Sheet metal processing in practice

Double duty

Coatings protect tools

and materials

Plus: Less wear –

longer service lives

The big picture

Transparency for shop machinery

with TruTops Monitor

Plus: Even faster response

to malfunctions

Credit note system

Xchange is TRUMPF’s

quality promise

Plus: Rebuilt parts are now

even more affordable


Part design workshops

encourage re-thinking

Plus: Saving time

and money with

engineering tricks



In operation

Technology news 4


The big picture, on demand 6

Laser processing

May we have a word?

The anniversary of the laser 10

Spare Parts and Bending Tools

Tucked away under the hood 11

Gentle bending 11

Technical Service

You can count on us – worldwide 12

Punching Tools

Coatings – double duty 13



Rethinking to save money 14


Changing players 16

Tips for fast tube fabrication 16

Spare Parts

Quality promise 17

As good as new! 17

Good to know

News about TruServices 18

Quick reference

Punching: Pages 12, 13, 14

Laser processing: Pages 4, 10, 12, 14

Bending: Pages 4, 11, 12, 14

Management: Page 6

TruServices Journal, February 2010 edition Sheet metal process-

ing in practice Published by TRUMPF Werkzeugmaschinen GmbH +

Co. KG, Johann-Maus-Str. 2, 71254 Ditzingen, +49 (0) 7156 303-0,, Responsible for content: Dr. Gerhard Rübling

Editor-in-chief Reinhold Groß, Project

coordination Katrin Oppermann Consulting Anke Roser, Presse-

und Öffentlichkeitsarbeit, TRUMPF Editorial staff pr+co. gmbh,

Stuttgart, Norbert Hiller, Julie Steinen, Monika Unkelbach Photos

Claus Langer, Digitalstock, Fotolia, KD Busch, Strandperle-Medien-

service Translation Stewart Lindemann, Wuppertal, Germany

Design pr+co. gmbh, Stuttgart, Ute Vogt Reproduction Reprotechnik

Herzog GmbH, Stuttgart Pritning frechdruck GmbH, Stuttgart

2 TruServices Journal 01|10

May we have a word with you?

The anniversary

of the laser

Dr. Paul Seiler, for many years

General Manager at TRUMPF

Lasertechnik, recalls the beginnings

and subsequent development

of a revolutionary

manufacturing technology.


New: TruTops Monitor

The big picture, on demand

The new TruTops Monitor software module

records all available machine data and evaluates

it in realtime. The goal: quicker response

in the event of malfunctions and more

productive planning for machine deployment.

Page 6

Technical Service

You can count on us — worldwide

Thrift is a virtue, but don’t cut corners

on service! We continuously expand

our network to be on the spot, all the

time, all around the world. Page12


Rethinking to save money

There’s major potential in

component optimization.

See how creative ideas

and suggestions on

part design can save

both time and money.



The term “Service Excellence” describes high aspirations and

high expectations. We know that our customers quite rightfully

expect us to achieve our own aspirations in TRUMPF services.

That is why we strive to fully satisfy their expectations,

day in and day out. But what does that mean for TRUMPF, in

very concrete terms? Over the past two years, in an effort to

align our operations more closely with customer needs, we

have conducted several in-depth customer surveys. As we evaluated

the results, we discovered that many of our subsidiaries

earned “excellent” ratings for certain processes.

The “Service Excellence Project” was then launched, concentrating

primarily on these outstanding examples. Denoted as

“best practice”, these model approaches are being introduced

in all of our markets, all around the world. To further improve

accessibility by phone, for example, we now put the caller directly

through to technicians who can provide expert support.

A central number is the gateway for all our service departments.

There’s no need to search through long phone lists. And even

though our technicians already receive exhaustive training,

we are continuing to intensify schooling to ensure excellent

service, on the spot, all the time. The project also focuses on

parts availability. The goal is to ensure that the right component

is always delivered, and that it arrives on time. Based on

the reported response times and an analysis of each process,

we have used the survey to determine what we must do to

achieve excellence in the users’ eyes. Ongoing monitoring will

let us institute further improvements whenever an opportunity

becomes apparent.

