Autonomous laser cutting – products and functions

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Large strides forward: intelligent sensor systems increase productivity

One part of our vision is already a reality. Intelligent assistance systems for laser cutting develop execution strategies, for example, which prevent collision with tilting parts, or make post-producing of parts out of scrap skeletons easier. Even nozzles are automatically inspected and replaced if necessary. The proportion of machine functions which control processes independently is ever-increasing.

An important milestone on the path to autonomous machines is the newly developed Active Speed Control system for adaptive feed control. The system monitors the kerf through the nozzle, oversees the cutting process and independently regulates feed speed. It ensures the right feed level for flame and fusion cutting, even in the event of thickness variations in a sheet, or if the sheet has been affected by quality fluctuations (i.e. rust or coating remnants). Data analysis makes quick and stable cutting possible. This can prevent disruptions to cutting, and noticeably reduces the number of reject parts. The operator is also relieved. They can pull up the most important process parameters or a live-image through the nozzle any time, and will be actively informed if the need for intervention arises. Tapeshots which were necessary up to this point are now a thing of the past.

Active Speed Control oversees the process, controls cutting

Cutting sensor system – Active Speed Control Keyvisual

How the Active Speed Control system for feed control works

The cutting process is overseen from above in real time, with monitoring through the copper nozzle. The sensor system observes the kerf, determines the optimal feed and readjusts if need be – hundreds of times per second. This minimises cutting interruptions caused by material differences such as fluctuations in sheet thickness, rust or coating contaminations. In the event of a potential cutting flaw, Active Speed Control stops the machine, and the TruTops Monitor software immediately informs the operator that intervention is necessary. Active Speed Control also reduces the formation of burrs and dross. The minimised reject rate leads to lowered parts costs.

How Active Speed Control performs when it comes to sheet metal

See for yourself how Active Speed Control showcases its intelligence with sheets greater than 4 mm – a direct sheet versus sheet comparison. Compensating for material differences does not require manual feed reduction. Up until recently, operator-based feed reduction led to heat accumulation in the material, causing it to fuse uncontrollably. Automatic feed control on the other hand prevents this intense build-up of heat.

Feed rate significantly above default values

Up until now, cutting data has informed a machine how a material of a certain sheet thickness should be processed. This process includes a buffer in the event that the quality of the sheet fluctuates, or if inexperienced operators had not optimally set it for the next order. This means the machine cuts at a lower feed rate than it can actually handle. Active Speed Control makes this buffer redundant. The sensor system allows the machine to work as fast as possible, and with as much process reliability as needed. Active Speed Control often achieves speeds which are noticeably higher than the default values contained in the cutting data.

Comparison between laser cutting with and without feed control

Cut contour without adaptive feed control

Material bulging can be easily detected when flame cutting mild steel without Active Speed Control, because the cut was not clean in certain areas. Ultimately, the feed needed to be stopped entirely, as a cutting flaw had occurred. This results in faulty parts and rejects.

Cut contour with adaptive feed control

Active Speed Control creates a clean cut, largely without a large amount of spatter or spatter residue. Rust and surface contaminations lead to automatic control and adjustment of the cutting head feed. This allowed cutting flaws to be prevented effectively.

Take a look behind the scenes

TRUMPF is a pioneer in the laser cutting industry. To ensure we remain so in the future, we research tirelessly, always on the boundary of technological possibilities. We have a clear vision on the path to autonomous machines: to make the work of operators easier, through simple and sophisticated operating concepts. Our solutions give them the ability to respond to potential malfunctions with ease. The focus is on cost-effectiveness, as compared to non-assisted processing, the part costs for autonomous processes are significantly lower.

