Bringing together the benefits of punching and laser cutting, combination machinery is one of the most versatile technologies that fabricators can add to their production. A combination machine, such as TRUMPF’s TruMatic 5000, combines the processes of punching and laser cutting, and even threading and forming, into one unit, allowing fabricators to handle a wide range of materials and designs. This versatility enables manufacturers to produce various components without the need for multiple machines.
Innovative technology like automated combination punch-laser machines can give fabricators a competitive edge. The technology fosters innovation in product design and helps manufacturers respond quickly to customer needs and offer more complex solutions. To further optimize productivity, several options can be added to combination machinery to take the system to the next level.
Tool setup, management, storage
On punch machines, tool handling is a necessity. While five- and 10-station multi-tools can increase the machine’s capacity, large-part file catalogs often require more tools than can be loaded on a standalone machine. These additional tools must be hand loaded into the rail.
To aide in this tool handling process, TRUMPF developed the ToolMaster, which stores tools offline and automatically adds and removes up to 90 tools from the rail, as needed. This enables quick changeovers and reduces setup times. In addition, the ToolMaster provides organized storage for punch tools, making it easy to access and maintain them, which helps prolong tool life and optimizes their performance.
By conducting setup operations in parallel with production, automated tool changing increases productivity by minimizing the downtime between jobs. It also makes tool setup easier by identifying and managing various tools, ensuring that the correct tool is used for each operation. This reduces errors and improves overall precision.
Capable of running during an unmanned shift, the fully automatic tool changer provides the necessary tools quickly, safely and in the correct sequence. The ToolMaster Linear provides space for an additional 18, 54 or 90 tools, which are automatically positioned in the linear magazine of the combination machine. Extra tool capacity makes it easy to quickly and automatically produce orders with varied or complex parts that require numerous tool changes.
Loading and unloading
Automated material handling unlocks a machine’s full potential. Material handling automation makes it possible for machines to operate continuously without interruptions for loading and unloading, which leads to higher production rates.
TRUMPF’s SheetMaster is an automation solution designed to enhance the productivity of the TruMatic 5000. The SheetMaster automates the loading of raw material sheets into the TruMatic 5000 and the unloading of finished parts from it. The automated load/unload feature reduces manual labor requirements, minimizes the downtime associated with manual handling and frees up operators to focus on other tasks. In addition, with cart options, the automation system can handle material changes to reduce the changeover time between jobs, contributing to overall efficiency.
To further decrease program changeover time, raw sheets are pre-separated by a peeling unit that is completely independent of the SheetMaster. By streamlining the workflow, the SheetMaster ensures that material is always available for processing and that finished parts are efficiently removed and organized. It can separate, palletize and stack finished parts, which makes it easier for operators to manage output and prepare for subsequent processes or shipping.
Cleanup is also made easier by automation. For example, TRUMPF’s GripMaster automatically removes and stacks scrap skeletons, remainder strips and microjointed sheets. The GripMaster detects and reports the scrap stack height so that the operator can remove stacks in parallel to production and simply unload the scrap using the integrated dumping table.
Small part sorting
Automation options go beyond the obvious large parts and extend to smaller and difficult-to-handle pieces. Another way to enhance the productivity of combination machinery is to add a chip conveyor and multi-bin sorting system. Implementing these features not only enhances productivity, but also helps manufacturers increase operational efficiency and reduce labor costs, which ultimately leads to higher profitability.
On the scrap side, any punch or combination machine will always generate “slugs” or bits of scrap metal. A chip conveyor transports the punch scrap from under the machine frame to a convenient dumping container. This gives the operator clear visibility of scrap buildup and ensures the machine can run for extended periods without interruption. Automated removal of waste not only keeps the work area cleaner, but a large and easy-to-use tipping container also minimizes the number of dump cycles required. Fewer dump cycles translate into more time for operators to concentrate on other essential tasks.
Another automation option, TRUMPF’s four-bin sorting system, complements the chip conveyor by organizing finished parts. While separating a sheet nested with many small pieces can be a hassle, the four bin sorting system allows for packed nests to be sorted accurately and during production. A special “small part removal tool” reliably removes parts that have been tabbed-in while laser cutting and sends them into the sorting hopper. This tool works with parts 7 in. by 7 in. or smaller.
Easy math for productivity
Combination punch-laser machines are designed to help manufacturers enhance productivity, improve quality and adapt to an ever-evolving market landscape. Adding automated tool setup, management and storage plus automated sheet loading and unloading features plus small part sorting equals more productive punch-laser processing.
By making simple additions to combination machinery, companies can subtract wasted time, reduce costs and multiply their productivity dramatically. It truly is a winning equation.
