Technology TruBend Series 3000

The machine concept has a wide range of innovative solutions which generously benefit the customer and guarantee bending part production that will meet the utmost of demands.

Outstanding machine precision commences with the quality of the machine frame. The machine frames in the TruBend Series 3000 have been calculated in line with FEM (Finite Element Method) and are extremely solid and robust.

Material properties/manufacturing procedure:

• Frame material – high strength steel with minimum tensile strength 530 N/mm2
• Electrically welded
• Stress relieved at an annealing temperature of 570°C
  - Holding time: 2 to 4 hours
  - Heating and cooling time: ~8 hours
• Surface sand blasted
• Multi-layer coating

The patented 4 cylinder concept – four hydraulic cylinders transfer the required pressing force to the press beam – a true innovation providing a multitude of benefits for the customer:

• Minimum flexure of the press beam as 4 cylinders now act on the press beam, meaning greatly improved bending quality
• Flat mode of construction and consequently greatest possible bending space for large and high swivel parts, meaning more bending part flexibility
• The spherical suspension cylinders/press beams guarantee the axial introduction of forces even with inclined position of press beam. This means clearly improved service life of the cylinder technology

The TruBend Series 3000 has a self–activating crowning system. The machine bed automatically compensates for the physical press beam deformation via crowning slots. This eliminates lengthy and wearisome setting work by the operator. In addition to this, with eccentric bending (station bending), the crowning effect can be regulated manually.

The back gauge ensures exact positioning of the sheet metal during the bending process.

The TruBend Series 3000 machines are available with two types of back gauge:

• 2-axes-system: Both stop fingers have a common X-axis and a common R-axis. The stop fingers are adjusted manually in the Z-direction. By pressing a button, the stop fingers are moved into position in front of the bending line, are adjusted manually and then brought back into the working position by pressing a button.
• 4-axes-system: Both stop fingers have a common X-axis and a common R-axis. The stop fingers are similarly moved automatically in the Z-direction. A 4-axes back gauge has proved to be a true benefit when producing a great number of different parts, in station bending and wherever the utmost in productivity is called for.
• A 5-axes back gauge (X1, X2 + R + Z1, Z2) is possible as an option. You can program this option with TruTops Bend or T3000.

The back gauge plate concept on the TruBend Series 3000 provides the advantage of an additional support for large-scale sheet metal parts with low thicknesses during the bending process. The standard stop range in the X direction is 880 mm.

The control T3000 - based on windows – provides the most modern of control technology. Particular attention is paid to the simplest of operation/programming and the great memory capacity. Uncomplicated administration of production data and bending programmes. Of course, specific customer´s data and parameter can be taken over into the control.

The operation of the machine control is simple and clear by means of:

• Key-board surface on the control
• USB interface for keyboard or mouse
• LCD flat screen 10.4“ colour display
• Aligning via control hand wheel for particularly sensitive axis feed with complicated bending parts
• 3D-simplifies the handling of bending parts for the operator (optional)

In addition, important machine functions can be activated via „function keys“. In practical operation, this means increased operating ease for the operator and faster working.

By means of the control T3000, a bending programme can be drawn up quickly and uncomplicatedly. Programming can be performed directly on the machine or externally via PC.

Where graphic programming on the machine is concerned, the relevant bending profile is sketched by the operator. The control automatically calculates a bending sequence and draws up the bending programme.

Transfer of external bending programmes via USB-interface on the machine control and via network connection (optional).

The programming function 'Radius-Boxen' for producing greater radii – the control calculates the required bending parameter.

The great memory capacity of 40 MB is sufficient for approx. 10.000 bending programmes (10 bendings/part, respectively).

Option: Offline-programming TruTops Bend.

All the top and bottom tools available at TRUMPF are filed in the tool data bank.

In addition, the following production data can be filed:

• 99 types of top tools
• 99 types of bottom tools
• 99 types of material – standard materials and specific customer materials
• Table of bending factors for specific customer factors

Angle correction memory – specific correction values are automatically proposed for certain parameter combinations.

Via the local network connection, the control provides access to the internet.

Consequently, a connection to TRUMPF Info Service Bending (all you need to know about bending) and e-shop (ordering tools and spare parts) can be made directly on the machine.

Advantages for the customer:

• Ordering bending tools around the clock – 7 days a week
• Always the most up-to-date offers with the most up-to-date prices
• Perfect order management requiring no paper and fax
• The most up-to-date know-how about bending

The TruBend Series 3000 machine concept makes it possible to select different tool clamping systems. Besides TRUMPF tool holder systems, Amada and LVD Style systems are offered. As a result the tools already exisiting at the customers´ can be used without any restrictions.

6.1 TRUMPF Tool Clamping

In practical bending, the TRUMPF tool holder system provides the customer with significant advantages. Irrespective of whether clamping is manual or automatic, TRUMPF clampings will convince you with the following features:

• Self-centering (no reference stroke)
• Tools can be used adjusted by 180°
• Top tools can be fitted vertically (Safety Click®)
• For head and shoulder bearing top tools

Every single argument listed above has a positive influence on productivity and bending quality.

The following TRUMPF tool clampings are available:

• TRUMPF manual screw clamping (standard)
• TRUMPF manual quick clamping „Quick Clamp“ (optional)

TRUMPF pneumatic clamping (optional)

When ordering, the customer can decide whether the machine should be equipped with the TRUMPF- clamping or with a tool clamp for external tools.

The following tool clampings are available as a standard:

• Amada style manual (standard)
• Amada style pneumatic (optional)
• LVD style manual (standard)

Other standard adapters are not required – the entire installation height between top and bottom tool is available for bending work.

7.1 BendGuard

The European standard EN12622 stipulates the obligatory furnishing of contact-free safety equipment on hydraulic bending presses.

With the BendGuard safety system, TRUMPF proves that safety and productivity are not contradictive.

Functional principle: Two laser beams preceding the tip of the tool safeguard the danger zone. If one of the laser beams is interrupted by an obstacle (e.g.: operator´s hand ) the machine stops.

In BendGuard operation, the operators switches using the foot switch – hands are free for safe handling/holding of the bending part. The press beam can move freely in rapid down mode. Consequently, safety, productivity and bending quality can be guaranteed with the TRUMPF BendGuard.

The European standard EN12622 stipulates the obligatory furnishing of contact-free safety equipment on hydraulic bending presses.

The TruBend Series 3000 provides the option of the light curtain safety system SICK and/or ISB Merlin. Here, the front part (working range) of the machine is safeguarded by means of light curtain. A cover plate prevents unintentional access from below. The prerequisite for safe operation with the light curtain is two support consoles, as the bending part cannot be guided manually by the operator during the bending procedure.

By using the TRUMPF folding tool, folding can be performed in one work cycle without any problems. After pre-bending 30°, the bending to be folded is pressed together. Of course, the folding tool can also be used as a normal die, so there is no tool change necessary after folding.

Wherever press brakes are used support tables, consoles, shelves, etc. are required.

The TruBend Series 3000 provides a mobile support table which fully complies with these requirements. The table serves as a supporting surface to guide the sheet metal (height adjustable). The entire carriage is mobile, however the wheels can be blocked. Measuring instruments can be stored safely and within easy reach in the integrated shelves.

Inaccuracies in the sheet metal size cut can be compensated for so quickly. The adjustment path amounts to +/- 5 mm and is set on a scale with a grading of 0.05 mm.