Connected machines deliver double the bending length and press force – single-machine operation boosts capacity – ToolShuttle with space for 60 meters of tools – shorter set-up and search times, higher productivity bold

The sheet-metal plates that demonstrate the power and precision of the TruBend Series 8000 are famously big and fat – and now the TRUMPF machines for bending large-format components can actually deliver twice the performance. How? In a tandem version. Bending expert Babette Kopp from TRUMPF Machine Tools in Teningen explains: “If you utilize two machines as just one, it gives you the option of doubling the bending length, that is, up to 8100 millimeters, and also of doubling the press force – and that adds up to 10,000 kilonewtons. In other words, the parts portfolio can be expanded significantly, because compared to any stand-alone machine in the 8000 series, the user can bend longer material.”

The tandem version comes as standard with a C-frame with a throat depth of 820 millimeters and a maximum distance between table and press beam of 820 millimeters. This, combined with the fact that the table width is a mere 140 millimeters despite the enormous bending forces, further increases bending flexibility and part variety. Of course, each machine can also be operated individually, for double the capacity with less setup work.

Rapid speed is also no problem in tandem operation

For safe operation in stand-alone mode, the two machines are separated from each other at the push of a button by a protective door. In tandem operation, the door moves back automatically, so that bending can take place along the entire length. To ensure maximum process reliability, the BendGuard safety systems of the two individual machines are connected to one another – so the entire bending length is directly under control on the tandem machine, enabling rapid speed even in connected operation. 

Surface-mounted version for easy installation

Installation of the tandem is uncomplicated because, unlike other large-format bending machines, it arrives as standard in the production hall as a surface-mounted version. Costs for elaborate machine foundations are no longer necessary. Instead, the two stand-alone machines are individually loaded from the truck and simply connected to each other. Here, the tandem partners are fixed together precisely using tensioning screws with fine threads. In addition, the machine tables are bolted using solid connecting elements – ensuring stability and accuracy during tandem operation for the best possible bending results.

Fewer tool changes for more productivity and part variety

With the TruBend Series 8000, high-quality bending is guaranteed by means of mechanical crowning with a precisely adjustable crowning curve. Thanks to the selective adjustment option of the crowning and precise synchronization of both machines, the tandem version offers bending results that are just as good as those of the stand-alone machine. The CNC-controlled crowning ensures constant angle accuracy along the entire bending length.

In contrast to the eight-meter-long stand-alone machine, the TruBend Series 8000 tandem version enables lower tool offset (I-axis) along the entire bending length. This allows a great variety of different bends, and also folds, using the same combination of upper and lower tools. The number of tool changes decreases, while productivity and part variety are both increased.

ToolShuttle – storage space for a full 60 meters of tools

For even more productivity on large-format TRUMPF machines, the ToolShuttle now offers a special storage system for upper and lower tools. Babette Kopp explains: “With the ToolShuttle, users are being given a tooling concept for heavy tools for the first time. It enables simple and ergonomic setup while minimizing setup and search times.” For TRUMPF bending machines in the 8000 Series weighing up to 600 tonnes, the ToolShuttle has room for up to 28 upper and 32 lower tool compartments – that adds up to total storage space for more than 60 meters of tools! In order to avoid tilting of offset tools, special storage compartments ensure correct support. Further storage space is provided by practical drawers in the lower part of the ToolShuttle.

Easy transportation of heavy tools – with the intelligent transfer unit

Via a moveable transfer unit with three tool holders at the top and bottom respectively, the tools are brought to the bending machine. This not only protects the operator’s back: if he equips the upper and lower transfer unit with new tools and moves them to the bending machine, he can also push the tools to be changed into one of the free tool holders at the same time. This means that he can equip and remove tools in just one operation. A useful additional option: The turning unit makes it possible to turn heavy and/or offset tools through 180 degrees without any effort at all.

A high-precision fully automated machine, which takes care of the production itself – this is the new TruLaser Center 7030. It offers highly efficient, automated and synchronous processes from programming to sorted and stacked workpieces. The machine operates with a hybrid drive system to meet the high-level development goal: eliminating all of today’s process hurdles during laser cutting. These include, for example, stoppages due to collisions with tilting parts, microjoin rework, splashing on the underside of the parts, and high programming effort.

