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TruPulse
TruPulse
Pulsed lasers

TruPulse

Pulsed peak power in the multi-kilowatt range for spot welding and seam welding

Laser welding of a pacemaker
Laser welding of a pacemaker
Pulsed lasers

TruPulse

The minimal temperature effects enable welding of pacemakers

    - / -
    • Overview
    • Applications
    • Technical Data
    • Options
    • Software
    • Sensor system
    • Machine solutions
    • Focusing optics
    • More Less
    Sophisticated power pack

    The tried-and-tested pulsed solid-state lasers in the TruPulse series enable short, high-energy pulses at high power. The pulse power of several kilowatts for a few milliseconds means that spot welding and seam welding are now also possible in places where other methods fail. Thermally sensitive applications in particular benefit from the advantages of pulsed solid-state lasers. With their modular layout, the lasers can be adapted to your individual manufacturing task. The TruPulse series has been technically optimized over decades, making the system highly reliable.

    Flexible

    Individually adaptable lasers due to the broad product portfolio and the modular layout of the TruPulse

    100% consistent power output

    With our real time laser power control, the exact power you select is the power at the workpiece.

    Accurate pulse-to-pulse stability

    The laser compares the pulse shape you have chosen with the actual pulse shape in a 10 μs cycle.

    Improved average power

    With the burst function you can temporarily increase the average power several times over.

    Integrated know-how

    The WeldAssist option provides suggested values for all of the process parameters depending on the material and welding depth.

    Efficient spot and seam welding with TruPulse
    Image of the technology inside the TRUMPF pulsed lasers
    TruPulse integrated beam guidance

    Due to its integrated beam guidance, the TruPulse can be perfectly adapted to your application. With up to six pluggable laser outlets and a flexibly configurable beam distribution, the laser beam can be split, switched over, disabled, and measured. In this way, it is possible to use the solid-state laser at one or more processing stations, with a time or energy split. This enables multiple welding processes to be performed at the same time or with a time delay. The modular layout enables subsequent repairs or extensions in the field.

    TruPulse laser precision welding
    Finely graduated

    In terms of power, energy, or focusability the TruPulse series covers the full spectrum of parameters for laser precision welding. The parameters for pulse energy and pulse duration are variable – so the laser device can be accurately designed for your application and used with flexibility during operation. With a maximum pulse power of up to 10 kW, pulse durations ranging from 0.2 to 50 ms and pulse energies of up to 120 J, the TruPulse lasers are perfect for many applications – for both manual and automated tasks.

    Burst function of the TruPulse
    Burst function

    The pulse energy and average power normally limit the pulse frequency of a laser. The burst function enables the frequency and the average power to be significantly increased for a short period at the same pulse energy level. You can therefore minimize the welding time per processing cycle and increase your productivity.

    Laser welding and cutting on an endoscopic instrument.

    Endoscopic instrument

    High precision is vital for medical instruments. The TruPulse is perfectly suited to these applications. The weld seams on this endoscope are barely visible.

    Spot welding on electronic plugs

    Electronic plug

    Electronic plug contacts are often reshaped and then fixed in place with the laser. The reliability of the TruPulse lasers ensures highly productive 3-shift operation with reject rates in the ppm range.

    Seam welding on a sensor

    Sensor module

    The low heat input resulting from the pulsed laser process protects the sensitive electronics of the power sensor module, which was seam welded with the TruPulse.

    Pulsed seam welding on the housing of an opto-electronic component.

    Opto-electronic component

    The cover of an opto-electronic component is attached to a housing via pulsed seam welding.

    Laser welding a plug in burst mode

    Plug

    With the aid of the burst mode functionality, the processing time for welding the plug is reduced by 70%. This is implemented by means of fast beam positioning via PFO scanner optics, paired with the capability of the TruPulse laser to emit multi-kW pulses with an increased frequency for short bursts.

