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Traditional Metal-Cutting Machines Are A Long Way From Being Ripe For The Scrap Heap

The mobility concept for individual transportation will in the relatively near future be a combination of progressively downsized internal combustion engines and electric drives, say some, while others predict that electro-mobility will secure jobs or even create new ones.

This, at least, is certain: traditional metal-cutting machines are a long way from being ripe for the scrap heap – equipped with smart technologies, they will also play a prominent role at EMO Hannover 2019.

“Changing over to electro-mobility signifies a radical transformation of production technology,” the then President of the Fraunhofer Society, Prof. Hans-Jörg Bullinger, warned back in 2010. For example, he predicted, the entire value added chain will alter in the automaking sector. The importance of electrification for value creation in the drive chain was scrutinised in last year’s VDMA study on Transformation of Powertrains. It was authored by the Aachen-based company FEV Consulting, which specializes in the automotive and aviation industries. It forecasts that the increasing dynamism in the electrification of vehicles and in drive technology will lead to radical changes in Germany’s entire mobility and vehicle industries and in significant parts of the mechanical engineering sector. Moreover, a vitally crucial role will be played by the research community and cross-sectoral networks.

Though the FEV’s experts anticipate that sales of internal combustion engines (including hybrid drives) for passenger cars in Europe, the USA and China, the three markets examined, will fall by ten percent by 2030 compared to 2016, nonetheless, substantial business will remain for component manufacturers, plus machinery and line producers. Because improved drive technologies – e.g. efficiency-boosting measures in the internal combustion engine and the transmission – also entail more stringent requirements for the production technology involved.

Manfred Maier, managing director and COO of the Heller Group, Nürtingen. Photo: Heller

At the same time, the study’s authors are anticipating a share of 22 percent in these three markets for exclusively electro-powered vehicles. The effects of electrification on the individual production processes that dominate for conventional drives are substantial. With a battery-electric drive, for instance, their value added is reduced by an average of 64 percent (excluding battery cell production). For (plug-in) hybrid drives, by contrast, value added will rise by 24 percent – here, besides an internal combustion engine an electric drive is also installed.

What’s crucial here is the bottom line. There, the study shows that the combination of hybrid drives, a higher level of complexity at the internal combustion engine and rising sales figures for vehicles (particularly in China) will exert a beneficial effect overall on the amount of value added.

In the estimation of the VDMA’s President Carl Martin Welcker, “the mobility transmutation process means enhanced opportunities for additional value creation in the mechanical engineering sector – for us, “transformation of powertrains” can be a source of growth”. There is still time for the companies, he continues, to master the transformation successfully, in order to modify business models and technologies appropriately. At the same time, however, the study shows clearly that hybridisation and electrification will gain wide acceptance on the market.

Mechanical engineering sector benefits from electro-mobility

The opinion of the VDMA’s President is shared in full by Marc Kirchhoff, Head of Industry Management Automotive at Trumpf in Ditzingen, “plant and machinery manufacturers in Germany can benefit from electro-mobility.” The mobility of the future will at Trumpf at the very least secure jobs in R&D, production and applications engineering and in some cases create new ones, “since lasers are indispensable for competitive production of electric cars. And today we’re already seeing a rising level of demand for production technologies involving electro-mobility.”

Due not least to the “equal attractiveness of internal-combustion and electric vehicles” forecast for 2024, says the VDMA’s President, the process of transformation should be tackled now at the latest by the companies concerned. That, says Kirchhoff, “is precisely what we’re doing, and on different levels. With our knowledge of the sector and the applications involved, for instance, we’re already supporting the sector in comprehending and developing new technologies and setting up complete production lines for series manufacturing. Many component suppliers and automotive specialists ask us to help in changing over their production operations for electro-mobility, because we’re familiar with the requirements nowadays faced by electric car manufacturers and their component suppliers, not least from other sectors.”

