Punching Machine Adaptability: Room to Grow

An entry-level segment punching machine that can gradually be expanded into a fully-fledged combination machine has caught industry attention with a host of innovative features from punching holes to bends flanges and forms threads. By Trumpf

The search for an economical, compact and automation-friendly punching machine that is specifically designed to grow with their business will be unveiled by Trumpf at this year’s Euroblech. The TruPunch 1000 can be expanded into an equally space-saving TruMatic 1000 fibre punch laser machine, allowing sheet metal processors to upgrade their machine to keep pace with their growing business.

Solid-State Laser

With its expandable functionality, the TruPunch 1000 provides the perfect entry point into the world of professional punching. It can handle sheets up to 6.4 mm thick at rates of up to 600 strokes a minute, yet is remarkably compact. With a footprint of just 6.5 x 4.9 metres, the TruPunch 1000 stand-alone machine is around 15 percent smaller than its predecessor.

“The space we have here is limited, but the compact TruPunch 1000 slotted into the same space previously occupied by a Trumatic 200,” said Thomas Herberger, managing director of Herberger Metallwaren, a company that participates in the product testing program. “Now we can process medium-format sheets without having to reposition them and that really speeds up our production process.”

As their business evolves, sheet metal processors sometimes yearn for the greater variety of parts that can be manufactured by a combination system – and with the TruPunch 1000 there’s no need to buy a second machine. Thanks to its novel modular design, the TruPunch1000 can be retrofitted with a laser cutting system, a laser evacuation unit and a beam guard system.

A three kilowatt TruDisk solid-state laser can be connected up to convert the TruPunch 1000 punching machine into a punch laser machine. This configuration precisely matches the other recent addition to the product range of Trumpf: the TruMatic 1000 fibre.

A First

This is the first time that Trumpf has offered a combination machine in the entry-level segment, a move that makes it easier for customers to make the switch from purely 2D laser processing to punch laser technology.

Customers who already have a TruDisk solid-state laser can also use this to operate the TruMatic 1000 fibre via the Trumpf laser network. The price of the new machine is undoubtedly appealing, and – with the TruMatic 1000 fibre’s specifications matching those of the previous TruMatic 3000 fibre model – customers don’t need to sacrifice anything in the way of performance.

Both the new models in the 1000 range offer completely redesigned drive technology, which is crucial to the success of the modular concept.

The patented “Delta Drive” literally marks a new movement in the world of industrial punching technology. The advanced engineering team of Trumpf came up with the new drive to facilitate the construction of smaller machines and open up new methods of material handling.

The secret of the Delta Drive is that it eliminates the need to move the sheet and work table in the y-axis – normally an integral requirement of sheet metal processing. It achieves this by making the punching head quickly manoeuvre in that direction.

This new approach involves a drive system that is powered by two servomotors. When the servomotors move in the same direction, they allow the punching head to move back and forth in the y-axis. And when the ball screws rotate in opposite directions, this activates the punching stroke.

The y-axis can be accelerated far faster in this arrangement, because the punch drive is also used for travel motion, eliminating the need to move the sheet or work table.

As a result, the punching process is more dynamic and the machine is more productive. Furthermore, the lower relative movement between the machine table and the metal sheet reduces the risk of jamming and collisions, making the process more reliable overall. Finally, the stationary machine table significantly reduces the size of the machine’s footprint.

Automatic Sorting

Both the TruPunch 1000 and the TruMatic 1000 fibre can automatically sort finished parts measuring up to 180 mm × 180 mm. All processed parts are sent down a chute into a sorting unit which moves in a linear direction. From there they can be sorted into a series of boxes (up to 4 different 400 mm × 300 mm boxes). The boxes are positioned below the machine, which provides for easy removal by the operator.

Due to the innovative movement of the punching head, the machine also offers an alternative way to remove the parts. This second method comprises an additional big flexible parts flap, which is available as an optional extra for the TruPunch 1000 and fitted as standard in the TruMatic 1000 fibre.

The flap can be equipped with a sensor that detects whether all the parts have been properly ejected from the machine’s working area. Designed with relatively generous proportions, this parts flap can also be used to eject long and wide parts into containers or onto conveyors or pallets during both punching and laser operations.

“Often we fill sheets with just four to six parts, and in the past we had to remove and sort them manually,” Trumpf testing partner Herberger of explained. “But with the TruPunch 1000 nobody has to keep watch over the process because the machine simply ejects the parts through the generously sized flap and places them straight in the crate for us.”

Right Fit

Trumpf was also determined to make the TruMatic 1000 fibre as compact as possible. One way the company achieved this was by developing a special space-saving beam guard system that is compatible with the machine’s modular concept. This protective housing is gathered closely around the machine table in a skirting manner. In punching mode it moves downwards, giving the operator a direct and unobstructed view of the process.

But as soon as the program switches to laser processing, the protective skirt rises and a hood is lowered over the Delta Drive, to which the laser processing unit is attached.

This protective screen effectively intercepts the small amount of scattered that could potentially escape at a shallow angle below the work table brushes during production. There are also two laser safety screens that allow visual monitoring of the ongoing process.

Even in their automated versions, these two machines from the 1000 product series are more compact than any other comparable machines on the market. Both of them can also be connected to the new SheetMaster Compact.

This automation system loads small and medium-format sheets and blanks and unloads micro joint sheets and scrap skeletons. Thanks to its optimised loading cycles, it can reliably complete most of these tasks while the machine is in operation. Both machines are equipped with an intuitive touchscreen to make life easier for operators. The MobileControl app can also be used to operate the machines from a tablet.

The TruTops Boost Punch software is required for programming, and both the license and maintenance agreement already come with the machines as standard.

Delta-Drive eliminates the need to move the metal sheet and machine table in the y-axis by moving the punching head in this axis instead.

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