    Laser parameters                        
    Laser power at the workpiece 20 W 30 W 40 W 60 W
    65 W
    70 W 90 W
    95 W
    110 W 110 W
    125 W
    140 W
    140 W
    150 W
    160 W
    200 W 300 W 530 W
    Max. peak pulse power 1.5 kW 3 kW 3 kW 3 kW
    5 kW
    4 kW
    6 kW
    5 kW
    6 kW
    8 kW
    4 kW 6 kW
    9 kW
    6 kW
    10 kW
    6 kW
    8 kW
    10 kW 10 kW
    Beam quality 4 mm▪mrad 12 mm▪mrad 16 mm▪mrad 8 mm▪mrad 16 mm▪mrad 12 mm▪mrad 25 mm▪mrad 16 mm▪mrad 25 mm▪mrad 12 mm▪mrad 16 mm▪mrad 25 mm▪mrad
    Wavelength 1064 nm 1064 nm 1064 nm 1064 nm 1064 nm 1064 nm 1064 nm 1064 nm 1064 nm 1064 nm 1064 nm 1064 nm
    Adjustable pulse duration 0.2 ms - 50 ms 0.2 ms - 50 ms 0.2 ms - 50 ms 0.2 ms - 50 ms 0.3 ms - 50 ms 0.3 ms - 50 ms 0.3 ms - 50 ms 0.3 ms - 50 ms 0.3 ms - 50 ms 0.3 ms - 50 ms 0.3 ms - 50 ms 0.3 ms - 50 ms
    Max. pulse repetition frequency 909 Hz 909 Hz 909 Hz 909 Hz 833 Hz 833 Hz 833 Hz 833 Hz 833 Hz 833 Hz 833 Hz 833 Hz
    Max. pulse energy 15 J 30 J 30 J 20 J
    50 J
    30 J
    60 J
    30 J
    60 J
    90 J
    30 J 30 J
    70 J
    90 J
    30 J
    80 J
    120 J
    55 J
    90 J
    60 J
    90 J
    60 J
    100 J
    Min. laser light cable diameter 100 μm 300 μm 400 μm 200 μm 400 μm 300 μm 600 μm 400 μm 600 μm 300 μm 400 μm 600 μm
    Structural design                        
    Dimensions, Basic version (W x H x D) - - - 980 mm x 1220 mm x 505 mm 980 mm x 1220 mm x 505 mm 980 mm x 1220 mm x 505 mm - 980 mm x 1220 mm x 505 mm 980 mm x 1220 mm x 505 mm - 1500 mm x 1370 mm x 730 mm 1500 mm x 1370 mm x 730 mm
    Dimensions, Extended version (W x H x D) - - - 980 mm x 1220 mm x 715 mm 980 mm x 1220 mm x 715 mm 980 mm x 1220 mm x 715 mm - 980 mm x 1220 mm x 715 mm 980 mm x 1220 mm x 715 mm - 1500 mm x 1370 mm x 990 mm 1500 mm x 1370 mm x 990 mm
    Dimensions (W x H x D) 485 mm x 700 mm x 800 mm 485 mm x 700 mm x 800 mm 485 mm x 700 mm x 800 mm - - - 980 mm x 1220 mm x 505 mm - - 1500 mm x 1370 mm x 730 mm - -
    Max. number of laser light cables 3 3 3 6 6 6 3 6 6 6 6 6
    Installation                        
    Protection class (air cooling) IP22 IP22 IP22 IP22 IP22 IP22 IP22 IP22 IP22 - - -
    Protection class (water cooling) IP54 IP54 IP54 IP54 IP54 IP54 IP54 IP54 IP54 IP54 IP54 IP54
    Ambient temperature (water cooling) 10 °C - 40 °C 10 °C - 40 °C 10 °C - 40 °C 10 °C - 40 °C 10 °C - 40 °C 10 °C - 40 °C 10 °C - 40 °C 10 °C - 40 °C 10 °C - 40 °C 10 °C - 40 °C 10 °C - 40 °C 10 °C - 40 °C
    PDF <1MB
    Technical data sheet

    The technical data of all product versions as a download.

    With TRUMPF you have the ability to adapt your solid-state laser to your installation and operating situation with flexibility. This applies, for example, to all beam guidance components and the control. You also have several options for the cooling water supply. Interfaces for different optics are provided right from the start. To save costs, your beam source can supply several work stations at the same time. The TRUMPF Remote Service helps you to ensure your system remains available, anywhere and at any time.

    Modular system of optical components
    Flexible, integrated beam guidance elements

    There are many options available to you for adapting the laser to your individual situation with flexibility. In addition to the laser power and pulse energy, you can also choose the number of fiber outlets up to a total of six. The laser power is regulated for each outlet. The plug & play optical laser cables can be easily connected to different work stations. This allows multiple work stations to operate simultaneously with split laser power or one after the other at full laser power. The modular layout enables field repairs to be carried out on site, as well as making the system suitable for retrofitting.

    TRUMPF laser network

    With the laser network, you can network one or more lasers with up to six work stations in each case. In the process, your laser either splits its power to multiple stations, or it supplies them in turns with full power. This will even enable you to combine different applications, such as welding and cutting. The overall availability of your manufacturing systems will increase as a result due to simple redundancy concepts.