We are doing all of this right now because good service knows

no business cycles. Excellence always pays off. We would appreciate

any and all constructive feedback that might help us further

improve our services. Please write to

Dr. Gerhard Rübling

Managing Director for Services

TruServices Journal 01|09 01|10 3

Technology News

What we’ve spotted …

Concrete “to go”

How is a concrete mixer actually

manufactured? At Stetter GmbH

it’s done with the help of the

TruShear 5163. The company,

located in Memmingen, Germany,

uses these plate shears to

make up the sheet metal panels

used in transit mixers, batching

plants and residual concrete recycling

systems. The staff particularly

appreciates the machine’s

digital control. While in

the past the stop had to be set

manually with a lever, just entering

a number is sufficient

now. The shears quickly and

precisely cut metal at gauges of

up to 16 millimeters. In this way

the TruShear unit ensures that

the parts used in mixing and

transport units will fit together

perfectly. The rear stop, which

is under NC control and can be

swung upward, is a major advantage.

This feature keeps longer

parts from getting caught in

the stop. That saves time and

reduces stress.


The digital controls for the

TruShear 5163 simplify work

at the Stetter Company.

4 TruServices Journal 01|10

In operation

A prize for safety

// The current film entitled “Safety First: TruBend”

shows how important information about safety

when using press brakes can be presented in an effective

and entertaining way. The production was

applauded with a Silver Globe at the World Media

Festival Awards in May 2009. The film is intended

make operators and owners more aware of the hazards

and thus to help avoid injuries when working

with press brakes. The movie contains information

on how a TRUMPF press brake works and on the

safety concept, including all the required protective

measures. The film’s predecessor, “Safety First:

TruLaser”, was produced in 2008. It was the first

safety training movie of this type and specifically

addresses those who use laser machinery. Both

films are components of our operator safety in-

// Automating 2-D laser cutting equipment is

hardly imaginable without the LiftMaster. The lifting

chain — which also powers the vertical movement

of its adjustable arm — has been equipped

with an automatic lubricator since mid-2008. This

ensures that the right amount of the right kind of

lubricant is always applied. That, in turn, reduces

chain wear and the potential for damage to the

suction frame and other assemblies — and the ex-

struction efforts. They also support service

technicians when turning the machine over

to the owner. The movies can be ordered

from the technical editorial office.


The LiftMaster runs like greased lightning

Brush holder

Tube (filled

with fluid)

The automatic lubrication unit for retrofit use keeps

the lifting chain “limber”.

The “Safety First: TruBend” DVD provides

clear and descriptive safety information.

tended service requirements that can result

from such damage. When dealing with older

machines, the service intervals prescribed in

the maintenance manual form the basis for

a long service life. If lubrication intervals

are not observed or improper oils are used,

then damage is sure to follow. LiftMaster

expert Mathias Frenzel urges operators

of older machines to retrofit the automatic

chain lubrication unit. The refit kit is

quickly installed and keeps the chain supple,

in the interest of process reliability. The

battery capacity and the lubricant reserve

will suffice for about one year of operation.

The lubricant tank and battery kit are replaced

in the course of regular maintenance

activities. The retrofit kit is, of course, also

available for the LiftMaster Sort.


Ignazio Spagnuolo,

software expert at

the TRUMPF Demonstration


A bag of tricks


the way

The Pathfinder function in

TruTops Laser guides the laser

cutting head along a carefully

calculated course over the sheet

metal. It seeks out a path that

does not cross previous cuts.

Following this prescribed trail,

the cutting head can move over

the panel at close clearance

since collision with earlier cuts

is precluded. Pathfinder — a reliable

“scout” — thus eliminates

raising and lowering the cutting

head to alternate between the

travel and cutting heights. This

makes for greater safety and

reliability and higher machine

operating speeds.


The “Pathfinder” function in TruTops Laser

guides the cutting head over the sheet metal.

Change water just once a year

// The TRUMPF Easy-Kit contains everything

you need to replace the water in the

laser unit’s two cooling circuits. The chemicals

are color coded, making it easy to get

the dosage right. The Easy-Kit has now

been further refined so that the water only

needs to be changed once a year. Not only

does this cut costs, it also increases ma-

The new Easy-Kit: even simpler, even more compact

From quick sketch to CAD drawing

// Turning a hand-drawn sketch

into vector graphics? That’s easy

enough with a special function

built into TruTops Calculate.

The software imports scanned

drawings and converts them

into the required format. This is

important since CAD systems

and programming systems can

only work with vectorized

drawings. Various settings and

adjustments enable vectorization

even for drawings that do

not contain exact geometric

shapes. What’s more, the brightness

of the original drawing can be adjusted

so that the program can better recognize

the shapes. Superfluous lines can

be deleted with a few mouse clicks. Thus,

chine availability. Instead of changing out

the entire volume of water you simply add

the “Biocide Refresh” agent at the prescribed

time. That’s all there is to it. This is

made possible by the new corrosion prevention

concept for the aluminum components

in the cooling system: “Water Care-

Aluminum”. As of 2010 the new, compact

Easy-Kit (Part No. 0387048) will be

delivered with all laser machines —

at the same price. And, all of the

customers who used the earlier

Easy-Kit version can now convert

older laser machines to annual

coolant change with the new Easy-

Kit. The previous Easy-Kit (Part No.