The new CBC (Cylinder-Bore-Coating) process technology as a constituent of automated production lines for crankcases. Photo: Heller

Many of the company’s existing products can be used as they are for manufacturing electrical components. For example, more than 500 lasers have been sold worldwide for use in battery production alone – and the number is rising steeply. “Our technologies are in widespread use among battery manufacturers,” reports Kirchhoff. “At Trumpf, one euro in ten of automotive sales is already accounted for by battery manufacturing.”

Kirchhoff explains the effects of electrification on the company’s individual production processes like this, “in our order books, we are seeing a significant rise in focusing lenses in conjunction with high-performance lasers for ultra-productive lines in the field of electro-mobility.” This is complemented by progressively more inquiries for green lasers used for welding copper and for solutions for cutting carbon-fibre-reinforced plastics.

It can thus be concluded that many firms in the automotive industry and its component suppliers, but also some new players on the market, have recognised the signs of the times and are preparing their production halls for mass manufacturing of electric cars. And because these inquiries are rising so significantly, “we offer lasers and laser systems specifically for the requirements of electro-mobility”.

Proportion of metal-cutting set to remain steady in the medium term “The individual-mobility concept of the near future will be a combination of progressively smaller internal combustion engines and electric drives,” believes Manfred Maier, Managing Director and COO (Chief Operations Officer) of the Heller Group, Nürtingen. There are numerous indications that the politically postulated goal of fully electrified vehicles cannot be created overnight; this will involve a protracted process featuring numerous intermediate steps: “For example, it’s probably going to take years, perhaps even decades, to put in place a fit-for-purpose infrastructure.”

Currently, at least, all relevant studies concur in predicting that passenger car fleets worldwide will increase by another 30 million vehicles over the next ten years. Purely electric vehicles are forecast to account for hardly more than ten percent of this figure. In the upcoming ten, twenty or more years, says Maier, “internal combustion engines will accordingly remain the paramount drive concept. For us, this means that in the medium term the proportion of metal-cutting work will tend to increase and as time goes by will not significantly decrease – if at all.”

In response to the call by the VDMA’s President to tackle with promptitude the process of transformation in the companies, Maier has a differentiated opinion, “first of all, we should realise what’s actually involved here. The paramount focus is on global CO2 emissions. This involves much more than just the questions of what drive concept a car is powered by or how a city’s air quality can be improved.”

This is why for years now, he continues, Heller has been productively engaged not only with the cutting of blocks, heads, crankshafts and transmission housings. The product spectrum primarily comprises four- and five-axis machining centres, plus milling and lathing centres for meeting the multifaceted requirements of the general mechanical engineering sector, the aerospace industry, energy engineering, contract production and many other sectors.

In addition, Heller has also adapted to the new situation in terms of its corporate structure. The Development New Business & Technologies Department addresses issues that will not immediately and directly become major earners, but may be important in the more distant future. Specialists there address the possibilities of additive manufacturing and new materials like CFCs.

The CBC (Cylinder-Bore-Coating) technology implemented exclusively in Heller’s machining modules, explains Maier, “is an excellent example of innovative technology supplementing the existing comprehensive machine portfolio. And it makes a significant contribution towards reducing CO2 emissions.” In 2016, the CBC technology was even nominated for the German Future Prize. The CBC cylinder bore coating process is based on the LDS two-wire technology used by Daimler and BMW, and is “so far the only one that can be reliably used for a relatively high production volume”. Around one million four- and six-cylinder engines will be produced with it per annum at Daimler in Untertürkheim alone. And since the end of 2018, a total of 65 coating lines for over eight million motors have been up and running worldwide.

EMO Hannover as a platform for solutions of the future

Heller’s COO Manfred Maier summarizes his expectations of the world’s premier trade fair for the metalworking sector as follows: “EMO Hannover 2019 offers us a platform for talking to our customers about current and future manufacturing requirements and finding shared solutions. EMO is at the same time also an excellent indicator for identifying developments in technologies and processes, and in machine tool manufacturing and at our customers as well, and possibly deriving from them new business models.”

New Extra Long Swisscut Inserts

ISCAR is launching a new SWISSCUT XL line featuring up to 10mm grooving depth capability. The new line will enable deeper machining when compared to the existing SWISSCUT INNOVAL line, enabling parting off up to 20mm diameter and turning at up to 5mm depth of cut.