The TruLaser Center 7030 moves the sheet metal and the cutting head at the same time and replaces support strips with brushing tables. It can reliably discharge small parts and sort them into containers, dispose of residues and slag, collects, sorts and stacks larger parts at the same time in parallel. In addition, it loads itself on the smallest surface even with raw sheets, stacks residual lattice and is largely programmed automatically. Numerous new, innovative and patented detailed solutions contribute to the coherent overall concept. Heinz-Jürgen Prokop, Managing Director of Development and Purchasing in the TRUMPF Machine Tools Division: “We were increasingly attracted to our customers’ needs, which required solutions for a secure overall process. This was not possible with the established machine concepts, we had to think completely new. ”

High dynamics through additional axis of optics
The TruLaser 7030 Center works with a TruDisk solid-state laser with six kilowatts of laser power. In terms of cutting productivity, it is in no way inferior to today’s high-end machine with flying optics, although the sheet with its relatively high mass is precisely moved over the brush table in the Y direction. This is achieved by two approaches. The sheet – maximum large format with the dimensions 3000 mm x 1500 mm – is moved over the short side. And: The cutting optics, which travel mainly in the X direction, has an additional axis in the Y direction with a travel distance of ± 55 mm. Thus only small masses have to be accelerated in small contours, which allows a high dynamic.

Secure parts support through the mobile “SmartGate”
In a hybrid machine of the support table for the sheet must be divided below the traverse of the cutting head. This results in a gap through which the laser beam can escape downwards, through which slag, nozzles and cutting gas are sucked off. The TRUMPF developers have invented the SmartGate to prevent sheet metal contours and allow highly efficient extraction. Two slides move synchronously with the cutting head. They can vary their distance from one another in order to create differently sized passage openings. With two positive consequences: the sheet metal is reliably supported during the cutting process, while small parts with dimensions up to 160 x 160 mm can be ejected downwards at the same time.

In order to ensure maximum process reliability, a push-out cylinder is installed on the cutting head which ejects the sheet metal parts downwards. The TruTops Boost programming system calculates the ideal ejection point automatically as a function of the part contour. Since the slides form a counter-bearing which is parallel to the plate from below, the workpieces can not be tilted. Residues and slags fall directly into the car or are transported from the machine by a conveyor belt. Gut Sorts a retractable sorting switch, the SortMaster Box Linear distributes it to up to eight containers.

Process-safe removal of parts from the skeletons
for the automated removal of the remaining portions of the skeletons, the TRUMPF experts SmartLift with the components and SortMaster Speed developed an intelligent, completely new, and above all process-safe approach: The cut-away portions are positionable from below via free Pins of the SmartLift with a lifting movement lifted out of the residual lattice – a total of 180 pins, also known as pins, are available. Each one can lift a weight of up to ten kilograms. This results in a much higher force compared to today’s vacuum solutions. At the same time, the SortMaster Speed presses from the top with its suction pads and provides an exact linear guidance during lifting. This makes it possible to reliably prevent tilting in the cutting gap. The two telescopic arms of the SortMaster Speed are equipped with three suction pads each, and can store and stack parts on up to eight Europalettes with a total area of 1.6 by 4.8 meters.

Only minimal cutting interruptions
The optimal positions of pins and suckers calculated TruTops Boost also automatically. This means that both very large and smaller parts can be taken up to check card size. Even complicated or very filigree geometries, which until now have been considered as non-removable, are raised safely and without additional programming effort from the sheet metal. The strategies for removing and cutting the parts are coordinated with each other in such a way that the machine cuts during transport.

Area productivity is now an important decision criterion. An order for the developers of the TruLaser Center 7030 was therefore: Space saving. This is achieved by means of a solution, which includes the transport route of the production hall at times. The machine has three drawer-type carts which can be driven out electrically to the aisle. In the middle carriages, pallets with raw metal stacks of up to 130 mm in height with a maximum weight of three tonnes can be inserted from the aisle. In the same way, there is a carriage for a residual lattice stack with a height of up to 250 mm and a carriage which carries the pallets with cut parts out of the machine. The separation, lifting and loading of the blanking plates into the clamping claws takes place automatically and parallel to the unloading of the residual lattice.
Programming in a single step