0370000) will continue to be available

for customers in Switzerland

since different regulations for coolant

additives apply there.


The vectorization function in TruTops Calculate can help

even in difficult cases.

without significant effort, a concept

sketched by hand becomes a tangible

sheet metal part.


TruServices Journal 01|10 5

Technology Software

6 TruServices Journal 01|10

Which machines are running? Which

are idling? Where has trouble been

reported? Any uncertainty about the

status of production equipment can

quickly become costly.

The big picture,

on demand

TruTops Monitor

lifts the fog

with a quick

command and

in realtime.

Machine status with just a quick click using the new TruTops Monitor

// Machines are certainly the greatest cost

factor in manufacturing operations. That is

why no expense should be spared for monitoring

and data logging at every station. In

the future, transparency about machine operations

can be achieved with a push-button

command — without major investment and

with superb ease of use.

The new TruTops Monitor software module

expands the scope of manufacturing

control and can be installed as a stand-alone

application. Its task is to record and evaluate

machine data and portray machinery status

continuously, in a clear representation,

without delay, in realtime. The objective:

quick response to disturbances, making for

efficient and highly productive planning in

machinery deployment.

Data right from the source

TruTops Monitor automatically collects every

bit of machine data available, from every

workplace. That includes standstills, alarms,

fault reports, reasons for disruptions, regularly

scheduled breaks, and maintenance

periods. A number of recording options is

available for selection as desired. In TRUMPF

equipment the process usually runs automatically,

under the command of the machine’s

controls. Even when using systems made by

other manufacturers, a standardized data

interface permits automatic registration. In

addition, the operator can enter information

manually, using dialogue fields at a terminal

or with a barcode scanner, so that operator

feedback can be processed immediately.

Machine condition at a glance

All of the machine data is reflected in TruTops

Monitor. That let you see the current machine

status at all times. Any disruptions

are reported to manufacturing control immediately.

The entire production organization

can be monitored in realtime, enabling

quick and closely defined response. What’s

more, the information stored in a database

TruServices Journal 01|10 7

Technology Software

How TruTops Monitor

boosts utilization

TruTops Monitor evaluates the

utilization rate for a machine

and reveals any effects that

have a negative influence on

that factor. Both serve as bases

for optimization.

A numerical example:

If a machine is being used in

single-shift operations, meaning

1,700 hours a year, and if

TruTops Monitor can achieve

just a five-percent improvement

in the utilization rate, then that

means 85 additional hours of

productive time.

TruTops Monitor makes for transparency

all across the shop floor,

without major investment. Fault

logs and detailed fault analysis

are immediately available to optimize


8 TruServices Journal 01|10

can be accessed whenever needed. Webcams

can even be linked with TruTops Monitor so

that — during unstaffed night shifts — fault

diagnoses can be undertaken, from a remote

location, as an initial step.

Your choice of depiction modes

The user can select which data TruTops Monitor

will register, record, evaluate and visualize.

Called up by a push-button command,

the fully intuitive program first presents standard

assessments in pre-configured charts.

These can be modified to suit the user’s wishes,

and that includes changing the observation

period or a decision as to whether individual

units are to be examined — or all of the

machinery together. TruTops Monitor can

show the results as bar charts or pie charts,

line diagrams or in some entirely different

way, depending only on the operator’s wishes.

Individual worksites can also be grouped

together — by cost centers, for instance.

Intelligent statistics

This new software immediately relays every

alarm and report, enabling complete and

instant analysis of this information. The ten

most frequent fault reports will automatically

be inserted in the screen. This is often enough

information to let the manufacturing or operations

manager identify the reason for the

malfunction and initiate the appropriate corrective

measures. This might be something

like showing a forklift operator that he causes

stoppages by interrupting the photo-electric

beam — to name just one simple example. A

filter system makes it possible to query certain

aspects — and cancel reporting for others.

Thus TruTops Monitor generates a comprehensive

store of data that can be used to

improve processes. A small but very useful

software tool with great effects.

