With the new TruBend 8400, bending is not rocket science

Challenges

Villing Technologie GmbH is no stranger to big (sized) challenges. The steel structures that are developed, designed and built in the company are usually large in size. In addition to a wide range of different mild steels, Villing also processes high-tensile materials such as Hardox and Weldox. "Previously, we cut the parts here in Friesenheim on a TruLaser 5060 or a TruTube 7000 fiber from TRUMPF. We then sent the semi-finished parts off-site for bending and ultimately welded them here," explains Konstantin Villing, adding: "Of course, the transportation of the large parts alone was an enormous and costly effort." The processes are also not optimal due to the dependence on partners. In order to work more flexibly in the future and ultimately also to save costs and time, Konstantin Villing decides to fill the gap in his portfolio and take over the bending himself from now on.

TRUMPF offers him the opportunity to test the new generation of the TruBend 8400 large format machine. "The system was delivered and started up at the beginning of November 2022. That was completely unproblematic," reports Villing. His problems begin when his only employee with bending experience leaves just before Christmas. "I had also sent him to a training course in Ditzingen," says Villing. He admits: "I was distraught. Now there was an amazing bending machine in front of me and I had no one who could operate it." But he is mistaken. With the help of the TRUMPF experts from Teningen, a few of his employees dare to tackle the TruBend 8400 and, with talent and enthusiasm for the job, are already delivering good results after a short time.

Solutions

With 400 tons of press force and a bending length of 4.4 meters, the new generation of TruBend 8400 has exactly the power that Konstantin Villing needs in his production. But it's not just the concentrated power that makes the machine an ideal addition to his machinery. "This new machine has numerous options that make my day-to-day work easier - and of course ease me into the new technology," he says. "If you know a bit about sheet metal, you'll be able to grasp the user interface even without much background knowledge.“ 

The redesigned machine control of the TruBend 8400 can be operated comfortably and intuitively via a multi-touch screen, just like the 5000 series machines. "My boys are all cell phone-savvy. Of course, things like that have a magical pull for them. They immediately understand what needs to be done," says Villing happily. Another new feature is the programming aid, which can be used to automatically create programs including NC code. The software displays the bending sequence as well as the tools that can be used. If the operator changes the tool, a collision check is carried out automatically. Villing thinks this is perfect - and not only for beginners. "The TruBend 8400 takes over a lot of the thinking process and the operator sees everything on the display - clearly and in three dimensions."

"We experimented a lot, but we didn't tilt any parts," reports Villing and admits: "Even with the TruBend 8400, amateurs can't make ultra-complex bends from a standing start, but we were able to make simple U and Z bends very well with sheets from two to 12 millimeters." Villing is also very satisfied with the bending accuracy. "We have already tried out the sensor-based ACB Laser angle measurement system, which is now also available for the 8000 series. A great thing, because precise bends are essential for the subsequent welding." Villing is also impressed by the installation height of 880 millimeters: "This allows us to bend small electrical cabinets in a single work step. That has already resulted in a new order for me."

Implementation

After the turbulent start, Konstantin Villing's optimism has returned. Since May, he has been working with a new employee who also has bending experience. "He can get a lot more out of the machine," says Villing confidently. Because there is still a lot to discover about the TruBend 8400. "The fact that we have managed so well despite the circumstances is of course also due to the experts from Teningen, who have always supported us - from the consultation stage, through start-up, to ongoing operation."

Forecast

Villing has already reached the point where it is no longer sending any parts off-site for bending. "Apart from more flexible processes, this of course saves me money. I am sure that it was the right decision to bring bending technology in-house, and the TruBend 8400 was the perfect start," says Villing. The heavy parts of the machine are currently still being transferred in by crane. But we have a pending request and if it becomes an order, the next thing on the agenda will be bending aids to relieve my employees.“

Last updated: 2023-12-07