the various possibilities and the synchronous interaction of the individual processes have a substantially fully automated programming indispensable. The TruLaser Center 7030 works almost as easily as a printer in the office. If you send a document with the appropriate job data – geometries, number of pieces, material types, sheet thickness – finished parts are sorted and stacked according to order. This includes the boxing of the parts on the sheet, the allocation of the cutting technologies, the removal strategies and the placing of the cut parts on the storage surfaces or the discharge into the containers.
SmartGate, push-out cylinder, pins, sorting switch and SortMaster Speed do not have to be programmed individually. Simulations running in the background take into account the properties of part geometry and material and thus ensure an optimal calculation result. They are supported by the clear order management of the TruTops Boost programming software. Programming is thus carried out in a single step and largely automatically, whereby the programmer can interactively adapt any proposal.
Consistently on the future oriented

The TruLaserCenter 7030 is able to operate over long periods independently and without operator intervention. This and the equipment with all necessary interfaces and functions makes it an ideal industrial 4.0 machine. Many TruConnect solutions can be used directly: The Performance Cockpit provides an overview of relevant production data. The Dot Matrix Code supports the networking of different processing technologies and creates transparency in the traceability of parts. The MobileControl app reduces the operator’s already very small presence time by remote control to a minimum.
With the TruLaser Center 7030, TRUMPF is a manufacturer of sheet metal pallets from all industries that cut sheets with a thickness of one to twelve millimeters thick. The fully automated laser cutting machine can be used in a single layer. With a utilization of two layers, the processing costs decrease by up to 30 percent compared to automated standard machines with solid state lasers. Heinz-Jürgen Prokop summarized: “TRUMPF has always strived to define the state of the art in its core work areas and to provide its customers with competitive advantages. The TruLaser Center 7030 is another proof. “

The laser system manufacturer TRUMPF has made extensive changes to the second generation of its hot forming machine TruLaser Cell 8030th At the trade fair Euro plate in Hanover, the company shows new features that enable the productivity of the plant can be increased by up to 20 percent. Other issues of significance is the so-called x-blast technology that can be machine downtimes and collisions between the cutting nozzle and the workpiece significantly reduced. Main fields of application of the revised TruLaser Cell 8030 is to continue the laser cutting of hot-formed 3D components as they are primarily in the automotive industry.

Fewer collisions thanks to larger nozzle spacing
The innovative x-Blast technology TRUMPF is a trick succeeded: In order to achieve good cutting quality, installed at the processing optic cutting nozzle had been as close as possible to act on the workpiece. The closer the nozzle, however, moves to the workpiece, the greater the risk of contact during the cutting process. And after each contact, the machine stops once, the productivity of the system can be sensitive to fall.

The new x-Blast technology, the working distance between the nozzle and the workpiece can now almost doubled. This reduces the number of nozzles contacts with the component significantly – and that in turn leads to considerably less machine downtime and at the same time to increased productivity. Since it comes with the x-Blast technology to less contacts also the lifetime of a cutting nozzle tenfold increased. Or in other words around: For the customers have to pay only 20 percent of the original cost of cutting nozzles.

Another advantage of the new technology: The process bandwidth doubled. Even with critical 3D geometries, in which the laser has to work under difficult process conditions, the TruLaser Cell 8030 can now cut the component quickly and in very high quality thanks to x-blast technology. With an ever-increasing proportion of automated machines in production, the advantages of x-Blast technology provide the ideal basis for a stable and reproducible component quality.

New functions for more convenience
Advanced TRUMPF has also its optical Butzenerkennung for quality control, called ObserveLine Comfort. It recognizes Schneidbutzen reliably and thereby increases production reliability. Problems caused by the plant operator collisions with trees or component can affect the machine accuracy. With the new feature ObserveLine Professional helps ensure this accuracy over a variably adjustable inspection interval. If the customer wants his machine, for example, at every hundredth component check succeeds – allocated to the individual component – in as low as 0.02 seconds. Thus ObserveLine Professional works almost at neutral and causes no noticeable delay in the production.