Two clamping screws provide very strong clamping and stability. The insert clamping screws can be reached from both tool sides and there is no need to remove insert clamping screws for indexing, which means no danger of falling parts.

The front insert extraction/insertion feature enables indexing the insert on the machine while maintaining a minimum overhang from the gang tool. A compact tool design with no projecting elements allows insertion of the tool through the constrained slots of a Swiss-type machine magazine.

A stopper plane beyond the cutting zone enables use of the second cutting edge of the insert, even if the first used cutting edge is completely broken.

The tools are offered in 12 and 16mm square shanks and inserts are available for parting, back turning, front turning and groove-turn threading applications. Inserts are available in carbide grade IC1008.

For more information, please contact ISCAR South Africa – Tel: 011 997-2700

Laser Marking Innovation

The use of the motorized Z axis is extremely simplified by the use of the joystick which is an essential tool if combined with the SmartFocus system. In particular, it allows the operator to easily determine the correct position of the scanning head for optimal marking, both on flat and complex surfaces with curves and edges.

The door of the MicroMark G3 has a vertical opening on the three sides of the machine to allow easy and comfortable access to the marking chamber. In addition, working with the door open wearing the safety goggles, it is possible to mark even bigger parts that would not normally fit in the machine.

Upon request the MicroMark G3 can be equipped with a motorized three sides door which allows for speeding up of the loading/unloading process. In fact, once the part is inside the marking cabinet and the operator pushes the starting cycle button, the door closes automatically and once the marking is completed it opens up again.

The 20mm thick work table measures 530 x 410mm. It is made of surface ground aluminium with a 30μm hard-anodized coating. The standard hole pattern is 50mm center to center. Each hole is ø8H7 at the top with M6 threads at the bottom. This makes it easy to affix guides, jigs or accessories with either pins or screws.

The exhaust system is fundamental for the operator’s health and the cleanliness of the machine. The pump with lateral channels, which has a die-cast aluminium structure, ensures a high air speed flow. The 3-stages filter has both HEPA H14 and activated carbon elements which remove potential smells, odors and micro-particles.

In order to simplify machine programming, it is possible to use the reader to scan production orders. LASIT software, using the key read by the scanner, can access a database and collect the variable fields as well as select the drawing that needs to be marked.

The Smart Focus provides for fast and accurate focus. By controlling the Z axis with the joystick, users can immediately and precisely focus the laser by intersecting the dot of the red lighted diode laser with the red lighted line of the scanning head. The red lighted line is electronically produced and it can be moved to obtain a marking that is out of focus when required.

The exclusive Lasit capability of projecting on the part to be marked virtually every pattern with the safe red light makes the centering of complex parts quick and easy for everyone. The pattern can be either imported (DXF) from your 3D model or desiG3ed directly in FlyCAD®.

For more information, please contact Elcomp – Tel: 011 238-7996/7

AMADA ENSIS 9KW/6KW Fiber Laser Cutting Machine

ENSIS-3015AJ 9kW/6kWis designed for high-speed stable cutting over the entire range of machining, from thin to thick sheet metals, which has been made possible by the evolution of AMADA’s original beam control technology (ENSIS technology) and the expansion of oscillator output from the conventional 3kW to 9kW/6kW.

High quality cutting over the thick material range is achieved by overcoming problems related to fiber lasers through reduced dross and bevel and improved surface roughness.

NC equipment is provided with the AMNC 3i, which can be operated easily like a smartphone. It is adapted to AMADA IoT V-factory and visualizes machine operating results including power consumption and processing costs, contributing to performance. Furthermore, it enables smart manufacturing through maintenance and support to maximize machine capacity, as well as proposals to improve production efficiency.

AMADA’s high-output oscillator provides for maximum output of 9kW/6kW to enable high-speed and high-quality cutting over the entire processing range (thin, medium thickness and thick sheet metals), based on energy saving and high-quality beams.

