Production “directly from the coil” with the new Tru Laser 8000 Coil Edition from Trumpf allows high volumes to be cut flexibly, sustainably and, above all, cost-effectively from a coil. The material savings are 15 percent.
© Trumpf
The automotive industry needs cost-efficient production. On the other hand, the lightweight construction required for lower fuel consumption calls for correspondingly lightweight materials for the car bodies. Particularly lightweight, high-strength aluminum alloys meet the safety requirements of the automotive industry. But aluminum alloys are generally less malleable and more expensive than steel, so should be cut sparingly. With Alumium Hotforming, Fischer, Achern, has an optimal forming process in house; now ‘only’ a cost-efficient way to cut the aluminum was needed for optimal production.
Since Fischer Group has just put Trumpf’s new TruLaser 8000 Coil Edition into operation, they don’t yet have any reliable figures on what the cost savings are for aluminum when coils are used instead of sheet metal. But “we previously had to have the coils cut by sub-suppliers in NRW and Lower Saxony, for example. Apart from the now better material utilization, we will save hundreds of truck trips in the next few years,” summarizes Hans-Peter Fischer, Managing Director and owner of the Fischer Group.
Designed for 24/7 operation and large-scale production
A common tool in high-volume production is presses with punching tools. But for every small adjustment of the respective components you need an adapted or even new tool, which takes time and costs money. In addition, presses require very massive, expensive foundations, quite unlike the relatively lightweight laser. The laser is also much more flexible and requires almost no changeover time. Since it operates without contact, it does not require a die change and changeover is done simply by reprogramming the control in a few seconds, whereas changing over a punch press takes in the order of one hour.
Conventional equipment such as punching is only worthwhile for large series and is less suitable for small series and prototype production. However, the machines for laser cutting have so far only been designed for large series to a limited extent. With the new TruLaser 8000 Coil Edition, producers can take advantage of flexible laser material processing even for large quantities.
The new laser blanking solution can fully process 25 tons of coiled sheet metal without human intervention. The components can be arranged more efficiently on the coil, which is up to 1.5 kilometers long, than on conventional metal sheets, saving around 15 percent of material. The elimination of tooling costs, optimum material utilization, reduced cycle times and high flexibility in production thus significantly increase profitability in production. In the case of steel, Trumpf already has experience here. “With this system, our customers can save almost 1700 tons of steel per year, which corresponds to around 4000 tons of CO2 and 1.6 million euros in material costs,” says Richard Bannmüller, Chairman of the Management Board at Trumpf Lasertechnik Deutschland.
The new plant was developed in cooperation with Siemens and Arku. Together with Trumpf, Siemens developed the control system and Arku was responsible for the coil module. It holds coils up to 2150 millimeters wide and can be loaded with various materials. The system cuts thin sheet with thicknesses up to 6.5 millimeters, regardless of the contours. It is of interest to all companies that want to manufacture larger quantities flexibly. The Fischer Group in Achern is one of the first three users of the new solution. The plant will be launched on the market in March.
© Fisher
Plant with intelligent features
When cutting the sheet, the innovative transport system ensures particularly fast material throughput. The entire line can be conveniently monitored and controlled from a mobile operating module, from the coil to the depositing of the sheet metal parts on pallets. The removal and the deposit positions of the sheet are automatically programmed and displayed on the screen.
The TruTops software calculates the input data for prefabricated cycles or part programs. The user therefore does not have to worry about specific robot movements or their programming. This means that no special prior knowledge or training is required for handling the robot.
To control unloading by means of a support strip conveyor and robot, Trumpf and Siemens used the new Sinumerik One CNC software, which is fully integrated in TIA Portal. With the data from the TIA Portal, the digital twin can be generated via Create MyVirtual Machine. In this way, the system can be virtually tested and commissioned and thus easily integrated into existing production lines.
With HFQ (Hot Form Quench) technology, the Fischer Group is able to form complex geometries from aluminum alloys with high efficiency. Multiple functions and properties can be integrated into the same component. This means fewer production steps, more effective processes, and competitive production costs. And with the new TruLaser 8000 Coil Edition, Fischer completes its aluminum production line. The plant and building therefore cost around 8 million euros, as an investment in the future.
Web:
www.trumpf.com