The new feature also provides Smart Approach especially when partial trimming of the workpiece improvements. Smart Approach determined accurately and quickly the actual height of the component edge; the laser fires the beam before he stands above the workpiece, and then moves the cutting contour from quickly. Smart Approach increases the productivity of the plant by up to nine percent. Another eleven percent coming from the dynamic drives. TRUMPF has readjusted and optimized the mechanical components at critical points and thus reaches the maximum acceleration of the drives now much faster than before. Overall, the productivity of the TruLaser Cell 8030 increases the 3D cutting of hot-formed components by up to 20 percent. Which laser is used for 3D cutting, can be selected flexibly depending on customer and application requirements. The TruLaser Cell 8030 is available with the proven TRUMPF disk lasers TruDisk 2000 TruDisk 3001 and TruDisk 4001 with two respectively three or four kilowatts of laser power.

Getting started with laser welding is now easier than ever before thanks to tolerant laser welding with the FusionLine technology and the production launch package. New design and software components have made operation even simpler.

Laser welding offers numerous advantages over conventional techniques: better weld quality, a robust bond and faster processing times. Right on time for Euroblech 2016, TRUMPF will be showcasing the TruLaser Weld 5000, a new laser welding cell that greatly simplifies the laser welding process for experts and beginners alike. This is thanks to the FusionLine option, which makes tolerant laser welding possible. It’s a laser welding process using welding wire supply that allows for the welding of components having gaps. Customers can also benefit from TRUMPF’s expertise with the production launch package: on request, TRUMPF experts will assist the user in starting up production for the first series part.

FusionLine – tolerant laser welding
Laser welding is known for its perfect results and high-quality visible seams. However, preparing components for laser welding calls for specific expertise. There ought to be as little tolerance as possible in the design – or at least that is how things were in the past. Now, FusionLine offers an ideal complementary technology that helps users get started. FusionLine makes it possible to compensate for component imperfections in the welding process and even to close gaps of up to 1millimeter in breadth. At the same time, the welding seam results and processing times offered by FusionLine significantly outperform those of components processed using conventional welding techniques. This means that users can take advantage of the perfect combination of laser beam guidance, optics and a weld feed system to perform cost-effective laser welding operations even if their component portfolio is not optimized for laser welding. It is now possible to laser weld an array of parts developed for conventional welding without having to modify them specifically for the purpose. This enables users to manufacture parts true to the drawing, and also more kinds of parts than before.

What is more, customers retain full flexibility. They are free to switch between FusionLine and the conventional laser welding techniques of heat conduction and deep welding with no need to reset the machine. That way, they can manufacture one series of components that isn’t worth modifying for laser welding using FusionLine, then manufacture a subsequent series using heat conduction or deep welding. Users can also switch between techniques on the same component. This allows them to laser weld more components than before, and to make fuller use of their laser welding unit.

Help getting started from TRUMPF experts
Those just getting into laser welding can cut their learning time on the new machine by calling on the support of TRUMPF experts to get started with production. Users consult with a TRUMPF application advisor to choose an example component that will be used to play through the start-up process.

In the course of a three-day workshop either at the customer’s own site or at TRUMPF, users first learn the basics of laser welding and fixture design. This knowledge is then put into practice on the example component they have selected. TRUMPF then designs the fixture while users apply the principles they have learned to create the component in their CAD system. Once the new machine has entered service, a TRUMPF application engineer runs in the component together with the customer. The TRUMPF expert will set up the program and optimize the parameters for the best results. This means that users can see at first hand which principles are important – with reference to a real production component. Plus, the machine is operating productively from the moment it enters service.

Faster welding times thanks to rotary module for shield gas guidance
Shield gas is used in laser welding to ensure as oxide-free a weld as possible. Before, the shield gas has been applied via a four-finger nozzle fixed to the processing optics. This meant that the whole laser head had to turn whenever there was a change in orientation. Thanks to the rotary module, the new TruLaser Weld 5000 features a movable nozzle that rotates around the optics. The result is faster welding times, since the robot does not have to reorient itself as much. This also simplifies programming and fixture design.

Status monitor and production screen for better overview
As well as offering a camera view of the work area, the new status monitor also supplies further information about the production status, including the remaining time, the current production program and the quantity of components manufactured. This gives sheet metal operators the most important indicators at a glance.

