TRUMPF is presenting a completely newly developed, fully automated and compact machine concept at the Euroblech 2016
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. “