Your contact for software:



click Services / Software

Phone: +49 (0) 7156 303-3 07 06

From a module to a system

It goes without saying that TruTops Monitor

can be augmented with other TruTops Fab

modules. In the final expansion stage all of

the production processes in sheet metal

manufacturing can be controlled. Job cost

calculations, order nesting, NC program

administration and inventory management

— all of these areas can be covered

with this modular software solution. Optimized

processes ensure punctual delivery,

reliable quality and absolute dependability.

Whether press brakes, punch

presses or laser cutting units –

TruTops Monitor keeps a close

eye on the entire shop floor.

Charts showing operational

states can be selected at will.

Evaluations – of operating

status, for instance –

are shown immediately.

Intelligent malfunction statistics

show the most frequent reasons

for faults, at a glance.

TruServices Journal 01|10 9

Technology Laser processing

Theodore H. Maiman

built the first laser, in 1960.

Milestones —

Laser development


TRUMPF was an early pioneer in

laser technology. As early as 1971

TRUMPF Laser GmbH + Co. KG

(then HAAS-LASER GmbH) launched

development work for its own solid-state

laser. In 1979 TRUMPF unveiled

the first TRUMATIC punch

press and laser cutting machine.

The beam sources were CO2 lasers

purchased in the USA, with 500

and 700 watts of output power.

1971 HAAS-LASER built its first solidsate


1979 TRUMPF presented the

TRUMATIC 180 L, its first machine

to combine punching

and laser cutting.

1985 TRUMPF developed and manufactured

its own CO2 laser and

HAAS-LASER presented the

first laser using a laser light


1987 The TRUMATIC L 3000 was the

first flat-bed laser cutting machine

with flying optics.

1991 HAAS-LASER presented a solidstate

laser with two kilowatts

of continuous cutting power

using a laser light cable, opening

the door to solid-state lasers

in the kilowatt range.

1999 The disk laser multiplied output

potentials for the solid-state laser.

2009 The first multi-kilowatt industrial

laser using high-performance

laser diodes as the

beam source opened up new

applications in welding.


May we have a word with you, Mr. Seiler?

The anniversary of the laser

The laser is celebrating its fiftieth birthday in 2010. Dr. Paul Seiler —

a pioneer in solid-state lasers and until 2003 General Manager at

TRUMPF Laser GmbH & Co. KG in Schramberg — looks back.

Was the laser’s triumph as an industrial tool a systematically planned project?

Dr. Paul Seiler: Quite the contrary! The discovery of laser light by Theodore H. Maiman in

May 1960 triggered a wave of euphoria and scientific inquiry. But that was followed by disappointments

and unfulfilled expectations toward the end of the decade. It was more by

chance that various development lines merged in Germany in the early 1970s. They culminated

in the first industrial application of the laser: welding spiral springs for mechanical

clocks, performed at the Carl Haas company in Schramberg.

What helped the laser make its breakthrough?

Dr. Paul Seiler: Automated welding for large numbers of spiral springs represented the

solid-state laser’s debut in industrial manufacturing. Further successful applications

prompted AEG-Telefunken and then in 1978 Philips — the world’s leader — to use lasers to

weld the electron guns for television picture tubes. This was the first instance of appreciable

piece counts. High-performance CO2 lasers, in turn, discovered their full potential in sheet

metal. In 1979 the first TRUMPF combination punch and laser cutting machine was presented

to industry. In 1980 Autz + Herrmann, a job shop

in Heidelberg, was the first to recognize the potential

of light as a tool.

Would you say that laser has a bright future

as a tool?

Dr. Paul Seiler: I’m quite confident about that. That’s

because engineers are very conscientious about aligning

developments with applications. More and more

industries are realizing how the laser can lend

speed, efficiency and economy to so many

manufacturing processes. The laser has “arrived”

as a tool. And laser light will most

certainly find uses as a tool in many other

fields. Its future is certain to be bright.

Additional information:


Dr. Paul Seiler

was a pioneer

in solid-state

lasers for industrialapplications.


Gentle bending

Clean surfaces and contours

with the RollaV die

// Bending that’s gentle on the surface and free of deformation is

no longer just an engineer’s dream. The special design of the new

RollaV die now makes it possible to bend sheet metal — without

deformation — near holes, notches and cut-outs. The contact surfaces

on the sides of the die press the sheet metal uniformly into

the lower die. This eliminates any relative movement between the

tool and the part being formed and that eliminates friction losses.

Panels with a film finish will no longer be damaged and the critical

surfaces of sheet metal panels intended to be seen are protected.