The TRUMPF production screen provides operators with an additional control option. It enables users to perform simple tasks such as selecting an existing processing program from the TRUMPF control – even if they have no programming knowledge. In other words, operators require far less knowledge of KUKA control technology in order to launch an existing program. On top of this, the production screen also displays the active program, the remaining time and quantity of components manufactured similarly to the status monitor.

Cube design and other hardware innovations
The design of the TruLaser Weld 5000 departs from its predecessor in various aspects. This version of TRUMPF’s laser welding cell features the striking cube design. It also comes with a swiveling support arm for the control panel, which contributes to ergonomic working and improved handling. On the exterior, TRUMPF has now fitted the TruLaser Weld 5000 with a status light, as successfully employed in the TruLaser Cell. These lights provide an immediate assessment of the machine’s status. A continuous blue light, for instance, indicates that the machine is in teaching mode. Bigger windows provide a better view into the safety cabin, and on the interior there are new approaches to lighting and suction.
The laser welding unit operates using a TRUMPF TruDisk laser that can also power other machines such as a 2D laser machine. In this sort of laser network, several machines share a single laser – which can significantly reduce the initial investment costs in a new machine.

Hot stamping dies require channels for coolants, so that the annealing sheet metal can be rapidly brought to a temperature below 200 degrees Celsius. Previously, coolant channels usually had to be drilled straight into the die, so a continuous position on the surface is made almost impossible, particularly when it comes to complex shapes. But now, with the help of 3D printing, Schuler is manufacturing prototype dies with channels running in an improved near net shape – therefore ensuring an equally fast cooling of all component areas and, as a consequence, improved part properties.

“The optimized cooling channel geometry makes the cooling of the die more homogenous and efficient”, explains Udo Binder, Head of the Intelligent Tooling Solutions Division at Schuler. “3D printing opens up new possibilities in the design of the cooling channels, so that they contribute to even cooling.”

Schuler uses laser melting as an additional manufacturing process. The base material is the same steel used in conventional hot stamping dies – albeit in the form of powder that is applied layer by layer and joined by laser welding. The result is a die segment that exhibits mechanical-technical properties of the actual die by up to 95 percent.

Before, Schuler carried out comprehensive examinations so as to determine ideal process parameters and the optimum composition of the powdered material. Extensive tests of the die segment for tensile strength and specific density followed. It is currently being tested for wear and series production. “The construction of hot stamping dies is practically predestined to be a new area of application for 3D printing”, summarizes Division Head Udo Binder. “We’re ready for it.”

Ultimate flexibility: the TRUMPF TruPunch 1000 is a punching machine for the entry-level segment that can gradually be expanded into a fully-fledged combination machine. The result of this evolution is the TruMatic 1000 fiber, a laser machine equipped with a whole host of innovative features that punches holes, bends flanges and forms threads.

Many TRUMPF customers want an economical, compact and automation-friendly punching machine that is specifically designed to grow with their business. To address this need, TRUMPF will be presenting a new compact entry-level machine at this year’s EuroBLECH. The TruPunch 1000 can be expanded into an equally space-saving TruMatic 1000 fiber punch laser machine, allowing sheet metal processors to upgrade their machine to keep pace with their growing business.

Metamorphosis based on a 3 kilowatt TruDisk solid-state laser
With its expandable functionality, the TruPunch 1000 provides the perfect entry point into the world of professional punching. It can handle sheets up to 6.4 millimeters thick at rates of up to 600 strokes a minute, yet is remarkably compact. With a footprint of just 6.5 x 4.9 meters, the TruPunch 1000 stand-alone machine is around 15 percent smaller than its predecessor. Thomas Herberger, managing director of Herberger Metallwaren GmbH+Co. KG, a company that participates in the product testing program of TRUMPF, explains the benefits: “The space we have here is limited, but the compact TruPunch 1000 slotted into the same space previously occupied by a Trumatic 200. Now we can process medium-format sheets without having to reposition them, and that really speeds up our production process.” As their business evolves, sheet metal processors sometimes yearn for the greater variety of parts that can be manufactured by a combination system – and with the TruPunch 1000 there’s no need to buy a second machine. Thanks to its novel modular design, the TruPunch1000 can be retrofitted with a laser cutting system, a laser evacuation unit and a beam guard system.

