min for a complete turret.

The rotary indexing conveyor system holds workpieces for up to 3hr of unmanned operation. The workpieces are placed on workpiece carriers, which ensure a defined contact surface and positioning. The operator loads the conveyor belt at the start of the shift and can devote himself to other activities during the processing time. This form of ‘flexible automation’ enables economical machine operation even with small batches - a decisive difference to large-scale automation, where dedicated systems only pay for themselves with high quantities.

End-to-end digital process
Production is based on an end-to-end digital process. Every tool and every tool holder exists as a digital twin in the system. The NC programs are created with CAM software, using not abstract tool geometries but the exact digital models of the tool holders actually used.

This enables collision checking as early as the programming phase, tool path optimisation based on actual tool dimensions and automatic generation of setup data. The operator receives a digital set-up list that specifies exactly which tools are to be set up and in which order. This system minimises set-up errors and significantly reduces the training time for new employees.

At EWS, quality is not ensured by measuring, but by process stability. The combination of process stability of the pick-up principle, repeat accuracy of the Varia tool system and thermal stability of the vertical machine enables the production of gears with tolerances in the micrometer range - without 100 percent control.

The statistical process capability is monitored by regular spot checks. Only when the measured values show that the process is stable is individual testing dispensed with. This production strategy significantly reduces lead times and quality assurance costs.

The EWS project shows that retrofitting is not an emergency solution, but can be a technically and economically superior alternative to a new investment - especially if the basic mechanical structure can still be used for decades.

For manufacturing companies with small series production, high quality requirements and high in-house production depth, the concept offers a tried-and-tested approach to modernising production technology.