At the same time the dies is particularly well suited for diagonal

bends and parts that are tapered. Very short lengths can be bent,

and in a variety of material gauges. Depending on the design of

the die, in sizes 1 to 3, sheet metal from 0.5 to 6 millimeters thick

can be procesed. The RollaV die thus makes for greater latitude in

bending — and less risk.

The RollaV dies can be used in these models: TruBend Series

3000, 5000, 7000, 8000 and the TrumaBend V-Series and C-Series.

Combination with the BendMaster is possible and programs are

written with TruTops Bend.


Martin Lambert, developer responsible for

laser heads, with the optimized phase shifter

The RollaV die provides greater leeway in bending.

Warp-free, in three sizes

Spare Parts and Bending tools Technology

Tucked away under the hood

// A small but important optical component

imposes circular polarization on

the laser beam: the phase shifter. This

technology makes it possible for the laser

to cut in every direction, at perfect quality.

The phase shifter itself is a mirror fitted

with an intricate dielectric layer. The coating

does in fact ensure correct polarization,

but also consumes more of the laser’s

energy. That makes the phase shifter

more sensitive than a conventional diverter

mirror inserted in the beam’s path.

Max. recommended


TRUMPF’s developers have now optimized

the phase shifter in the TruLaser

3030 and 5030 and in the TruMatic 7000

to such an extent that it will last as long

as a diverter mirror. This was achieved

in part by an ingenious change in the

unit’s dimensions and in part by optimizing

the installation location. It is

now found tucked safely away under the

laser’s protective hood.


RVT100-1 RVT100-2 RVT100-3

1.5 mm 3 mm 6 mm

Max. outside radius 5 mm 9 mm 24 mm

Min. bending angle 30° 65° 75°

Die width 8 mm 15 mm 35 mm

Max. loading 1 000 kN/m 1 500 kN/m 2 500 kN/m

Minimum side length,

outside dimension

4.7 – 5.6 mm 8.7 – 10.2 mm 24.3 – 26.5 mm

TruServices Journal 01|10 11

Technology Technical Service

You can count on us — worldwide

Customer service is our strength and your advantage

12 TruServices Journal 01|10

Perfectly organized: Maintenance

All of the preventive maintenance

carried out under our Service

Agreements follows a standardized

checklist. This guarantees first-class

quality, all around the world.

Information: Telephone hotline

The technicians who staff our help

desks are experts in their fields. Our

specially developed service information

system shows them your machine’s

complete “biography” at a

glance. That makes for quick error

identification and concrete suggestions,

while you’re still on the phone.

Expert: Repairs

Our technicians participate in excellent

training. Troubleshooting and quick

problem solving are major topics during

the months of schooling at the

Ditzingen Training Center. The technicians

gain practical experience by accompanying

experienced co-workers

during commissioning, repair work and

maintenance at client operating sites.

Versatile: Commissioning

From on-site consulting prior to

delivery — including help in finding

a suitable forwarding company —

right through to expert installation,

start-up and operator training: our

specialists are at your side.

Flexible: Service Agreements

Do you want even more comprehensive

service support?

That’s easy enough. Our individualized

service contracts

boost machine availability

through regular maintenance

and, with software updates,

keep you on top of things.

On call: Remote diagnosis

In many cases our help

desk can solve problems

from a distance. That

makes a service call unnecessary

and reduces

downtime, too. Every inquiry

is processed and

logged in the service information

system. This

helps achieve clear and

reliable diagnoses and

short response times.

Boundless: Service

Fifty-two service sites and 1,100

service technicians in regions

all around the world. You know

we’re nearby, wherever you


>> isc@


New and gentle pressure: A stripper with a polyamide coating

The stripper has to satisfy two opposing

requirements. On the one hand it has to

separate the sheet metal perfectly from the

punch. On the other hand, the presser foot

and stripping process cannot leave an imprint.

And it is precisely for such applications

that TRUMPF now offers strippers

with a newly developed polyamide coating.

This finish, thanks to its smooth surface, is

impervious to dirt and is wear-resistant. It

offers dust and chips hardly any opportunity

to lodge in place. Over and above that,

the stripper with this new coating is far less

2The primary cause of wear in punching

tools is the formation of the so-called

built-up edge — where particles of the material

being processed join with the surface

of the punch. Coatings can avert this phenomenon.

The result: longer service life,

even after being resharpened several times.

TRUMPF offers three different variations.

The choice depends on the application and


MultiDur T iCN, the time-tested standard

coating, is distinguished by toughness and

hardness and offers great wear resistance.

