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State of the art laser systems for materials processing

07 July 2009TRUMPF - State of the art laser systems for materials processing

Carsten KeimInternational Sales Lasers and Laser SystemsTRUMPF Laser- und Systemtechnik GmbHTWI Cambridge, UK07 July 2009

TRUMPF Group Business DivisionsMedicalElectronicsLaser Power ToolsMachine Tools TechnologyElectronics TechnologyPower ToolsMachine Tools

Operating tables, surgical lights, ceiling pendants

Power supplies for induction heating, plasma and CO2

laser excitation

Lasers and Systems for production technology

Power tools for sheet metal processing

Machine tools for flexible sheet metal processing

Sales (mil €) 1 874 8 Sales (mil €) 551 7 Sales (mil €) 126 2

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End of fiscal year: June 30, 2008; consolidated within the business division; figures rounded

Sales (mil €) 1,874.8Employees 5,469

Sales (mil €) 551.7Employees 1,805

Sales (mil €) 126.2Employees 513

- Ca. 2/3 of all TRUMPF products use laser technology- Over 30 years experience with lasers in industrial environments- Worldwide laser service with 57 TRUMPF companies

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The right laser source for every application

TruFlow TruPulseTruDiodeTruMicroTruMark TruFiberTruDisk TruCoax

- One supplier for all laser technologies- Wavelengths from 0,343 µm to 10,6 µm- From low power to high power applications

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0,1 1 10

IRUV

30,3 µm

10,61,03/1,060,35

Main TRUMPF Turn Key Systems with CO2 Lasers

- TruFlow/TruCoax CO2 Lasers for 3 D and 2 D High Power Laser Processingu o / uCoa CO ase s o 3 a d g o e ase ocess g- Laser Cutting, Welding, Cladding, Surface Treatment, …

TruLaser Cell 7040 (3D Laser) TruLaser 3030 (2D Laser Cutting)

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TruMatic 7000 (Laser + Punching)TruLaser Tube 7000 (Tube Cutting)

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Typical Applications on TruLaser Cell 7040

Tailor Welded Blanks 3D Laser Cutting

Coating

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Deep Welded Differentials

Remelting

Annealing

Glazing

Surface Refinement

Higher productivity with automation

Removable split wall for dual station operation permitting safe e o ab e sp t a o dua stat o ope at o pe tt g sa eloading/unloading of midsize parts during the laser process

Linear changer allow to load bigger and heavy parts outside the machine

Rotary table minimize non-productive time and offer a single loading/unloading position

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Saving money by faster cutting at reduced costs

Error free set up by optics identification and lens monitoring for operation safetyError free set up by optics identification and lens monitoring for operation safety Minimum non productive time by high machine dynamics:

max. V = 173 m/min & A = 16m/s² Dynamic cutting optics 40 m/s² with piercing on the fly High Speed Cutting Process with 4 to 6 KW & plasma resistant height regulation High operating safety in case of collisions by magnetic coupling

Constant working quality by a constant raw beam diameter independent of position or laser power

receiver

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emitter

receiver

Reduction of the current operation costs

Reduction of cutting gas consumption by improved cutting nozzles and processes

52 % 64 %

Recommendation due to best proportion of process stability and consumption

of cutting gas

educt o o cutt g gas co su pt o by p o ed cutt g o es a d p ocessesConsumption of the cutting gas

The more accurate the machine …

The smaller the nozzle

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Consumption of the cutting gas / B-pillar

Additional reduction of the cutting gas costs through compressed air(approx. 0,30ct versus approx. 0,06ct per Nm³/h) possible

diameter … The lower the cutting gas

consumption … The lower your costs!

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Easy laser welding – modular optics

Laser diversity from 2 to 15 KW depending on application and productivityLaser diversity from 2 to 15 KW depending on application and productivity Many applications with modular optics: basic optics body with

3 tool lengths (short, medium, long) 5 focal lengths (195, 230, 280, 330, 380 mm) 4 gas supplies (slim, water-cooled, lateral with/without water cooling) optical or tactile measurement tools filler wire

Shorter non-productive times by teaching with height regulation andtechnology tables for welding applications

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Applications - Welding with high power CO2 Lasers

Critical, clean, spatter free welds with smooth surfaces desire the CO2 wavelength

Powertrain applications Aerospace: Turbines Heat exchanger: Beer tanks

Critical, clean, spatter free welds with smooth surfaces desire the CO2 wavelength

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Automotive: Steering shaft Tube & Profile ProcessingSwitchgear boxes

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Main TRUMPF Turn Key Solid State Laser Systems- One machine concept is not limited to one laser source

D di th li ti th i ht t bi ti b h- Depending on the application the right system combination can be chosen