Performance analysis: TRUMPF developers optimise the processing for all sheet thicknesses

It just gets better – TRUMPF developers are evaluating cutting data in order to further optimise Active Speed Control

Agile project planning: 2D laser development employees in a sprint review

Electrifying: future technology arises in the electronics lab as well, where new components are put through their paces

Nothing escapes a trained eye: visual inspection of part quality during the development process

Nothing ventured, nothing gained: testing new functions and control parameters under real-world conditions are also part of the development of new machines

Full overview: checking the protective glass after test running a machine in development

There is no "I" in team: technical breakthroughs such as Active Speed Control and the development of the TruLaser Center 7030 can only be achieved as a team

Ready for the future – be prepared for anything with intelligent functions from TRUMPF

Assistance systems make life easier; they shorten and simplify many processes in laser cutting, as well as make them noticeably more reliable. This allows you to put your machines to optimal use, and minimise manual interventions. In addition to the newly developed Active Speed Control, TRUMPF also offers solutions for every process step in the form of intelligent functions. A compact selection of functions for autonomous laser cutting can be found here.

AdjustLine

AdjustLine allows you to cut even materials of inferior quality quickly and with ease; the function automatically adjusts the parameters to the situation. This allows you to reduce the number of rejects and material costs.

Assistenzsystem Automatischer Düsenwechsler

Automatic nozzle changer

The nozzle changer automatically changes the cutting nozzle if required for processing a new order or due to wear. This allows you to benefit from reduced non-productive times and fewer manual interventions.

BrightLine and BrightLine fiber

The zenith of edge quality: for stainless and mild steel, your CO2 laser cuts with BrightLine. However, with BrightLine fiber, even the solid-state laser can deliver cutting results of the highest quality.

Collision protection

When cutting thin sheets, there is often the threat of collisions due to tipping parts. The sophisticated collision protection is a type of airbag for your cutting head, which guarantees utmost process reliability and prevents structural damage.

Condition Guide

The light on the Condition Guide shows you the status of important elements which influence the cutting capability; if required, the program provides you with recommendations for action and generates prognoses of when maintenance is needed.

CoolLine

Not even tight contours pose a problem with CoolLine. The function keeps your workpiece cool during the entire cutting process. This means that you can cut even intricate parts and achieve even tighter nests.

DetectLine

A camera system precisely determines the position of inserted sheets and enables reworking of cut parts with absolute precision. Additionally, the DetectLine automatically measures a cut focusing comb, and sets the focus position.

Drop&Cut

Thanks to the camera support in Drop&Cut, you can reproduce parts from existing programs in a matter of seconds. Additionally, you utilise unused remainder sheets.

Highspeed Eco

With Highspeed Eco turbo-charged cutting, you can double your sheet throughput and your feed rate, while your cutting gas consumption reduces by up to 70%. This makes nitrogen cutting with solid-state lasers extremely efficient.

One-cutting-head strategy

Replacing cutting heads is always time consuming; simply eliminate it entirely. With the one-cutting-head strategy, you process all sheet thicknesses with the same cutting head.

Assistenzsystem Online Status Schutzglas

Online condition checking of the protective glass

Spatter can contaminate the focusing lenses of CO2-machines. LensLine monitors the lens and switches the beam off in the case of emergencies. The advantage of this is that the machine is only idle for a short amount of time for lens cleaning.

Smart collision prevention

Avoid expensive collisions with smart collision prevention: your machine processes parts and inner contours in a sequence that cleverly takes into account the tipping of parts that have been cut free.

Smart nozzle automation

If your nozzles are no longer in perfect condition, this can lead to burr formation. The consequence of this is reworking or rejects. Smart nozzle automation substitutes in the right nozzle and checks nozzle condition and beam centring.

Advantages for your laser processing

The future of laser cutting is becoming simpler and less stressful. Read here to discover the advantages that integrating autonomous and partially autonomous technologies can offer for your 2D laser processing operation.

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TRUMPF's vision of autonomous machines

We believe that the future is characterised by autonomous machines which lighten the load on operators. Learn more about our vision for autonomous machines and the far-reaching opportunities offered by machines, which are increasingly operating independently.

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Curious about the future of laser processing?

What does autonomous laser cutting mean for your parts production? What benefits are there to you? Our 2D laser cutting experts would be happy to answer these as well as other questions.

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