A 3 kilowatt TruDisk solid-state laser can be connected up to convert the TruPunch 1000 punching machine into a punch laser machine. This configuration precisely matches the other recent addition to the product range of TRUMPF: the TruMatic 1000 fiber. This is the first time that TRUMPF has offered a combination machine in the entry-level segment, a move that makes it easier for customers to make the switch from purely 2D laser processing to punch laser technology. Customers who already have a TruDisk solid-state laser can also use this to operate the TruMatic 1000 fiber via the TRUMPF laser network. The price of the new machine is undoubtedly appealing, and – with the TruMatic 1000 fiber’s specifications matching those of the previous TruMatic 3000 fiber model –customers don’t need to sacrifice anything in the way of performance.
Revolutionary punching head
Both the new models in the 1000 range offer completely redesigned drivetechnology, which is crucial to the success of the modular concept. The patented “Delta Drive” literally marks a new movement in the world of industrial punching technology.

The advanced engineering team of TRUMPF came up with the new drive to facilitate the construction of smaller machines and open up new methods of material handling. The secret of the Delta Drive is that it eliminates the need to move the sheet and work table in the y-axis – normally an integral requirement of sheet metal processing. It achieves this by making the punching head quickly maneuver in that direction – a revolution in punching head technology.

This new approach involves a drive system that is powered by two servomotors. When the servomotors move in the same direction, they allow the punching head to move back and forth in the y-axis. And when the ball screws rotate in opposite directions, this activates the punching stroke. The y-axis can be accelerated far faster in this arrangement, because the punch drive is also used for travel motion, eliminating the need to move the sheet or work table. As a result, the punching process is more dynamic and the machine is more productive. Furthermore, the lower relative movement between the machine table and the metal sheet reduces the risk of jamming and collisions, making the process more reliable overall. Finally, the stationary machine table significantly reduces the size of the machine’s footprint.

Automatic sorting
Both the TruPunch 1000 and the TruMatic 1000 fiber can automatically sort finished parts measuring up to 180 millimeter × 180 millimeter. All processed parts are sent down a chute into a sorting unit which moves in a linear direction. From there they can be sorted into a series of boxes (up to 4 different 400 mm × 300 mm boxes). The boxes are positioned below the machine, which provides for easy removal by the operator. Due to the innovative movement of the punching head, the machine also offers an alternative way to remove the parts. This second method comprises an additional big flexible parts flap, which is available as an optional extra for the TruPunch 1000 and fitted as standard in the TruMatic 1000 fiber. The flap can be equipped with a sensor that detects whether all the parts have been properly ejected from the machine’s working area.

Designed with relatively generous proportions, this parts flap can also be used to eject long and wide parts into containers or onto conveyors or pallets during both punching and laser operations. Thomas Herberger, managing director of TRUMPF product testing partner Herberger Metallwaren GmbH+Co. KG, explains how it works: “Often we fill sheets with just four to six parts, and in the past we had to remove and sort them manually. But with the TruPunch 1000 nobody has to keep watch over the process because the machine simply ejects the parts through the generously sized flap and places them straight in the crate for us!”

Compact yet safe
TRUMPF was also determined to make the TruMatic 1000 fiber as compact as possible. One way the company achieved this was by developing a special space-saving beam guard system that is compatible with the machine’s modular concept. This protective housing is gathered closely around the machine table in a skirting manner. In punching mode it moves downwards, giving the operator a direct and unobstructed view of the process. But as soon as the program  switches to laser processing, the protective skirt rises and a hood is lowered over the Delta Drive, to which the laser processing unit is attached. This protective screen effectively intercepts the small amount of scattered that could potentially escape at a shallow angle below the work table brushes during production. There are also two laser safety screens that allow visual monitoring of the ongoing process.

Intelligent automation and control
Even in their automated versions, these two machines from the 1000 product series are more compact than any other comparable machines on the market. Both of them can also be connected to the new SheetMaster Compact. This automation system loads small and medium-format sheets and blanks and unloads microjoint sheets and scrap skeletons. Thanks to its optimized loading cycles, it can reliably complete most of these tasks while the machine is in operation. Both machines are equipped with an intuitive touchscreen to make life easier for operators. The MobileControl app can also be used to operate the machines from a tablet. The TruTops Boost Punch software is required for programming, but fortunately both the license and maintenance agreement already come with the machines as standard.