ENSIS technology allows the laser beam to be controlled freely into the optimum beam form according to material quality and thickness. Additionally, the auto collimation mechanism is provided as a new feature. The variable range of the condensing diameter has been expanded greatly to achieve excellent stable cutting over the entire thickness range. Furthermore, combined with a high-output oscillator, the technology enables high-speed stable cutting of thick sheet metals, cutting with reduced dross and bevel and improved surface roughness.

In addition to the new beam control technology, the fiber laser cutting machine employs Clean Fast Cut (CFC) technology and Easy Fast Cut (EZFC) technology to dramatically reduce the consumption of assist gas during nitrogen cutting, which is used mainly to cut stainless steel. It applies an original non-contact nozzle developed by AMADA that supplies assist gas at a low pressure to reduce processing costs, while maintaining cutting quality.

For more information, please contact Amada – Tel: 011 453-5459

HD-TC Profile-Pipe Cutting Laser More Stable With Added Laser Sensors

DURMA shortened process time by improving centering with the newly added laser sensor centering option added to the HDTC machines.

It is possible to control the size and irregular structure of the profile during cutting or before cutting with the help of sensors to ensure that the internal contours to be cut are at the right point.

In existing HD-TC machines, the centering measurement is achieved by scanning the profile surface through capacitive sensors. The advantage of the laser sensor system is that it gives more precise results in a shorter time. The user can take measurements at the distance determined by the user, and precise results are obtained in a shorter period of time as the process of measuring by the sensor is shortened for parts requiring precise measurement with internal contours.

The advantage being fast set-up time, less problems during cutting, best solution in a short time and measurement frequency is dependant on operator request.

For more information, please contact Spectrum Machine Tools – Tel: 011 865-4090

Durma HDF/HDFL 3015

An integrated shuttle table maximizes productivity and minimizes material handling times. The shuttle table and pallet change system allows convenient loading of new sheets or unloading of finished parts, while the machine is cutting another sheet inside the working area.

The available shuttle table is fully electric and maintenance free; there are no hydraulic oils to handle and table changes are fast, smooth and energy-efficient.

An optional lateral automatic scrap conveyor allows the removal of scrap pieces from the working area without the need to interrupt the cutting process. The sideways operation of the short conveyors allow for easy maintenance and trouble-free running.

The Durma HDF/HDFL 3015 fiber machine achieves highest dynamics and fastest laser processing cycle times thanks to the combination of rigid mechanics and a state-of-the-art numerical control and drive system. Programmes can be loaded easily into the machine with a USB stick or over a fast Ethernet connection with the company network.

In the high-pressure auto-focus cutting head for the fiber laser the cutting lens is shielded from the laser process by an exchangeable low-cost protection window. The 1μm wavelength light is very sensitive to dust or other contamination produced in the cutting or piercing process, therefore the cutting head is being well protected in an additional cover to ensure that all critical parts remain as clean as possible.

The integrated capacitive distance sensor is capable of having the head follow height differences in the sheet even at the extreme high cutting speeds that can be achieved with the fiber laser technology, while state-of-the-art linear motors promote accuracy and increase productivity.

The CAD/CAM software provided has all the tools to import or draw parts, prepare and optimize automatically different geometries for the laser cutting process and make efficient nests.

The all-solid-state fiber laser technology reduces maintenance requirements, and offers the lowest possible running cost with a wall-plug efficiency of 30% and without the need of any laser gas. When the application requires a broader spectrum of material types to be cut and the maximum thickness range is limited, the fiber laser is the ideal solution and it will cut faster at lower cost than any CO2 laser at the same laser power.

For more information, please contact Spectrum Machine Tools – Tel: 011 865-4090

First Cut Takes Over Messer SA Operation

First Cut recently concluded a mutually beneficial agreement with the company Messer Cutting Systems in Europe to take over the latter’s South African operation.

Messer has had a presence in South Africa for the past 15 years from a single office in Gauteng. In terms of the new agreement, Messer will be able to service the entire country more effectively via First Cut’s presence throughout South Africa. The agreement came into force in January this year, and the Messer agency is now part of First Cut’s machine division managed by Anthony Lezar.