MultiDur Performance guarantees

even longer tool life. This high-end coating

for mild steel and stainless steel also reduces

friction between the tool and the material

being processed. Tooling can be used for a

considerably longer period of time.

likely to leave an impression when used

as an active presser foot. These units can

process sheet metal up to eight millimeters

thick and are compatible with

standard strippers if needed.

Used with the active

die, which guarantees

unblemished quality

on the back of the

panel, coated strippers

are your guarantee

of impeccable

surfaces all around.

Coatings — double duty

MultiDur Alu is the coating developed

especially for punching aluminum. It reduced

friction and, as a result, edge buildup

is significantly reduced. MultiDur Alu

Punching Tools Technology

Polyamide-coated strippers for scratch-free sheet metal processing and the MultiDur line of

coatings to limit tool wear. Special finishes protect the punching tool against abrasion and ensure

reliable processing. Especially in light of the increasing use of high-strength materials, this is an

extra that pays off in the long run. >>

Long-lived thanks to coatings: MultiDur

Number of punching strokes








Uncoated MultiDur TiCN MultiDur


The new polyamidecoated

strippers leave

far less noticeable

impressions when used

as “active presser foots”.

guarantees these advantages even when

processing aluminum dry, so that laborious

touch-up cleaning of the sheet metal

after processing is eliminated.

MultiDur Alu

Coatings make tooling

more resistant to wear

and able to withstand

even extreme use.

TruServices Journal 01|10 13

Knowledge Consulting

Rethinking to save

Sometimes it’s just a tiny trick. Sometimes more extensive

creative solutions reduce the number of processing

steps in manufacturing and reduces costs. Working with

your engineers in part design workshops, TRUMPF develops

ideas and manufacturing options that help optimize

your components.

This is how a workshop works

Using a real part as a concrete example, the group discusses

options for optimizing manufacturing and design.

Those ideas are converted into sketches and models. The

new part is then engineered using a CAD system and

made up in the shop. The outcome is a part that can be

fabricated more quickly and more economically thanks to

a few tricks, some creative ideas and applied knowledge.

Are you interested in more profitable manufacturing?

Together we can find a solution.

14 TruServices Journal 01|10

“Part design workshops” deliver innovative ideas. Shown here are just

three of the many successful part optimization solutions worked out

in more than 275 workshops.

TRUMPF workshops on part design focus

on these subject areas:

• Sheet metal

• Laser welding

• Tubing

• Sheet metal processing sequence

The workshops are designed for employees

involved in engineering, work scheduling and manufacturing.

The sessions last about three days.

Your contact for consulting:



click Services /Consulting

Phone: +49 (0) 7156 303-3 63 41

75% fewer parts

50% less welding

52% cost reduction

Laser cutting for part

consolidation and

simple positioning

Example: Guide frame

Before After


• 8 parts, 2 drawings

• Angles, bars

• Weld, position

• 16 welding seams

• Jigs are required

• 100% costs

• 2 parts, 1 drawing

• Sheet metal

• Simple welding,

no positioning

• 8 welding seams

• Only chucking is required

• Microjoints and manual


• 52% less expensive



75% fewer parts

58% less welding

41% cost reduction

Reducing the number of

parts through bending

Example: Roller holder

Before After

• 4 parts

• 2 angles, 1 tube, 1 bar

• Laborious welding,


• 12 welding seams

• Simple jig required

• 100% costs

• 1 part

• Sheet metal

• Simple welding

• 5 welding seams

• Simply chuck in place,

no custom jigs required

• 41% less expensive



processes pay off.

67% fewer parts

100% less welding

38% cost reduction

Replacing welding with

laser cutting and bending

Example: Cable tray bracket

Before After

• 3 parts

• 1 tube, 2 bars

• Welding, positioning

• 8 welding seams

• Simple jig required

• 100% costs

• 1 part

• Sheet metal

• No welding

• 38% less expensive

TruServices Journal 01|10 15

Knowledge Software

Changing players

“Storage”, the new inventory tool, replaces TC-Cell

// Featuring the most modern architecture, a user-friendly Windows

GUI and even more advanced functions, “Storage” — the new inventory

administration and material flow control concept by TRUMPF —

supersedes “TC-Cell”.

Storage, a TruTops Fab Module, administers both manual storage

and automatic warehousing systems. Simple storage location management,

positive batch surveillance and optimum linkage with machinery

are the major advantages Storage offers. One new feature is that

all the functions can be called up conveniently in a Windows graphic

interface for intuitive control. Simplified navigation and user-oriented

screen modifications make using the system easy.