The latest generation of programmable focusing optics starts remote processes autonomously – intelligent scanner optics I-PFO facilitates efficient production processes on the fly

The laser specialist TRUMPF has given the latest generation of its programmable focusing optics (PFO) a clever update: the new I-PFO is a so-called intelligent scanner optics. They no longer merely run their programmed sequences, but communicate continuously and in real time with their most important partner in remote processing on the fly – the industrial robot. The robot continuously transmits its position and movement data to the I-PFO, enabling the latter to recognize their own positions in the working area of the robot cell, so that they know precisely where they need to weld, mark, structure or ablate material on the workpiece.
Three mirrors for three dimensions
The new TRUMPF I-PFO forms the laser beam to the tool for a wide variety of processes by adapting the focus diameter, depth of focus, image distance and power density precisely to the desired process. With the aid of two deflection mirrors inside the optics unit, the laser beam can be aimed at all positions on the X and Y axes within the processing area for spot or seam welding, for example. The laser practically scans the working area – hence the name “scanner optics”. A likewise moveable lens focuses the laser beam on the Z axis. Neither the workpiece nor the optics unit must be moved for three-dimensional processing. During processing on the fly, the scanner optics unit sits on a freely moveable manipulator, such as an industrial robot. This greatly enlarges the processing area in all three dimensions. For this purpose, the new I-PFO features focal lengths of 450, 900 and 1200 millimeters. The automobile industry is a typical area of use for the I-PFO, for example for laser welding of doors, seats, hatches and other large body parts.
The intelligence in the I-PFO
The new I-PFO demonstrates its intelligence first and foremost by autonomously starting processing whenever the geometry and process technology make it possible to do so. Up to now, implementing remote processes was very expensive and time-consuming. With regard to partners, the I-PFO unit is flexible: the robot-independent system can be combined with TruDisk, TruFiber and TruMicro lasers up to a maximum of eight kilowatts of laser power and is compatible with all industrial robots that are equipped with a real-time interface for path planning. An external control unit is no longer required. The new technology facilitates the interaction of the robot, optics and laser beam source without any additional hardware or software whatsoever. This not only reduces investment costs, but also minimizes the space requirements for the robot cells. Moreover, several I-PFO units can be operated with a single laser, so that the beam source in the production network is optimally utilized.

A new femtosecond laser system by TRUMPF facilitates economical, high-quality glass welding, with no additional material required – the process is already in use in the production of laser light cables at TRUMPF

Economical, high-quality laser-welding for glass? That posed a major challenge – until now! The laser specialist TRUMPF has developed a femtosecond laser system that replaces conventional joining processes such as glueing. The advantage: in contrast to glueing processes, no additional materials that are susceptible to evaporation or embrittlement are required. This reduces costs and increases durability as well as the stability of the seam. The special nature of glass poses considerable challenges with regard to processing: glass is hard and brittle, has lower thermal conductivity than metal and tends to crack when heated unevenly due to the internal tension developed. Femtosecond laser systems can prevent such cracking. “The laser system must permit variable programming of pauses and pulses,” explains Elke Kaiser, applications engineer at TRUMPF.
Glass is permeable to light with wavelengths ranging from ultraviolet to near infrared. Absorption takes place only when the energy densities are very high, so that processing within the glass is facilitated. The highest performance density lies deep in the lower glass at the focal point. The energy from several thousand laser beam pulses causes a melt pool to be created and pushed upwards in just a few milliseconds. Skillful thermal management and an optimal ratio of pulses and pauses prevent the glass from cracking.

Protective caps for laser light cables are laser-welded instead of glued

Glass components that were previously glued to each other can now be economically welded with high-quality results, as TRUMPF has demonstrated in its own production of laser light cables. Until recently, the lids of the protective caps for the laser light cables were glued on. Now, lasers are used to weld them on. The joint strength of the glass parts depends primarily on the level of pulse energy. The pulse energy for 1030 nanometer infrared light needs to be 9 microjoule.
TRUMPF is currently building a laser-welding system for reliable glass welding for mass production of the protective caps for the laser light cables in its own production plant in Schramberg. Elke Kaiser states, “The laser system also serves as a pilot system to demonstrate to potential users that new, innovative laser methods are reliable and ready for deployment in glass processing and offer immense advantages.” The new laser welding methods for glass prove their economy and efficiency by eliminating the disadvantages of conventional methods such as glueing: optical beam paths are no longer contaminated, there is no evaporation and no long-term embrittlement of adhesives, which means that the protective caps made of glass will be considerably more durable. TRUMPF is currently preparing further applications for the laser welding of glass for use in its own production.