Messer Cutting Systems equipment comes into its own in industries such as motor vehicle and mining equipment manufacturing, construction, shipbuilding and railroad rolling stock manufacturing. Messer boasts a 120 years successful track record and its name is synonymous with high quality. In line with this, Messer equipment currently in service in South Africa is renowned for its longevity and outstanding performance.

The PowerBlade has a large area for processing with fibre laser, with working widths of up to 4,500mm, and working lengths of up to 50 metres.

Popular products available in South Africa and with relevance in the laser and fabrication sectors are Messer’s LaserMat and PowerBlade units. The LaserMat’s many advantages include large area processing with the CO2 laser and on-board resonator. The machine has working widths up to 4,500mm and working lengths of over 50 metres. Beam path length compensation guarantees the highest cut quality over the entire working area. The LaserMat’s onboard laser protection hood (laser protection class 1) permits direct crane loading, even with large special formats or parts. The infinitely rotating laser bevel head allows for continuous bevels from -45° to +45°.

This machine is highly dynamic and has simultaneous speeds of up to 140m/min with the highest acceleration of up to 1g. Its track has been specifically designed for laser requirements and has been grouted after levelling to deliver the highest positioning – and repetitive accuracies.

In addition to versatile products such as these, Messer places considerable emphasis on innovation in order to promote productivity. At EuroBLECH 2018, Messer Cutting Systems launched the notable new MetalMaster Xcel cutting machine. With an emphasis on fast process cycles, high acceleration and even better cutting quality and accuracy through smooth guidance from the helical gearing and linear guides, the MetalMaster Xcel is ideal for the busy fabrication shop.

In terms of the range of Messer Cutting Systems equipment, First Cut will be distributing the complete portfolio, and will be able to provide everything showcased on the Messer website. Furthermore, Messer welding electrodes will now be manufactured and sold by First Cut in South Africa.

With immediate effect, all Messer equipment in operation locally will be supported by First Cut and in order to maintain the continuity of Messer’s after-sales service, spares and backup, First Cut has taken over the company’s current service technicians and most of its local staff. Some members of First Cut’s technical team have already been sent for training in Germany.

For more information, please contact First Cut – Tel: 011 614-1112

Bystronic – More Safety In The Laser Cutting Process

Tilted parts are a risk factor during the laser cutting process. They can cause a collision with the cutting head. This results in the disruption of cutting jobs, rejected parts and in the worst case, costly damage. However, they also impede automated unloading, as the automation system’s grippers have difficulty picking up tilted parts.

Until now, micro-tabs have been a time-intensive method of preventing cut-out parts from tilting. The software positions small connections between the contour of the part that is to be cut and the residual grid in the cutting plan. In this way, parts remain fixed to the surrounding sheet after cutting. One disadvantage of this solution is the cut parts require reworking in order to remove the traces of the micro-tabs. Another disadvantage is the automated removal of the finished parts is impeded because the micro-tabs make it difficult to remove the parts from the residual sheet.

Left: Perfect cutting result thanks to TiltPrevention.
Right: Tilted parts after laser cutting without TiltPrevention.

Another approach is to use software to guide the paths of the cutting head during the cutting process so that, as far as possible, it circumvents risky sections where parts could tilt. However, this solution does not eliminate the root of the problem: Parts protrude, still represent a risk and are difficult for automation systems to cope with.

Algorithm generates the ideal cutting sequence

With TiltPrevention Bystronic has now developed a new solution. In future, BySoft 7 will use this intelligent assistant function to compile cutting plans in such a manner that parts cannot tilt during the cutting process. This largely eliminates the need for micro-tabs.

How does it work? An algorithm calculates the mechanical behavior of the parts while they are being cut out of the sheet. To achieve this, TiltPrevention takes into account a wide range of parameters: What is the density of the material that is being cut? What is the geometry and weight of the parts that are to be cut? How high is the pressure of the gas that flows out of the cutting head during laser cutting and exerts pressure on the parts? How are the parts positioned on the cutting grate? Are there enough contact points?

Left: Simulation of the optimized cutting sequences using TiltPrevention.
Right: Laser cutting without TiltPrevention with piercings in critical areas (red) and risky paths of the laser.

