Bending is no longer a mystery with the new TruBend 8400

Challenges

Villing Technologie GmbH is accustomed to handling substantial parts. The steel structures that the company develops, designs and builds are typically quite large. In addition to a variety of different mild steels, Villing also processes high-tensile materials such as Hardox and Weldox. "In the past, we used to cut the parts here in Friesenheim on a TRUMPF TruLaser 5060 or TruTube 7000 fiber. "We would subsequently send the semi-finished parts off-site for bending and later handle the welding process here," elaborates Konstantin Villing. "Transporting these large parts alone was, of course, a significant and expensive undertaking." The processes were also far from perfect due to reliance on external partners. To enhance flexibility in the future and, ultimately, to save costs and time, Konstantin Villing resolves to bridge the gap in his portfolio by bringing the bending process in-house.

TRUMPF provides him with the opportunity to evaluate the new generation of the TruBend 8400 large-format machine. "The system was delivered and commissioned in early November 2022. Everything went smoothly," reports Villing. His problems begin when his only employee with bending experience leaves the company just before Christmas. "I's also sent him on a training course in Ditzingen," says Villing and admits, "I was desperate. I now had an excellent bending machine, but nobody who could operate it." However, he was mistaken. Assisted by TRUMPF experts from Teningen, some of his employees took on the challenge of operating the TruBend 8400. With talent and enthusiasm for the job, they are already achieving commendable results in a short period.

Solutions

With a press force of 400 tonnes and a bending length of 4.4 meters, the new generation of TruBend 8400 provides exactly the power that Konstantin Villing requires for his production facility. Yet, it's not solely the concentrated power that makes the machine an ideal addition to his resources. "This new machine has a raft of options that make my everyday work easier and also assist me in adapting to the new technology," he says. "If you have some level of familiarity with sheet metal, you'll find it easy to navigate the user interface even with limited background knowledge." 

The revamped machine control on the TruBend 8400 offers convenient and intuitive operation through a multi-touch screen, similar to the 5000 series machines. "My team is tech-savvy, especially with mobile phones. Features like this naturally captivate their interest, and they quickly grasp what needs to be done," expresses Villing with satisfaction. Another noteworthy feature is the programming aid, which allows for the automatic creation of programs, including NC code. The software displays the bending sequence along with the available tools that can be used. If the operator changes the tool, a collision check is performed automatically. Villing thinks the machine is perfect, and not just for beginners. "The TruBend 8400 does a lot of the thinking for you, and the operator can clearly see everything in three dimensions on the display."

"We experimented with various setups, but none of the parts turned out wrong," reports Villing, although he does acknowledge that, "Even with the TruBend 8400, newcomers may not get to grips with highly complex bends right away, but we have successfully created simple U and Z bends with sheets ranging from 2 to 12 millimeters." Villing is equally pleased with the bending accuracy. We have tested the ACB laser sensor-based angle measurement system, which is now also available for the 8000 series. This is crucial because accurate bends are vital for subsequent welding." He also highlights the impressive installation height of 880 millimeters, stating, "We can bend small electrical cabinets in a single step. This has already landed us a new order."

Implementation

After an exciting start, Konstantin Villing is very optimistic. In May, he employed a new member of staff with bending experience. "He'll be able to harness the full potential of the machine," says Villing confidently. Indeed, there is much to explore about the TruBend 8400. "The success we've achieved despite the circumstances is undoubtedly due to the expertise of the team from Teningen, who have provided consistent support, from the initial consultation through commissioning to ongoing operation."

Forecast

Villing now no longer outsources any parts for bending. "In addition to achieving more flexible processes, this naturally results in cost savings for me. I am certain that it was the right decision to bring bending technology in-house, and the TruBend 8400 was the perfect way to get started," says Villing. Currently, the heavy parts are still fed in by crane. However, we have an enquiry on the table, and should it materialize into an order, the next priority will be to procure bending aids to ease the workload for my employees."

Date: 07/12/2023