Something for everyone

A trip to Trumpf's Ditzingen headquarters for its IN-TECH is always likely to be an enlightening experience for those looking to invest in their sheetmetal capabilities.

A trip to Trumpf's Ditzingen headquarters is always likely to be an enlightening experience for those looking to invest in their sheetmetal capabilities, and with 2010 being the 50th anniversary of the first functional laser, the German manufacturer's recent IN-TECH exhibition provided an opportunity to catch up with some of the latest innovations.

Back in May 1960, working in Hughes Research Laboratories in California, Dr Theodore Harold Maiman fired the first laser beam. With a device consisting of a synthetically grown ruby rod inside a xenon flashtube and small enough to fit in the palm of a hand, one brief flash of red light launched a technology that would open new doors across a whole range of industries and scientific discovery.

In 1979, Trumpf introduced the first combined laser and punching machine and in 1985, launched itself as a full laser machine manufacturer with its first CO2 laser to be designed and produced completely in-house. With a power of 1kW, the machine was the first compact laser resonator with high frequency stimulus and paved the way for a multitude of new technologies for cutting, welding and marking.

At the core of Trumpf's laser machining philosophy is that while a universal laser beam for all applications is an ideal goal, practice shows that diverse applications require different laser technologies and as such, the company offers a variety of options across the spectrum of CO2, solid state and marking technologies, as highlighted at its IN-TECH event.

Renewed focus

Amongst the new products on show for sheetmetal processing, laser technology, automation and medical systems was a prime example of this philosophy – the new TruLaser 5030, available in both CO2 and fibre versions, with the former featuring a novel mirror cutting head concept as an option for heavy-duty applications. Lenses are considered a weak link in typical laser systems where productivity is the main objective due to their vulnerability to contamination at high output, where debris can be absorbed and transformed into heat, affecting focusing properties. The new system removes the lens completely and instead, focuses the beam using two water-cooled copper mirrors.

Not only is the system significantly more rugged, soiled mirrors are much easier to clean and are at a much lower risk of permanent damage so the user can process materials outside their usual range. The life cycle of the focusing element is also extended while maintenance can reduced from every 24 hours to an average 240 hours.

According to Trumpf, the mirror cutting head matches any lens cutting head for performance as far as sheet thickness is concerned, however the user application will ultimately determine which cutting head is more advantageous. Typically, lens systems are still beneficial for high speed or compressed air cutting where they can provide full flexibility and very high advance speeds. For standard processes and demanding tasks however, the mirror cutting head delivers strong processing results. 

Solid speed

At the opposite end of the application spectrum, Trumpf believes that the fibre variant of its TruLaser 5030 is also a significant step forward, claiming that users can shave 20% off the cost of producing thin sheetmetal parts through the use of its solid state system to achieve very high cutting speeds.

While in principle, the new machine can cut the same sheet thicknesses as the equally performing CO2 version, for applications such as cutting stainless steel up to 4mm thick, its 1.03μm wavelength makes it possible to cut sheet using flame cutting and nitrogen at up to three times faster while maintaining the same part quality and can also cut non-ferrous metals such as copper and brass, as well as the usual suspects.

Versatility has also been improved as the solid state laser can be placed independently of the machine. More significantly however, is that both the machine and the solid state laser come from the same source, so the two components are optimally adjusted to each other.

With both models, users can process sheets measuring 3,000mm by 1,500mm and to keep processing time as low as possible and increase the flow rate of parts, both machines includes features already proven in the CO2 version such as a one cutting head strategy, automatic tip changer and all the necessary data for a smooth cutting entry. 

Wide ranging savings

Having visited IN-TECH back in April, David Connaway, managing director of Cirrus Laser, based in West Sussex, has since placed the first UK order for the TruLaser 5030 fibre machine, its first of this type. The subcontractor, which offers laser and waterjet cutting as well as pressbrake folding plans to have the machine installed in Autumn 2011 to coincide with the conclusion of its lease of a TruLaser 3030.

Making the announcement at the recent MACH event, Mr Connaway explains that: “Having spent most of the morning at Ditzingen in the massive showroom viewing the automation systems, I found the star of the show lurking unobtrusively in a corner. The Trumpf technicians running the machine showed me the features, the cutting quality, the reduced floor space, reduced power input, simplified cutting head technology, reduced servicing requirements, remote laser positioning, fast drives, totally enclosed processing – the list was endless – and when asked by Scott Simpson, Trumpf UK's technical director, to sign on the dotted line there really was no second thought.” With all its current machines being CO2, the benefits of solid state technology were highly appealing. Cirrus currently spends several hundred pounds a month on high purity resonator gases every month and as well as reducing this cost, the 3kW fibre TruLaser 5030 offers the same cutting performance as its 5kW counterpart. In the longer term, this improved energy efficiency will delay the need for Cirrus to invest in its own electricity substation at an approximate cost of over £50,000. The fibre machine also occupies 20% less space than the CO2 model.

Mr Connaway concludes: “I could accommodate three models of this new machine in the space needed for just two CO2 machines, which means I don't have to factor in moving premises in order to increase my production. And this machine needs just one service a year, so my maintenance costs are reduced.” Cirrus laser has also invested in a new Trumpf Liftmaster Compact system, due for installation this August, to automate its current 3030 laser. This will allow the company to run lights put machining under full automatic control.

Trumpf
www.uk.trumpf.com
 

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