Subsequently, TiltPrevention recommends lead-in and lead-out points of the laser so that tilting of the parts after cutting is prevented to the greatest possible extent. In addition, the function proposes the best possible route for the cutting head over the metal sheet. This creates an ideal cutting sequence for all parts on the cutting plan. Cutting in such a manner that the cutting head never travels over parts that have already been cut out.

Regardless of the users’ level of experience, TiltPrevention supports them with an ideal cutting strategy that can be automatically incorporated into the cutting plan. Users can carry out customized adaptations at any time using the simulation created by TiltPrevention: modify the nesting of parts, reposition the lead-in and lead-out points of the parts, and add micro-tabs where required.

For more information, please contact First Cut – Tel: 011 614-1112

TRUMPF Makes The World’s Most Flexible 3D Laser System Even Faster

At this year’s EuroBlech, TRUMPF launched the latest generation of its TruLaser Cell 7040, one of the most productive and versatile 3D laser systems in the world. As with previous versions, users can opt to equip their machine with either an energy-efficient disk laser or a CO2 beam source.

This allows the machine to process a broad range of materials, including steel and light metals, without the need for time-consuming re-tooling. Operators can choose between cutting and welding operations in 2D or 3D and TRUMPF has given this new model a major productivity boost by reducing non-productive time, integrating automation features and improving processing quality. Users also benefit from consistently high quality parts and excellent reproducibility as well as reduced energy and material costs. The new machine is particularly suitable for industries that need to produce many different product variants in a short space of time, for instance job shops, the automotive industry and aviation.

The TruLaser Cell 7040 is an inherently powerful and flexible machine, offering the largest range of beam sources and highest laser power on the market and capable of executing multiple machining processes. To make the machine even more efficient, TRUMPF has worked on cutting down nonproductive time. This encompasses any activity before or after processing that does not add value to the process – re-tooling or loading and unloading, for instance. “When companies are making batches of products that change on a frequent basis, the cost of this non-productive time really adds up,” says TRUMPF product manager Thomas Kirchhoff.

The TruLaser 7040 saves time thanks to its smart optic set-up station, a swivel-mounted apparatus mounted on the machine frame that automatically orientates the optics within the work area. This improves accuracy, resulting in consistently reproducible, high quality cutting results.

Two different beam sources allow the machine to process a broad range
of materials, including steel and light metals, without the need for time-consuming re-tooling.

It also enables the operator to start producing batches much faster than before, since hardly any time needs to be spent on set-up. As a further improvement, TRUMPF engineers have also included optimized cutting parameters for both beam sources in the machine control system. Thanks to these integrated laser technology tables, operators need only select the material and thickness and the machine will automatically choose the right cutting parameters for settings such as power and gas pressure. That eliminates the need to hunt for the best parameters manually and enables operators to start the process quicker. What’s more, it increases machining quality and decreases scrap rates by locking in the optimal parameters right from the very first part.

In a bid to further boost productivity, TRUMPF experts have also drawn on the latest generation of TRUMPF lasers. The range of compatible products includes highly efficient TruDisk lasers up to 5kW as well as tried-and-tested CO2 TruFlow lasers offering as much as 6kW of laser power. During laser cutting, X-Blast technology ensures increased process reliability by enabling the nozzle to machine the sheet metal at twice the distance. That results in fewer collisions, guaranteeing higher quality, burr-free cutting results even in the case of highly complex components.

The TRUMPF experts have also set out to significantly boost part quality by integrating BrightLine Weld, a technology developed by TRUMPF for low-spatter laser welding. “With this technology, not only do we get a better quality of weld seam, we can also triple welding speed and achieve a major boost in overall productivity,” says Kirchhoff. The developers have also incorporated doors made of glass fiber composites into the new design. These are almost half the weight of their steel equivalent, shaving the time needed to open and close the doors by three seconds. That can help achieve time savings of up to 35 percent per processing cycle.