Storage is a TruTops Fab module that can run autonomously. Used

in conjunction with other modules in this comprehensive software

solution, it offers numerous additional options. So, for instance, it is

now possible to automatically manage remnants in accordance with

the remaining geometries or to conveniently initiate stock reorders

using the “Purchasing” module.


Tips for fast tube fabrication

New productivity tools for TruLaser Tube

16 TruServices Journal 01|10

3-D engineering provided by the client can

be imported with a push-button command

and augmented by designing positioning jigs.

For even better performance: Storage is the successor to TC-Cell.

// 3-D tube interface: Importing and processing 3-D data. The

3-D capacities in TruTops Tube enable quick engineering for the

widest variety of tube designs.

The 3-D tube import function can now be used to read in designs

that have already been engineered in 3-D, with a push-button

command. This applies to the .STEP, .SAT, .IGES, .sldprt, and

.sldasm file formats. Your advantage: physical tubing attributes

can be allocated to these imported components. What’s more, automatic

processing in the TruTops Tube technology section is possible

immediately, without post-processing or time-consuming


Positioning aids: Are you familiar with the function used to

pre-process customer data, making it possible to generate data for

positioning jigs used to simplify assembly? The useful positioning

aids help avoid incorrect assembly. The parts are keyed so that they

can be assembled in one way only. Positioning aids also improve

joint welding quality by ensuring that the parts are in full contact

across all the mating surfaces and cannot slip. This represents an

ideal solution for attached fixtures.


Quality promise

New: Spare Parts made simple and sure with Xchange

// TRUMPF stands for continuing high quality. But if — contrary to

all expectations — a spare part should fail within the first four

years, then “Xchange”, the new credit system for spare

parts, goes into effect. When purchasing the replacement,

the customer receives a generous credit note

for the returned part. Xchange is used for all highvalue

parts. If a component is an Xchange part,

then this is indicated in all the delivery documents

and is visibly labeled on the carton. The

parts returned will be thoroughly overhauled

by TRUMPF and, of course, meet the company’s

high quality requirements. A plus for the customer:

lower prices! These reconditioned parts are being

sold, effective immediately, at prices 30 percent

below those for new parts — as long as supplies last.


Rebuilt parts in

customary TRUMPF

quality are a genuine

alternative. Take

advantage while

supplies last!

If an Xchange part

fails prematurely,

then we fulfill our

quality promise

with generous


// Here is where the inner values

count, making rebuilt parts by

TRUMPF an attractive alternative.

At TRUMPF, “rebuilt”

naturally means that the parts

are technically perfect. That is

why the guarantee terms are

identical to those for new parts.

And if the new part is an Xchange part,

then the reconditioned part is also covered by

the Xchange system. The savings are considerable:

a full 30 percent when compared with the new part.

That makes it worthwhile to overlook the occasional

scratch in the paint. Rebuilt components and the Xchange

credit system for spare parts — an exciting prospect for

everyone interested in saving without sacrificing quality.


Spare Parts Knowledge

As good as new!

New: Rebuilt Spare Parts more

economical than ever

TruServices Journal 01|10 17

Knowledge News

Good to know

Liquid Gold

// Anyone who scrimps on oil might ultimately pay a high

price. The Universus gold 5W40 hydraulic fluid, now available,

makes sure the TruBend 3000 and 5000 Series machines

run like clockwork year after year. This fluid offers tangible

advantages that return handsome dividends. The new hydraulic

fluid tolerates mixing with other HLP and HLPV oils.

The result: Even if someone grabs the wrong fluid when topping

off the system, the costs for a complete fluid change and

disposal are unnecessary in most cases. A further advantage:

Universus gold 5W40 is compatible with water. Up to 0.3 percent

water content in the hydraulic circuit will not cause

clouding or foaming, nor will it affect air separation qualities.

This is a major benefit when operating in regions where high

temperatures and high humidity prevail. In comparison to

HLP and HVLP compounds, this new fluid contains more

detergents, to keep the system cleaner, longer. The fully-synthetic

Universus gold 5W40 ensures long service life — about

ten years — for each fill. It is significantly more stable in vis-

The right program, every time

Monika Baierl-Möhler calls herself Sherlock Holmes

since software troubleshooting has been her specialty

for nineteen years now. As project manager, she helps to

write the TruTops suite used to generate NC programs for

TRUMPF machinery. To make sure that the programs and

controls match perfectly, this precision mechanic is often

called upon to contribute to machine engineering efforts.

Anton Hiller has worked at TRUMPF for 31 years now.

