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Sensitivity Studiesfor the Development of Laser MachinesDr. Jens OttnadAdvanced Development TruLaserTRUMPF Werkzeugmaschinen GmbH Co. KG

Agenda TRUMPF Challenges for the development of laser cutting machines Sensitivity studies- Laser & machine’s dynamic- Optical system SummarySensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.20123

About usWe are a high-tech company that focuses onmanufacturing technology, laser technology andmedical technology.We offer our customers both innovative and highquality products.We are represented in all world markets,close to our customers with 58 subsidiaries.We are a family business established in 1923 and ourgoal is to stay economically independent.Sensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.20124

At a glance2011/12Changein percentSalesmil. EUR2,328.2 15.0Income before Taxesmil. EUR210.9 13.8Expenditure on Fixed Assetsmil. EUR152,5 151.2R D Expendituresmil. EUR193.4 22.4Employees as of June 30number9,555 11.8Sensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.20125

TRUMPF Group Business DivisionsMachine ToolsLaser Technology/ElectronicsMachine chine tools for flexible sheet metal andtube processing,Power tools for sheet metal processingLasers forproductiontechnologyPower supplies forinduction heating,plasma and CO2laser excitationSurgical lights,operating tables,video solutions,supply systemsSales (mil )EmployeesSales (mil )Employees1,8905,918MedicalTechnology7272,330Sales (mil )Employees184713End of fiscal year: June 30, 2012; consolidated within the business division; figures roundedSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.20126

TRUMPF Historie – eine Innovationsgeschichte vonder Komponente zum High-end SystemChristian TRUMPF acquires the mechanical shop Julius Geiger.Flexible shafts for medical application and printersSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.20127

TRUMPF – a success story from a single componentto high-end systemsFirst manual operating motor-driven scissor for sheet metal cutting70 EmployeesSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.20128

TRUMPF – a success story from a single componentto high-end systemsPatent application for a guide of coordinates by the youngengineer Berthold Leibinger.First step towards numerical controlled motion70 Employees145 EmployeesSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.20129

TRUMPF Historie – eine Innovationsgeschichte vonder Komponente zum High-end SystemTrumatic 20: first numerically controlled sheetmetal processing machine. Pure automaticoperation by „Lochstreifenspeicherung“.70 Employees145 EmployeesSensitivity Studies of Laser Machines TRUMPF325 MitarbeiterWOST 2012 - 30.11.201210

TRUMPF – a success story from a single componentto high-end systemsFirst steps into laser technology first punch and laser machineTRUMATIC 180 LASERPRESS70 Employees145 EmployeesSensitivity Studies of Laser Machines TRUMPF325 EmployeesWOST 2012 - 30.11.201211

TRUMPF – a success story from a single componentto high-end systemsTRUMPF is manufacturer oflaser sources (CO2-Laser).70 Employees145 MitarbeiterSensitivity Studies of Laser Machines TRUMPF325 Employees1500 EmployeesWOST 2012 - 30.11.201212

TRUMPF – a success story from a single componentto high-end systemsFirst 2D-laser cuttingmachineTRUMATIC L300070 Employees145 EmployeesSensitivity Studies of Laser Machines TRUMPF325 Employees1500 EmployeesWOST 2012 - 30.11.201213

TRUMPF – a success story from a single componentto high-end systems20.000 TruFlowCO2-Lasers sold70 Employees145 EmployeesSensitivity Studies of Laser Machines TRUMPF325 Employees1500 EmployeesWOST 2012 - 30.11.20128500 Employees14

Cutting and laser technology define theperformance progressPerformance5000 Watt50m/[email protected] (20) mm3000 Watt34m/[email protected] (12) mmTruFlow CO2-Laser2000 Watt9m/[email protected] Watt11 m/[email protected] mm1990Sensitivity Studies of Laser Machines TRUMPF4000 Watt11 m/[email protected] mm8000 Watt11 m/[email protected] m/[email protected] mm6000 Watt11 m/[email protected] m/[email protected] mmTruDisk SS-Laser20002010WOST 2012 - 30.11.201215

Solid state lasers almost doubled the portfolioTruFlow CO2-LaserTruDisk SS-LaserTruLaser 7000 SeriesTruLaser 5000 SeriesTruLaser 3000 SeriesTruLaser 1000 Series2008Sensitivity Studies of Laser Machines TRUMPF20092010WOST 2012 - 30.11.20122011201216

Sensitivity studies help to find efficientlaser - machine combinations Input parameter laser- Forward feed Input parameter of the machine’s dynamic- Acceleration- Jerk Output- Average velocity- Duration of production Test case- Sheet metal 2.500x1.250 mm²- 169 parts- TruLaser 3030 33 minutesSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.201217

Virtual control unit as basic modelVNCK “virtueller NC-Kern” by SiemensAdapterVNCKSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.2012Trumpf HMI18

Results (1)Sensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.201219

Results combinationSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.201220

High quality laser cutting requires severalparameters in a certain rangelaser beamguiding systemlaser sourceSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.201221

Basic optical design calculated with ZEMAXX 3000 mmY 1500 mm25X 0 mmY 0 mmDiameter of laser beam / mm201514 mm19 mmAB Anf.AB MitteAB Ende105002000400060008000100001200014000Distance vom laser source/ mmFor both beam diameters, the beam waist is placed be in the centre of the machineSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.201222

Optical components and it’s parameters forsensitivity studyadaptive mirror 1[pressure]Laser[waist diameter,waist position,power , ]mirror[focal length]mirror (plane)adaptive mirror 2[pressure]mirror (plane)ZXlens[focal length]adaptive mirror 3[pressure]YSensitivity Studies of Laser Machines TRUMPF05.01.2012 13:243D LayoutWOST 2012 - 30.11.2012Trumpf Werkzeugmaschinen DitzingenTW562bu23

ResultsSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.201224

Results with active compensation (mirror 3)Sensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.201225

Summary First steps towards the field of CAE based robust design Sensitivity analysis are already helpful For simple models only a minor improvements can be achieved Knowing the technology and the simulation model is a huge benefitSensitivity Studies of Laser Machines TRUMPFWOST 2012 - 30.11.201226

Surgical lights, operating tables, video solutions, supply systems Power supplies for induction heating, plasma and CO 2 laser excitation Lasers for production technology Machine tools for flexible sheet metal and