Tool information

Calibration tool

2015-01-08

TRUMPF Werkzeugmaschinen GmbH + Co. KG

Stanzwerkzeuge
D-70839 Gerlingen
Fax: +49 7156 303 - 31150
Internet: http://www.trumpf.com
E-Mail: export.tooling@de.trumpf.com
 1. Adaptive stroke calibration on
punching machines

Constant embossing depth TRUMPF is the only company in the world offering adaptive stroke
and precision forming calibration on punching machines. A constant embossing depth
and precision forming are thus possible, regardless of sheet
thickness tolerances.

Problem: Sheet thickness Everyone knows the problem: In practice, sheet thicknesses are
tolerances never constant. A sheet 2 mm thick may vary by up to ±0.13 mm,
according to EN10131. This in turn has an impact on the
machining results and on the accuracy of the final product. Imprints
and identification marks on the sheet will thus vary in depth and
there are also consequences for forming.

Compensating for sheet With adaptive stroke calibration, TRUMPF has solved this problem.
thickness tolerances The solution comprises a
 Calibration tool and
 Extended ram control software.

Extremely high accuracy –
from the first part on
With this new function, the thickness of the present sheet is
measured in only 2.5 s (plus tool change time) at an extremely high
accuracy of ±0.03 mm and the ram stroke is adjusted to the
thickness measured. Tolerances in sheet thickness are thus
automatically compensated for.

2 Adaptive stroke calibration on punching machines 2015-01-08 WZ58EN

 2. Tool

Calibration tool Fig. 40321

Tool components Calibration tool, Punch, complete Die, complete

complete
1205-92-A6 1205-92-A2 1205-92-A5
Tab. 1

WZ58EN 2015-01-08 Tool 3

 3. Applications

Material thickness 0.5 to 8 mm

Option Adaptive stroke calibration must be available.

Applications Adaptive stroke calibration can be used to improve process

reliability, especially in the following technologies:
 Embossing
 Marking
 Multibend: Even higher angle accuracy.
 Multishear
 Roller pinching: When notching on one or on both sides and
when producing predetermined break points.
 Knocking out: Particularly when using the double knock-out
tool.
 Deburring:
– Constant chamfer size in roller deburring and with the
Deburring MultiTool.
– When producing the chamfered laser edge in conjunction
with the roller pinching tool.

4 Applications 2015-01-08 WZ58EN

 Function
1 2 1

3 4 5

1 Air gap 4 Sealing washer

2 Upper part 5 Air hole for die check
3 Retainer ring

Die design Fig. 40323

1. The calibration tool is loaded from the linear magazine into the
tool adapter using a standard cartridge.
2. Through the air hole (5) for die check, compressed air flows
under the die sealing washer (4).
3. The punch travels in steps of 1/100 mm centered onto the
prepared sheet. This causes the upper part (2) and the sealing
washer (4) of the die to move downwards. The compressed air
can escape through the air gap (1) which now exists.
4. At the instant when the compressed air escapes, the
corresponding ram position is saved and is then taken into
account in future.
5. The calibration tool is then returned to the linear magazine.

Machines The calibration tool can be used on the following machines:

Machines Software version

TruPunch 1000 (S05) V3.10
TruPunch 3000/ TC 3000 R V2.50
TruPunch 3000 (S11) V2.0
TruPunch 5000/ TC 5000 R V4.0 with NCU 573.3
V5.0 with NCU 573.5
TruMatic 3000/ TC 3000 L From beginning of the series
TruMatic 6000/ TC 6000 L V3.30 with NCU 573.3
V4.0 with NCU 573.5
TruMatic 7000 V02.02 B01
Tab. 2

WZ58EN 2015-01-08 Applications 5

 4. Tool data at the control

Tool length and die height At the machine, the tool length and die height must be entered in
the tool data at the control. The respective values are engraved on
the punch and die.

TruPunch 3000 / 5000

TruMatic 3000 / 6000
without active die

1 Die height 2 Tool length

Fig. 41957en

TruPunch 5000 with active

die (option)

1 Die height 2 Tool length

Fig. 57895en

Note
Enter the same value for die height (1).

6 Tool data at the control 2015-01-08 WZ58EN

 TruMatic 7000
without active die

2 Tool length

Punch dimension Fig. 57896en

1 Die height

Die dimension Fig. 57897en

WZ58EN 2015-01-08 Tool data at the control 7

TruMatic 7000 with active die
(additional data)

1 Required options

Fig. 57898en

8 Tool data at the control 2015-01-08 WZ58EN

 5. TruTops

Tool type 35 The calibration tool is handled by TruTops as tool type 35 and is
supported starting with the following versions.
TruTops Version
TruTops V1.0
TruPunch 1000 (S05) V2.0.1
TruPunch 3000 (S11) V2.2
TruTops Boost V1.0
Tab. 3

Please refer to the TruTops Software Manual for information on

programming.