    Convenient and flexible control

    The TruPulse can be equipped with virtually all standard fieldbus interfaces for control and actuation. The following are also available: real-time interface, parallel digital I/O, interface for process sensor systems, OPC UA software interface, and analog input boards.

    The TruPulse has an interface to connect TRUMPF processing optics, such as the PFO 20.
    Interface for intelligent optics

    Intelligent optics can be synchronized with your laser via a dedicated interface. For example, the CFO focusing optics or PFO scanner optics can be used optimally for your purposes. You can program the processing optics easily via the laser control system. You do not need additional PCs or control systems.

    Remote Services

    In the event of an error, TRUMPF service experts will remotely access your laser via a secure remote connection. In many cases the error can be remedied this way, or the configuration of the laser can be modified in a way that enables you to continue manufacturing until the spare part arrives, thus minimizing idle time in production.

    Flexible cooling options

    For cooling of the laser you can select between water/water or water/air compressor cooling, which means that the TruPulse laser can also be used at high ambient temperatures. If you already have your own cooling circuit in place, you can use it in conjunction with a plate heat exchanger.

    WeldAssist

    The WeldAssist database provides you with welding parameters for various materials and focal diameters. This makes set-up easier for frequently changing laser applications.

    Intuitive operation as a result of the TruControl control

    TruControl

    TruControl is the control software for your TRUMPF solid-state laser – for quick and simple operation. You can program pulse shapes individually to match your application. The laser power is controlled in real time to ensure maximum reproducibility of your process results. In order to retrace important quality data of your produced parts even years later, the optional DataStore software module records all data relevant to quality.

    If external controls are present, TruControl will communicate with them via all standard interfaces. Inputs are made via the touchscreen of the operating panel or via a panel PC. You can integrate your laser into the network via Ethernet and connect multiple PCs.

    Due to the TRUMPF sensor systems, your production will always be effective and cost-effective. The sensor products VisionLine, CalibrationLine or integrated pyrometers ensure stable processes by monitoring all the processes in laser production, playing an important part in your process reliability. Processing continues uninterrupted during measurement – no interruptions are required, saving you valuable production time.

    Image processing

    TRUMPF VisionLine image processing detects features on the components and ensures that welding is always in the correct location.

    Image processing, VisionLine Basic
    VisionLine Basic

    A digital camera image with cross-hairs in the laser focus helps with workpiece monitoring and teaching.

    Calibration tool

    The TRUMPF CalibrationLine tool checks and corrects the focal position and laser power on the workpiece at regular, individually definable intervals.

    CalibrationLine Focus checks whether the focal position on the workpiece still matches the requirements.
    CalibrationLine Focus

    Regular checking of focal position

    Lasers and laser systems – with us, the perfect pair. All beam sources are optimally attuned to the requirements of the TRUMPF laser systems. You can choose from numerous versions and options, resulting in a system which is precisely tailored to your task. It is, of course, also possible to integrate our lasers directly into your production lines.

    TruLaser Cell 3000, unique and universal
    TruLaser Cell 3000

    Unique and universal

    TruLaser Station 5005, the easy way to start with laser welding
    TruLaser Station Series 5000

    The easy way to start with laser welding

    TRUMPF offers you all the components you need for beam guidance from the laser to the workpiece. This also applies for various focusing optics which have proven themselves to be precise and reliable over many years of industrial use. The optics can be easily integrated – both in stand-alone processing stations as well as in complete production lines. The modular structure enables the optics to be continually adapted to the laser types as well as the different processing situations.

    Focusing optics

    Regardless of whether you are welding, cutting, ablating, heat treating, or drilling, you can count on high-quality process results with robust focusing optics from TRUMPF.

    BEO D25 focusing optics
    BEO D25

    Compact welding optics for lasers with power of up to 200 W

    BEO D35 focusing optics for welding with solid-state lasers
    BEO D35

    Versatile application – welding, cutting, and drilling

    BEO D70 focusing optics with observation camera, crossjet, and aerator nozzle
    BEO D70

    Large working distances with small focal diameters

    Controlled focusing optics CFO
    CFO

    Intelligence for your welding process – CFO processing optics for solid-state lasers

    Programmable focusing optics

    The ideal optics for remote processing

    Programmable focusing optics PFO 20
    PFO 20

    Welding and drilling with the programmable focusing optics PFO

    TRUMPF processing optics
    PFO 33

    Welding and drilling with the programmable focusing optics PFO

    This product range and information may vary depending on the country. Subject to changes to technology, equipment, price, and range of accessories. Please get in touch with your local contact person to find out whether the product is available in your country.

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