He ensures that the software is assembled and shipped as

requested. When the order is received Anton Hiller enters

all the software components in the TRUMPF Support

System. In this way the service department has a

survey of the programs installed in the customer’s equipment

and can automatically supply current updates according

to the maintenance contract.

18 TruServices Journal 01|10

2 clever minds

A fluid for all occasions: The new Universus gold 5W40 keeps

press brakes fit – even under the most adverse circumstances.

cosity than petroleum-based fluids. Full performance is assured

even at high and low temperatures. A special additive

also reduces surface friction. The “stick-slip” phenomenon —

the abrupt transition between sticking and sliding inside the

hydraulic cylinder — is avoided.


Quicker installation

// The service team has made its goal to reduce by a

full thirty percent the set-up times for every kind of

technology. SYNCHRO, the TRUMPF manufacturing

philosophy, will help do this. SYNCHRO means perfectly

coordinated procedures, from sales to final assembly.

That’s because a customer who buys a machine

expects not only first-class technical expertise

but first-class service, as well. And that starts with

the delivery. TRUMPF can, for instance, recommend

capable forwarders to handle the shipment.

If desired, the customer can also

buy complete shipping services from

TRUMPF. Once the machine is

on the shop floor, forwardlooking

preparations can help

avoid nasty surprises. That

saves both time and money

and is easier on everyone’s

nerves, too. An on-site inspection

by a sales associate

or installation manager

helps to prepare the customer’s

staff, the surroundings

and the service team for

the upcoming work. That’s a

service that pays off.


More productive bending

// Enhancing productivity is the spirit embodied in the new 6.0

version software used to control all of the press brakes in the

TruBend Series 5000. One intelligent twist to speed up manual work

is the “parallelization” of operations. An optimized strategy for rear

stop motion makes for quick and safe repositioning. In parallel to this,

the foot switch can be used to trigger the stroke right from top dead

center. The beam and backgauge move together, saving time. While

this is happening, the backgauge dives at high-speed into the safety

area. Because this unit is hinged, there is no danger of fingers being

pinched. The software provides further benefits in terms of speed: The

BendGuard now recognizes the box

height and, when working in the box

mode, runs without stopping. Tests

on equipment housings have shown

that — with eight bends made at two

stations — the equipment achieves up

to twenty percent shorter machining

periods for the individual parts. In

addition, the 6.0 software provides

faster bending cycles in automated

systems using the BendMaster or industrial

robots. This is done, for example,

by reducing the mute point

from five millimeters to just one and

thus maximizing the high-speed

mode at 200 mm/sec. The new software

can be retrofitted on all units

in the TruBend Series 5000 with

TASC 6000 controls.


V max

TRUMPF in-house fair: INTECH 2010

// From April 27 to 30, 2010, the TRUMPF campus in Ditzingen will

once again be transformed into an innovations fair for sheet metal manufacturing.

The services division will also be on hand with a range of interesting

subjects. Visitors will learn how the Integrated Tool Management

and new Punching Tools can save valuable time and money. They

will also see how TruTops Monitor keeps you on top of everything in

your manufacturing operations (see also our article on Pages 6 to 9).

And of course you can also obtain complete information about our applications

consulting, workshops and training seminars. Attending will

certainly be worth your time. We are looking forward to seeing you.


Rear stop



With its optimized travel strategy

the backgauge quickly approaches

the safety area. The upward movement

poses no hazard to the operator.

TruServices at a glance

> Finance

Stay flexible on a solid basis

> Software

Programmed for success

> Punching Tools

Know-how for every application

> Bending Tools

Customized to your specifications

> Spare Parts

Quality in every detail

> Technical Service

You can count on us

> Service Agreements

For the highest

machine availability

> Product Enhancements

Your machine can do more

> Customer Training

The knowledge advantage

> Consulting

Advice through experience

> Pre-owned Machines

First choice for second hand


Wash troubles away.

The prime objective of good

service in mechanical

engineering is to increase the

customer’s operating yields:

boosting production output by

way of increased machine

availability. This is closely

associated with the service

organization’s obligation to do

everything necessary to correct

deficiencies — as quickly as

possible. This may be done with

remote maintenance, often saving

the technician a service visit. Our

global service information system

shows a machine’s entire history

and that makes for positive

diagnoses and short response

times. Problems are remedied

quickly reducing downtime. If

a part needs to be replaced, then

our lightning fast spare parts

service makes it easy. That’s

service to clean up the problem.

Thinking service?

Think blue!

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