Operation

TruPunch 3000 / 5000

TruMatic 3000 / 6000

Switch element: Measurement/Calibration cycle Fig. 40486en

WZ58EN 2015-01-08 TruTops 9

 TruMatic 7000

Measuring / Calibration cycle Fig. 57899en

The measuring program is generally activated
at the beginning of the program and before a forming operation.
 Meas./Comp. cycle
The following variants are offered in this cycle:
– Automatic: The program decides on its own whether a
measurement should be carried out. Previous
measurements, including deviations, are analyzed in the
process.
– Measuring + comp.: A measurement is made at every
activation and the value measured is passed on.
– Calibration only: No measurements are made. The last
value measured is, however, still passed on.
– Switched off: No measurements are made and no
calibration is carried out.
 Waiting time: Interval between 2 measurements. Prerequisite
is that constant results were attained in the previous
measurements.
 Delete data: All previously obtained measurement values are
deleted. New measurement series are established.
 Batch change: A control measurement is forced.

10 TruTops 2015-01-08 WZ58EN

 Programming

TC_SHEET_CALIB  Programming in the NC: The TC_SHEET_CALIB command

activates the measuring cycle.
The calibration position is defined by entering the X and Y
position; ideally, it should be in the sheet center.
TC_SHEET_CALIB( <Tool Id. number>, <X-Pos>, <Y-Pos>).
– <Tool Id. number>: Id. number of calibration tool being
used.
– <X pos>: X coordinate of calibration measurement.
– <Y pos>: Y coordinate of calibration measurement.
 Programming in the PLC: Benchmark data, such as speeds,
is stored in the PLC applications. The measuring cycle can
also be started via the switch element or PTT table.
 Start of calibration: Calibration is always active when the
option is activated.

Problem solutions

Error source Error message/Cause

Sheet too thin „No switch point found“
Sheet too thick „No measuring point found“
Wrong sheet loaded or „No switch point found“
or „No measuring point found“
Wrong measurement vale Contamination through chips
– Clean the die
– Clean the punch surface
– Clean the die adapter

Reference values not identical to the Correct the reference values

input values
2 different calibration tools with
different reference values in use
Measurement values fluctuate
Assign the reference values to the
calibration tool currently in use
Contamination from outside
– Lubrication oil
– Hydraulic damage

Ram positioning inexact Contact the Service department

Tab. 3

WZ58EN 2015-01-08 TruTops 11

 6. Maintenance

Risk of injury from preloaded pressure springs!

CAUTION
 Loosen 6 screws (12) 1 on the tool underside evenly.

Maintenance interval Every 1000 operating hours or after 3 months’ use.

Removing the die 1. Undo 6 screws (12) on the tool underside evenly.
2. Do not tilt the main body (8) when loosening the screws.
3. Remove the main body (8).
4. Loosen four cheese-head screws (13).
5. Remove the washer (10).
6. Remove the pressure springs (6).
7. Lift out the retainer ring (4).

Cleaning the die 8. Using a lint-free cloth, clean the sealing surfaces of the retainer
ring (4) and washer (10).
9. Clean the parts, where necessary.
10. The top cover (5) has an additional hard coating. If necessary,
the top cover must be replaced. This can be done only at the
manufacturer’s as the reference value must be established.

Mounting the die Note

The groove of the retainer ring (4) must be located opposite the
plate rim of the top cover.

11. Re-assemble the top cover (5), retainer ring (4) and washer
(10).
12. Using four cheesehead screws (13), fasten the top cover,
retainer ring and washer together.
13. Insert four pressure springs (6) in the circular recesses.
14. Mount the main body (8) on the pre-assembled component.
15. Tighten the six hexagon socket cheesehead screws (12) of the
main body (8) evenly.

Cleaning the punch  Use a lint-free cloth to clean the contact surface.

1
The item numbers refer to the numbers in the spare parts list.

12 Maintenance 2015-01-08 WZ58EN

 7. Spare parts list

1
2

10 5 6 11 7

12 13 14

Calibration tool Fig. 40930

WZ58EN 2015-01-08 Spare parts list 13

 Number Order number Designation Quant.
1 1312841 Punch, fixed 1
2 63548 Alignment key 1
3 14346 Cheesehead screw ISO4762- 1
M3X8
2
4 1312212 Retainer ring 1
2
5 1312842 Top cover 1
6 363414 Pressure spring 4
7/11 1585069 Adjustment key with countersunk 1
screw
2
8 1312827 Main body 1
9 352174 Straight pin, ISO8734-5h6X16 1
10 1312843 Sealing washer 1
12 117017 Cheesehead screw, ISO4762- 6
M5X12
13 360214 Cheesehead screw,. DIN 7984 4
M5x8
14 147517 Straight pin, ISO8734-6m6X22 2
Spare parts list Tab. 4

2
The reference value must be re-assigned when these parts are replaced.
This can only be determined at the Gerlingen plant.

14 Spare parts list 2015-01-08 WZ58EN