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14 CASE STUDY Laser Machining Modular laser cell for flexible 3D material machining Dynamic and Flexible Trumpf has had 3D laser machining cells in its product line for several years. With the new TruLaser Cell Series 7000, the concept was once again significantly improved, especially regarding its usability, productivity and modularity. The new machine is controlled with Sinumerik and Simodrive technology. The applications of 3D laser machining cells are manifold. Regardless of whether for laser welding, laser cutting or integration into complex production lines, these cutting systems are equipped for numerous production jobs, and are particularly suitable for the automotive industry. The experience gathered from numerous projects was incorporated into the new TruLaser Cell Series 7000. Larger work area, less machining time The compact laser machining cell features a 2,000-millimeter x-axis (TruLaser Cell 7020) or 4,000-millimeter x-axis (TruLaser Cell 7040), along with flexible automation modules. The y-axis is designed as an extension boom with a work area of 1,500 millimeters. It includes a very slender and compact z-axis with a 750-millimeter work area. Two axes of rotation provide the machines with complete 3D flexibility. The new, compact design has led to an increased the work area of one meter, while occupying same amount of space. The high dynamic performance of the TruLaser Cell Series 7000 with an axis acceleration of 1g saves time when needing to position the machining head on the component. With a PKW-B column made of highstrength steel, for example, the machining time is reduced by 30 percent as compared to the predecessor machine using the new high-speed cutting performance of the five kilowatt laser. “The TruLaser Cell Series 7000 economically welds, cuts and machines surfaces of everything from aluminum to ultrahigh-strength steel in 2D or 3D,” as Klaus Löffler, head of international laser systems sales for Trumpf’s laser technology division, explains. Automation enhances productivity Of key importance also for users is the option of automating the operation to further enhance productivity. Two-station operation, whereby a partition divides the machine into two work areas, enables the simultaneous setup and machining of workpieces. This increases the machine capacity of the job shop operation considerably. Linear and rotation changers simplify the handling of workbenches and components. Thanks to the modular construction, all automation components are easily retrofitted. One particular innovation is the machining head, which features a magnetic coupling that disengages if it collides with the workpiece. As a result, there are fewer standstill times. The machine is not damaged and requires no costly readjustment. The laser cells are available with a Trumpf CO 2 laser with up to six kilowatts of power for cutting applications, and up to 15 kilowatts of power for welding applications. Trumpf solid state lasers with up to eight kilowatts of power are also alternately available. Superior Siemens “laser guidance” As with all laser machining systems of Trumpf, Sinumerik and Simodrive are used to handle the control and drives of the TruLaser Cell Series 7000. Trumpf utilized the open design of the NC core to integrate laser-specific functions into the Sinumerik 840D, to visualize the transformation for the 3D laser head and to optimize the communication of the laser and clearance control. Also wireless As a special “option” and teaching supplement, Trumpf also offers a display panel with a “wireless” link. The operator interface of the main control console is mirrored via WLAN (wireless local area network) and VNC (virtual network computing) on a distributed, battery-operated operator panel. Consequently, the operator is always aware of the current axis position. A Simatic Mobic T8 distributed industrial webpad serves as the access point. The “wireless design concept” has the advantage that the user, for example, can also take the display pan- motion world 1/2007
15 3D laser machining systems are suitable for many applications The operator is optimally protected during machining The machine head is equipped with a magnetic coupling that disconnects in the event of collisions with the workpiece All pictures: Trumpf el with him (or her) to the master office, and is always informed as to the status of the machine. Thanks to Sinumerik Safety Integrated, the TruLaser Cell Series S7000 is also stateof-the-art in terms of safety engineering. The operator is protected against uncontrolled axis movements and can, for example, in two-station operation, safely set up the second workpiece parallel to machine operation. As a result of the fact that the speeds are also reliably monitored, the operator can move about safely in the work area at any time, without any restrictions in terms of usability. Safety Integrated opens up new opportunities to enhance the operating convenience. For example, the axes remain under control after the safety equipment is opened. They are monitored for standstill by Safety Integrated. Once the safety equipment is closed, the axes are immediately ready for operation, and the operator does not have to switch on the power. Thanks to Safety Integrated, it was possible to also reduce the number of safety engineering components as compared to the predecessor machine. More information: www.siemens.com/sinumerik E-mail: thomas.wissert@siemens.com motion world 1/2007
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