Trumpf’s TruTops Weld has been designed to work with the TruLaser Weld 5000 laser-welding cell. Offering an intuitive, user-friendly interface, the software incorporates a broad range of the company’s accumulated technological expertise, including welding parameters and information on processing angles. The software also integrates all of the TruLaser Weld functions, such as the rotary module and TeachLine sensor system.

TruTops Weld increases machine availability by allowing users to create welding programs on a PC rather than in the laser-welding cell. This capability means the machine can keep producing parts during programming, while also making it much faster to create programs.

With teach-in programming, machine operators have to individually program every point to which the robot will travel during processing. In contrast, TruTops Weld calculates these points on the robot’s path automatically.

The programming process consists of four steps. The first step focuses on the part: the programmer defines the points to be welded by clicking the corresponding part edges. Welding parameters can then be selected from a comprehensive database. Alternatively, programmers can choose to use parameters they have calculated themselves. At this early stage, the software automatically calculates the paths of motion and creates a preliminary program.

TruTops Weld then finalises the program in what is known as ‘system mode’, which enables the user to virtually place the part on the positioner inside the laser-welding cell. The software detects any potential collisions and helps the user to find a position and path of motion that the robot can follow without meeting any obstructions. This simulation is particularly helpful for complex parts.

Finally, the programmer transfers the program to the welding cell. The TeachLine sensor system then checks the exact position of the part and compares this information to the simulation. If TeachLine identifies any discrepancies, it automatically adjusts the program accordingly. Users still have the option of carrying out a conventional teach-in process.