Fig. 1 TRUMPF Maschinen Austria GmbH + Co. KG
With bending machines from the TruBend Series 5000, press forces of 50 to 320 tons and edge lengths of 1.25 to 4 meters are possible. energy tubes of the R4.1L series from igus are used to supply the bending device.

New Concepts Help Drive Popularity of New Machine Tool

A hybrid hydraulic drive and the latest in cable management make press brake fast, efficient, and quiet.

The Trubend 5000 was a big hit when it hit the European machine tool market in 2015. It came to North American last year and continues building momentum. A combination of high productivity, high energy efficiency, low noise, and precision operation are its driving forces.

The Trubend 5000 is offered by TRUMPF Inc., Farmington, Conn., is the North American subsidiary of Trumpf GmbH, Stuttgart. The company has about 70 subsidiaries, nearly 11,000 employees and generates annual sales of more than $3 billion. The Connecticut facility is the largest of 70 subsidiaries and is the largest manufacturer of fabricating machinery in the United States.

Hydraulics Provides Muscle

According to Vincent Iozzo, Trubend product manager, the hydraulic system of Trumpf’s Trubend 5000 machines was re-engineered and now uses Trumpf’s on-demand servodrive. The on-demand servodrive consists of a hydraulic pump driven by a variable-speed electric motor. Considered a hybrid drive, it saves energy by powering the hydraulic pump at just the right speed and torque to deliver the precise flow and pressure to match changing load demands.

Iozzo says that compared to the previous generation of machines, the redesigned Trubend 5000 provides higher acceleration for 20% higher productivity while also exhibiting greater energy efficiency and quieter operation. The hydraulic system is said to use about half the energy of a conventional system while performing equivalent work. He adds that the hydraulic system does not need a heat exchanger and requires about half the amount of hydraulic oil as a conventional hydraulic system.

A look into the inner workings of the bending device: motor, encoder and sensor cables as well as an earth cable are guided in the e-chains from igus and supply the bending tool, which is completely manufactured at the Linz location. (Source: igus GmbH)

Saving Assembly Time, Cost

TruBend Series 5000 units are known as press brakes in the metals industry and have a bending tool for large or heavy parts upon which the sheets are processed and placed. The tool supports up to 30-degree angles and its height can be automatically adjusted. “For large and very heavy workpieces, this support is necessary to bend the sheets accurately, requiring only one operator,’’ says Volkmar Schmidt, head of technical purchasing at TRUMPF Maschinen Austria. The bending device can be moved freely from left to right.

These machines contain multiple cables that must follow long spans of machine motion. Left unguided, these cables could easily become tangled, not to mention wear out from repeatedly rubbing against each other and a machine’s surfaces. To prevent these potential problems, TRUMPF relies on energy chains from igus when the bending device is moved. igus, Cologne, Germany, operates its North American facilities in Providence, R.I.

For the Series 5000, TRUMPF uses R4.1L series chains from igus, which are enclosed tubes using overlapping lids instead of the standard crossbars. The lids can be opened at both ends and pivoted upwards by 115 deg., which cuts assembly time and cost. If necessary, they can be removed completely, fitted again, and closed by pressing downward.

Tubes Protect Interior Cables

“We originally developed the e-tubes so as a swarf-proof version of our e-chains for use in moving applications exposed to flying metal swarf of other small particles,’’ explains Elvis Kaufmann, technical sales consultant for igus Austria and responsible for TRUMPF Maschinen Austria. “The cables inside are, therefore, reliably protected and moved.

TRUMPF prefers the closed version to give the Series 5000 Machines a more discreet appearance. “We feel it is more visually attractive if only one black tube can be seen instead of colored cables or colored dots on the outside of the machine,’’ adds Schmidt.

Rolling noise is also reduced, resulting in quiet operation of the chain. Other important factors are the easy assembly, small bend radii, and exterior height. The E4.1L has considerably less mass than the E4.1 heavy-duty chain, and the e-tubes are about 30% lighter. “That allows machine builder not only to save a lot of drive power, but it’s also possible to accommodate even more cables and hoses in the limited space,’’ Kaufmann offers.

All cables are securely laid and guided in separate chambers of the energy tubes. (Source: igus GmbH)

Secure Layout of Cables

“Interior separation of the chain is important so that all cables can be laid securely in separate chambers,’’ Schmidt explains. “To achieve this, igus offered advice and guidance on site. For smaller tasks we do the design of the chain online. But for more complex designs or prototypes, personal support is important to us, so that we can be sure we’re on the right track.”

TRUMPF keeps very few igus energy chains in stock. The company usually orders 1-2 days before production, and the e-chains are then supplied in the correct length directly from igus. igus’ service is critical to TRUMPF’s success. “I’ve worked for TRUMPF for 25 years, and cannot remember a time we did not use igus chains,’’ Schmidt offers.

See how the TruBend Series 5000 works on this YouTube link. Viewers can see the bending device at work at the 2:07 mark of the video.

100,000 products available from stock. No minimum order required.

For more information, contact igus at (800) 521-2747, stop by IMTS booth 134521 in the East Hall, or visit www.igus.com.

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