Punching, cutting and bending above their weight

Last year the UK operation of the German manufacturer of punches, laser cutters, bending machines and power tools recorded its highest turnover of, £45.7 million with this year estimated to grow by 5% to more than £47 million.

The company recently held its annual three day industry showcase to customers at its headquarters in Luton. Perhaps the biggest attraction was a world premier for Trumpf's TruLaser 3030 fibre laser with the machine builder's patented BrightLine Fiber technology.

Part of the already successful 3000 mid-range of machines with TruDisk lasers the addition of BrightLine technology gives the machine much greater flexibility with higher rates of productivity. BrightLine gives job shop owners the option of changing from thin to thicker sheet material cutting much more rapidly. The system uses a combination of beam generation, guidance and focusing to create a more powerful and flexible laser.

On thin sheet materials the TruLaser 3030 can speed up cutting times and reduce energy costs. At the thicker end of the scale it can cut mild steel up to 25mm thick and stainless steel and aluminium up to 20mm. The company says that the edge quality of the cut is better compared to other solid state lasers and comparable to CO₂ lasers. It is also able to cut non-ferrous materials such as copper and brass up to 8mm thickness. Maximum speed of the cutting head in two axes is 140m/minute simultaneously.

Lee Moakes, service director at Trumpf UK comments: “BrightLine Fiber has transformed the belief that this technology is purely for thin materials by proving its performance on cutting the thick materials also. This product launch demonstrates that we are continuously pushing technology and boundaries further.”

Punching productivity

Another new machine on show at the open house was Trumpf's latest TruPunch 2000. Trumpf argues that punching machines still represent a cost-effective alternative to lasers when it comes to processing thinner sheet metal. They also offer the flexibility to carry out processes such as tapping, marking and countersinking and some bending and forming options through the rotating tool holder which can carry different tools for various applications. Power consumption is also significantly lower compared to a laser machine.

The TruPunch 2000 is described as an entry-level model offering high productivity. It has high axis speeds of up to 108m/minute, short set-up times and a maximum stroke rate of 900/minute when punching and 1,600/minute when marking.

An on-demand drive feature limits power consumption and also means that less noise is generated during non-productive times. Improvements in process reliability and material utilisation are made possible by skeleton-free processing without the need for repositioning and only one clamping operation.

The TruPunch 2000 can be supplied as a standalone or automated machine and features a compact footprint. Automation comes in the form of Trumpf's SheetMaster Compact system so the automated version can be comfortably accommodated even when production space is at a premium. Brush tables with loading and unloading aids ensure careful material handling.

Making its mark

Trumpf's expertise in developing and manufacturing its own lasers means it has also extended the technology to other applications aside from cutting.

The company sells a range of part marking lasers designed to mark parts with identifying characters such as barcodes, text and data matrix codes for traceability as well as logos and other emblems.

At the open house the TruMark 5010 laser marker was unveiled for the first time in the UK. The machine combines, laser, scanner, controls and internal focus position control in a single housing for integration into manufacturing lines. The machine can also be supplied as a mobile model for marking large part structures.

The TruMark 5010 can be used on a wide variety of substrates including metal, plastic or organic materials and produces high standards when deep engraving and surface finishing. Typical users are found in the automotive, aerospace, medical and electronic product sectors.

As a portable device, the 5010 can be applied to the workpiece without the need to move heavy and cumbersome components to a marking station. Intelligent sensors ensure the entire process is conducted safely and accurately. A laser light cable guides the beam from the mobile frame that holds the laser, safety controls and suction system to the scanner unit at the workpiece.

When the operator positions the TruMark 5010 Mobile Marker, a vacuum is created which hermetically seals any gap between the machine and component. If the head is not positioned correctly sensors prevent the laser emitting its beam. It also features an integrated vacuum unit which removes any vapours created in the marking process.

Also featured at the open house was the TruBend 3000 series press brake which achieves cost-effective bending even if throughput levels are low.

The latest addition to the range is the TruBend 3066 with a press force of 600kN and 2m bending length. It is supplied as standard with a 2-axis back gauge but can also be specified with a 4- or 5-axis variant. This makes it possible to position sheet metal securely, even where complex part geometries are involved.

The operating controls are simple and intuitive: the machine operator can sketch components and program them graphically via a large display with modern multi-touch control. The exact bending parameters are calculated by the control circuits based on Trumpf technology data. Power in hand

Trumpf also promoted its latest range of TruTool hand power tools designed for drilling, trimming, nibbling, slitting and shearing applications. The new cordless machines are claimed to be lighter with longer battery life and shorter recharging times compared to other power tools used in metalworking.

The company also gave pre-release information about a new software program intended to be used across all of its laser, punching and bending machines. TruTops Boost software will be introduced in the UK in July.

The software will allow the whole design and programming process to be achieved more quickly and efficiently from 3D CAD design through to the nesting of the parts. The software automatically carries out much of the repeated NC programming duties automatically for users. It is estimated the ‘Boost' button reduces mouse clicks for programming down from around 300 to 30.

Trumpf recognises that one of the main reasons customers return to buy products is its investment in its aftersales service. The company's philosophy is to support customers through the entire lifecycle of their machines from the point of purchase with finance options, service and support and finally through to decommissioning ready for sale through its used market channels. A further development of this approach is a £160,000 investment in a new TruService Centre at its site in Luton.

Mr Moakes concludes: “The TruServices Centre brings together all our aftersales support under one roof, enabling us to highlight our one stop shop advantages to our existing and future customers. Here we demonstrate our ability to help our customer grow with their business through our consulting services, advanced training options and our tooling and software developments.

“It also highlights our existing core advantages such as the X-change spare parts system in which we offer credit notes of 75, 50 and 25% on many of our replacement parts inside the first four years. With our new X-change 10 system items on our solid state lasers have credit values for 10 years. We also still offer to extend or restart machine warranties for up to five years within our service agreements.”

TRUMPF UK
www.uk.trumpf.com/en.html