Mechanical engineering company publishes preliminary figures for 2015/16 fiscal year: Sales slightly higher than previous year at 2.8 billion euros.At the end of fiscal year 2015/16, ending June 30, 2016, the TRUMPF Group successfully registered a 3 percent increase in sales. According to preliminary calculations, the figure amounts to 2.8 billion euros (previous year: 2.7 billion euros). The order intake, at 2.8 billion euros, lay roughly at the level of the previous year.

“Even though we were unable to keep sales growth as strong as in the previous fiscal year,” said Dr. Nicola Leibinger-Kammüller, President and Chairwoman of the TRUMPF Managing Board, “this result is still satisfactory in view of the global situation.” Here she mentioned the economic slowdown in China and Brazil, the sanctions against Russia, and also the strength of the Swiss franc.

She added that over the past fiscal year, TRUMPF had pressed ahead with several targeted investments in the future, including the development of new machines and business models, and structural expansion of locations in Germany and abroad.
Among the reasons for the increase in sales, the company mentioned developments in some regional markets. In Spain, for example, TRUMPF achieved double-digit sales growth. Growth in France was also in the double digits, regaining pre-recession levels. Sales in Germany grew by around 5 percent, to almost 600 million euros.

TRUMPF also achieved significant sales increases in Japan and the Asia-Pacific region. In China, however, economic growth cooled. According to preliminary calculations, revenues there totaled roughly 360 million euros – a decrease of around 2 percent over the previous year (369 million euros).

So far, the recent Brexit decision in Great Britain has not seriously endangered business prospects there over the long term. With its sales company (90 employees) in the UK, TRUMPF generates around 55 million in annual sales. Since 2008, with its subsidiary SPI (300 employees, around 70 million euros), TRUMPF has also manufactured lasers in Great Britain that are sold worldwide. “We have been paying special attention to the market ever since the referendum,” said the TRUMPF President, “but demand for our products has so far remained unbroken.”

The official figures, including the TRUMPF company’s annual profits, are due to be presented at the Annual Press Conference in Ditzingen on October 19, 2016.

All Metals Fabricating, Inc. recently expanded its fleet of fabricating equipment with a TruLaser 5030 fiber with an 8kW TruDisk laser with two TruStore 3030 storage towers. The TruLaser 5030 fiber is the only 2D laser cutting machine in the industry available with an 8kW solid-state laser. First available with the 8kW laser in November 2014, this highly productive machine was quickly embraced by fabricators across North America for its ability to significantly boost productivity when processing medium and thick sheet metal. The system at All Metals Fabricating is the first of its kind in Texas.

As a highly productive, universal powerhouse for cutting sheet metal, the 8kW TruLaser 5030 fiber is able to process thin materials with impressive speed as well as thick material with exceptional quality. With BrightLine fiber, the 8kW TruLaser 5030 fiber can process up to 1 inch steel and 1.5 inch stainless and aluminum. The laser source, machine, optics, optional cutting technologies, automation, storage systems and software were all developed by TRUMPF to work perfectly in tandem, achieving maximum performance and keeping cost-per-part to an absolute minimum.

As a job shop processing a wide variety of materials and thicknesses, All Metals Fabricating looked to invest in the best fiber laser machine technology on the market. All Metals Fabricating CFO Lance Thrailkill explains, “We believe in giving our employees the best technology available and providing the best tools so they can be innovative in their work.” The company also invested in TruStore 3030 storage towers to increase efficiency as well as the laser’s beam-on time. “We strive to be a worldclass manufacturing facility that supplies the best quality at the best price. The power and performance of our new TruLaser 5030 fiber enables us to deliver parts faster and more economically for our customers,” says Thrailkill. “In addition, BrightLine fiber will enable us to cut thicker material much more efficiently, which will increase our capabilities and competitiveness in that niche of the industry.”