It can do what none other can: It can process without scratching. Moreover, the high-end  TRUMPF system can maintain speeds like never before, thanks to additional X and Y axes for the laser cutting head.The movements of these flying optics are superimposed on the axes of the table. To coordinate such complex kinematics, TRUMPF has developed a CNC controller combining the high-performance “IndraMotion MTX” controller by Bosch Rexroth with the drive-based “IndraMotion MLD” motion controller, to utilise the advantages of decentralised intelligence.

While the higher-level NC control system regulates the main movements of the workpiece directly, the drivebased motion logic moves the laser head in an additional 52-millimetre radius. The superimposition of the two movements significantly increases the absolute traverse speed, shortening processing time, in particular for detailed parts with complex contours and many directional changes. At the same time, it steadies the motion of the machine table, transferring sudden movements to the tool head, thus moving significantly lower mass. This means the machine runs more quietly and with less vibration than conventional concepts.

The Rexroth control systems work with the same internationally standardised control software. The automation system calculates the contouring error for the superimposed motions in advance, carrying out detailed processing steps with the workpiece stationary. That means the table doesn’t need to make corner movements with braking and reacceleration; it simply takes the shortest path while the parallel additional axes even out the difference and cut out the finer geometries. So the new design – at any speed – is able to achieve very high precision.

Since the beam guides have also been redesigned, the TruMatic 7000 can now work with a single focus by default. That means the combination machine uses the same cutting head for all sheet thicknesses, and time-consuming changeovers are eliminated. An automatic nozzle changer also takes care of changing cutting gas nozzles. That reduces downtime while  simultaneously increasing flexibility. The user can cut any material at any time and at any thickness, in any order, even in unmanned 24-hour operation.

When it comes to unloading, the TruMatic 7000 also sets new standards. First, scrap can simply be cut up and disposed of through the laser die, which has a particularly large diametre at 52 millimetres – so flap cycles can be eliminated entirely. And second, the newly designed two-part laser flap also helps reduce unloading time. It consists of two flap halves that move the part, which can be up to 500 by 500 millimetres in size, out of the workspace within a second. The laser flap of the TruMatic 7000, equipped with brush lines, can also be lifted by one or two millimetres so that the sheet does not contact the laser die during cutting. That means no more scratches on the bottom of the sheet at the laser station. This measure is part of the scratch-free processing strategy of the new punch/laser combination machine.

Another feature is the active die which works from the bottom, like a second punching head. It is built into the underside of the work table and its height can be adjusted. When sheet metal is positioned or moved on the machine, it can be lowered under program control, not touching the table. So even during punching and forming, no scratches on the underside can occur.

The active die provides users with more flexibility, allowing larger and higher forming with entirely new tools. In addition, forming upwards and downwards can be made in a single step. That is because the active die enables an active forming stroke from underneath in the following way: The machine positions the sheet metal, while the die is lowered. Once the table is in the desired position, the punching head clamps the sheet from above, and the die performs the active stroke from below. Then, the punching head and the die move back to the starting position before the table is repositioned. Another advantage of the active die is that the sheet metal now always lies completely on the table, meaning that it can be processed closer to the clamps because there is no deformity. That reduces the dead zone, lowering material costs. In addition, the active die simplifies programming for the machine. It no longer represents an error contour which must be taken into consideration during calculation of the positioning movement.

Besides the laser and punch functions of the machine, its automation has also taken a step forward to match the productivity of the machine. When using the SheetMaster loading and unloading unit, which integrates seamlessly into the open NC control system, the machine can cut and unload up to four parts at the same time. The SheetMaster has four suction strips which can be positioned up to 120 millimetres in the Y direction. Together with the suction frame, which can be offset by 400 millimetres, the strips can be positioned to the right and left of the laser head. The suction strips, whose flexible suction cups are all vacuum-monitored, grip the parts before they are separated from the sheet skeleton. The last millimetres of the cut are carried out with the sheet stationary – increasing process reliability for fine geometries.

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