Last but not least, TRUMPF has taken operators’ needs very much into account in this new version of the TruLaser Cell 7040. Programming and teach-in are easier because operators can now see inside the machine without having to make unnatural movements. This improvement stems from a moveable, swivel- mounted control panel that operators can quickly adjust to their height and stature. The white paint finish and balanced lighting give operators a clear view of the work area at all times.

For more information, please contact Retecon – Tel: 011 976-8600

Trulaser Series 1000 – Re-Engineered From The Ground Up

TRUMPF has re-engineered the TruLaser Series 1000 from the ground up. These machines can now be automated across the board. The TruLaser Series 1000 also handles many cutting-related processes autonomously to drive down part costs.

Equipped with a robust laser and proven functions such as collision protection, these machines cut sheet metal in a process-reliable way. And the intuitive operating concept reduces training time. Beyond that, TRUMPF added new features such as protective glass monitoring and BrightLine fiber. Previously available only in higher 2D laser classes, they serve to optimize processes and boost machine efficiency.

The cutting head deflects if it collides with a tilted part.

The new series consists of two types of machine, the TruLaser 1030 fiber and the TruLaser 1040 fiber with work areas three and four meters long, respectively. The TruDisk solid-state laser operates at constant power and is insensitive to reflections off copper, brass and other materials that reflect when cut. TRUMPF ships these machines out with data for cutting many commonplace materials and thicknesses of sheet metal. It enhances their process reliability – they can even cut copper with nitrogen. Machines with a fourkilowatt laser are equipped with BrightLine fiber. With this function, they can cut thick mild steel in a process-reliable way. In the event of a collision with tilted parts, a special protective mechanism deflects the cutting head to prevent damage. The TruLaser Series 1000 deposits slag and small parts in five pull-out drawers below the machine’s frame.

This re-engineered line of TRUMPF machines is far more dynamic than its predecessor. Positioning speed is up from 85 to 140 meters per minute. This speed is down to the design of the machine’s body, which combines a rigid machine frame with a lightweight motion unit and powerful drives. The machine cuts all materials and sheet thicknesses with the same cutting head. It changes nozzles automatically thanks to the optional nozzle changer. Sensors monitor the optics’ protective glass and let the operator know when it is time for a replacement. Visual inspections are a thing of the past. All this reduces the machine’s set-up time. The TruLaser Series 1000 also saves time during the cutting process. The PierceLine feature reduces piercing time by up to 80 percent and protects the machine and material. These machines operate very energy-efficiently with an average power consumption of 13 kilowatts for the 3-kilowatt laser and 14 kilowatts for the 4-kilowatt laser. They also come with more energy- conserving features, as do their periphery modules.

The TruLaser Series 1000 automatically changes nozzles to the correct type.

The TruLaser Series 1000 features a new 18.5-inch multi-touch control panel. It displays the most frequently used menu items at the top level. If the operator interrupts an operation, the control unit enables processing to resume at the same point. The monitoring capability is not limited to the protective glass: Other sensors track the condition of components that impact the machine’s cutting performance. A traffic-light readout on the control panel called the Condition Guide indicates the status. It also offers guidance when the operator needs to take action. Flow charts make it easier to forecast actionable events and provides a more efficient way of scheduling maintenance work.

A semi-automatic pallet changer is a standard feature. The operator can prepare new sheets, while the machines are operating and sort or unload cut sheets parallel to the cutting process. Users may also opt to equip the TruLaser Series 1000 with automated LiftMaster components. They load raw sheets and remove the cut sheets. TruLaser Series 1000 machines may be connected to the compact TruStore storage system or to a large Stopa storage system.

The MobileControl app serves to operate the TruLaser Series 1000 using a touchpad situated near the machine. TruTops Monitor software tracks the machine’s status continuously and notifies the operator in the event of a malfunction. The TruLaser Series 1000 affords users the opportunity to access the machine’s digital enhancement. It contains five apps that assess machine data and deliver the results to users. AXOOM, a TRUMPF subsidiary, provides the cloud platform for processing these data. The apps provide an insight into tool and material usage and display the current machine status to users on the go.

For more information, please contact Retecon – Tel: (011) 976-8600

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