Compact welding optics reach even hard-to-access areas within the component

A shortage of skilled workers, frequently changing components, and limited production space pose challenges for many manufacturing companies. TRUMPF is introducing the new TruLaser Weld 3000, a compact robotic laser welding cell that can be programmed significantly faster thanks to AI while requiring very little space.

The new TruLaser Weld 3000 can be programmed either directly at the machine in the conventional way or offline using the TruTops Weld software, for example from the office. This is particularly advantageous when working with frequently changing components: Employees can create new programs on the computer while the machine continues production. In addition, welding programs based on CAD data are created significantly faster than with conventional programming. The TeachLine Touch function can then be used to correct minor deviations. Weld points can be repositioned simply by tapping on the machine screen. This reduces programming and setup time by up to 50%. Corrections are even easier with the TeachLine AI feature extension. An AI-based process detects deviations in the weld points and corrects the robot path according to the actual component configuration. This allows the system to be set up more quickly for new components. Another advantage: Even less experienced employees can operate the laser welding cell.

Newly developed welding optics – approximately 40% smaller – expand the range of applications for the TruLaser Weld 3000. Thanks to its compact design, the welding robot can reach even hard-to-access areas within a component, such as the interiors of deep housings, crates, or boxes. This enables users to automate the production of a wider range of parts and reduce manual rework.

TRUMPF relies on proven laser welding technologies to ensure process stability and weld quality. These include BrightLine Scan, which is a combination of a high-frequency scanner and motorised focus adjustment. It enables greater gap bridging of up to 0.4 millimetres and wider welds for better tolerance compensation. The BrightLine Weld function distributes the laser power between an inner and outer core in the laser light cable. This reduces spatter – particularly during deep welding – and ensures high-quality results. For larger gaps of up to approximately 1.5 millimetres or materials that require filler metal, FusionLine combines the laser with filler wire for targeted material deposition.

The TruLaser Weld 3000’s protective enclosure has a footprint of 3.65 x 3.65 metres, making it about 24 percent smaller than the smallest version of the TruLaser Weld 5000. This means that the laser welding cell ideal for confined production environments. Despite its compact design, the machine can process pallet-sized components thanks to a KUKA Iontec robot with a 2,100-millimetre reach. To align the components, the user can choose between a conventional welding table, a tilt-rotate positioner, or a compact rotary changer for loading and unloading parallel to production.

With a laser power of three or four kilowatts, the TruLaser Weld 3000 welds stainless steel and structural steel up to eight millimetres of material thickness, as well as aluminium up to six millimetres.

Typical applications include equipment and plant engineering, sheet metal components for data centres, medical technology, and the kitchen and food industries.