TruLaser Cell Series 3000 TruLaser Station

Possible Sources:- TruDisk- TruDiode- TruFiber- TruPulse

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TruLaser Cell Series 7000 TruLaser Robot 5020 TruLaser 7040 NEW

Multiple Processes with TruLaser Robot 5020

I t ti f ll l f th Integration of all lasers of the TruDisk, TruPulse and TruDiode series

Standard options enable config-uration acc. to customer’s wishes

Comprehensive range of services to support production and development

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Technology packages allow

Laser welding Laser cutting Deposition welding Remote welding

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Turn Key Solution all from one Supplier: TRUMPF

Solid State Remote Welding:Robot with PFO

Welding: Roof Seam of VW Passat

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Laser Welded Parts of VW GolfLaser Metal Deposition

Principles of Programmable Focusing Optics PFO 3D

S h i d ti fSynchronized motion of scanner mirrors and robot path

PFO 3D

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Source: Kuka

PFO 3D 3D scanner, max. 8 kW Until end of 2008,

TRUMPF sold > 800 PFO‘s worldwide

applied since 1999

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Cost efficientThe TRUMPF LASERNETWORK

Full use of the laser capacity is made possible by the TRUMPF LASERNETWORK

One laser can serve up to 6 different machining stations

Each station is connected

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directly to the laser by means of a fiber optic laser cable and a control cable (field bus system)

External ProgrammingTruTops Cell

Import the most common 3D CAD standard formats

Contour preparation and technology data

Simulation and collision check

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Integration of fixtures

Automatic generation of robot program

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Process schematics Laser Metal Deposition

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Technology package laser deposition welding

Powder conveyor

Delivery hose

Powder splitter

Focusing optics

Powder nozzle(s)

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Powder nozzle(s)

Chiller for optics and

nozzle

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Deposition Welding Process

Coaxial Nozzle 3-Beam Nozzle Off-Axis NozzleCoaxial Nozzle 3 Beam Nozzle Off Axis Nozzle

Working Plane

2D l ith i i l3D l f ldi2D nozzle for precise

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2D nozzles with minimal interference contours

Linear seam –trailing powder feed

Laser power ≤ 12,000 W

3D nozzle for welding in forced position

Powder focus ≥ 1.5 mm Laser power ≤ 6000 W Oxygen contamination ≤ 50 ppm

2D nozzle for precisedeposition

Powder focus ≥ 0.3 mm Laser power ≤ 2000 W Oxygen contamination ≤ 20ppm

Main TRUMPF Turn Key Marking Systems andLow Power TruLaser Cells & Work Stations

- Manual or Automated Laser Cells and Work Stations with TruPulse Lasers for Precision Cutting and Fine Welding, Drilling and Scribing

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TruMark Station 5000

TruLaser Station 5004

- Marking by colour change, engraving, ablation, …- Please visit our marking laser stand outside!

TruLaser Cell 3010

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TruPulse Systems - Application Examples

Spot welding Seam welding Trephine for hip joints

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Precision cutting Scribing Endoscopic devices

The right pulsed laser for each application

Grading according toGrading according to

Average Power

Focusability /beam quality

Maximum pulse energy

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Optimization of the investment costs

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Accurate pulse shaping and burst mode

Welding optimization by defined variation of the pulse peak power Welding optimization by defined variation of the pulse peak power within one pulse (max. 50 ms) and Programmable time steps: 10 µs

Burst Mode: Instead of e.g. 10 pulses/s 10 in 0,25 s and then refresh during handling time more productive lower investment

Burst Mode Option

0 75

time

Pulse powerTime for

workpiece handling

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Programmed pulse shape

0.25 s 0.75 s

time

Energy storage

Max.

Min.

Applications TruMicro Laser

Wafer Dicing/Isol. solar cells AblationMicro structuring cylinder wall Ablation

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Processing of turbine blades Drilling fuel injection nozzels Precision drilling in ceramics

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Applications TruMark – Marking on metal and platics

Water meter Safety switch Marking by tempering

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Printed circuit board Gear wheel Day/Night Design

And next ? … Operation “Space Elevator”

In the baking heat of the Mojave desert …t e ba g eat o t e oja e dese tTruDisk Laser delivers 8 KW photonic power to climb into space …

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But most innovative in real world applications …

Key Supplier Award 2009:

Innovation

Daimler AG awarded prizes to 14 companies for

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Daimler AG awarded prizes to 14 companies for their outstanding achievements at the first Key Supplier Meeting, which was held on March 12, 2009 at the Mercedes-Benz Center in Stuttgart. For the first time ever, the awards included a prize for innovation.

Thank you for your attention!

And now let us talk about your application – please visit us …d o et us ta about you app cat o p ease s t us

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