TUBE TECH MACHINERY SRL

cUTTING AND WELDING LAsEr mAchINEs

2

“WHEN I FOUNDED THE TTM GROUP, I WAS AIMING AT FILLING A VOID IN THE MARKET BY DEVELOPING AND MANUFACTURING LASER WELDING SYSTEMS FOR SPECIAL APPLICATIONS.

F i o r e n z o C a s t e l l i n iTTM GROUP'S CEO

Over just a few years, with tenacity and determination, we have provided our clients with innovative tailor-made solutions, which have allowed us to achieve important goals.

A team of highly skilled professionals has allowed us to install a large number systems worldwide, meeting full customer satisfaction and allowing for considerable increase in productivity whilst ensuring the highest quality standards.

I am proud to say that the TTM group has now achieved its most important goal, to be considered as excellence in Laser welding systems. A great result to be proud of for me and for all those who have taken part in this extraordinary challenge that we undertake every day with commitment and passion”.

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OUr mAchINEs ArE ThE rEsULT OF A cOrPOrATE cULTUrE ThAT OrIGINATEs IN ThE mOsT ImPOrTANT INDUsTrIAL DIsTrIcT IN ITALY

Nothing happens by chance: Innovation is the result of research and engineering, which draws on the experience, confrontation, technological intelligence and professional competency of one of the world's most appreciated territories and an industrial culture.

TTM is an integral part of this commitment and it plays a leading role in the manufacture of high performance laser cutting and welding machinery and systems.TEchNOLOGY

Is OUr PAssION

TECHNOLOGY

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Specialisation and applied research combined with the continuous proactive confrontation with our clients' engineering allow us to manage a unique wealth of experience.

Behind the performance and reliability of our machines there is all TTM's know-how, the guarantee of an industrial group that plays a leading role in a specific market and has proven to be particularly sensitive to the development of new products.

OUr LAsEr cUTTING AND WELDING mAchINEs DrAW ON AN EXTrAOrDINArY WEALTh OF TEchNIcAL AND PrAcTIcAL KNOWLEDGE

UNIQUE KNOW-hOW OF ThE hIGhEsT LEVEL

TECHNOLOGY

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UsING ONE OF OUr sYsTEms mEANs ImPrOVING ThE QUALITY OF ThE PrOcEss As WELL As PrODUcTIVITY

The features of every system are the result of a design aiming at optimising the overall manufacturing process.

The result is a system that is perfectly integrated within the plant, thereby improving its quality and productivity. The machine operates in the most efficient way and human intervention is only limited to controlling, thereby creating a synergy that ensures the highest yield and tangible cost reduction.

OPTImIsEDmANUFAcTUrING

PrOcEssEs

TECHNOLOGY

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A TEAm cOmBINING cOmPETENcE AND PAssION: PEOPLE WhO LOVE ThEIr JOB AND ADD VALUE TO ThE cOmPANY

Our personnel is the first and main value of every one of our plants. Professional resources forming a motivation and close-knit team. This is why we regard passion for what we do as a strategic growth factor.

Rewarding individual competencies and creating synergies: this is how we design and manufacture excellent solutions.

NOT JUsT TEchNOLOGYWE PUT OUr hEArT IN IT

TEAM

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SOLUTIONS ADDING ONE OF OUr sOLUTIONs TO OUr PrOcEss Is AN OPPOrTUNITY TO UNDErsTAND hOW AND WhAT TO ImPrOVE IN ThE OVErALL PrODUcTION chAIN

The advice of our technicians is a precious reference to rethink work dynamics and establishment and plant layouts, whilst aiming at the highest yield.

Our approach to and development of the order allow us to be a reliable partner for our client. Choosing one of our systems is the best chance to turn this technological investment into a strategic

opportunity.

EVErY rEsULTIs TAILOr-mADE

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A sYNErGY OFTEchNIcAL sOLUTIONsFOr rELIABLEAND cOmPETITIVE sYsTEms

SOLUTIONS

We operate as our client's partner, exceeding the logic of the most advanced supplier. The aim is to interface with the client, providing fully customised solutions.

Being a partner means providing the most effective advice on manufacturing requirements. Our engineering supply is our strong suit, which has made us leading problem solvers.

ThE TTm rEsEArch TEAm FOcUsEs ON INTEGrATED sYsTEms cOOrDINATED WITh hIGh PrODUcTIVITY LEVELs, cONsIsTENT OVEr TImE

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FOr OUr sYsTEms, WE UsE LAsEr sOUrcEs WITh ThE hIGhEsT PErFOrmANcE FOr EVErY sPEcIFIc APPLIcATION

roFin

iPG

trUMPF

ThE “IDEAL” sOUrcE Is EXAcTLY ThE ONE YOU NEED

TECHNOLOGY

YLS series fibre laser (multi mode laser). The advantage to use one single laser for both high and low power applications.

Reduced energy consumption given equal power. Does not require mirrors to steer the laser beam.

High performance fast axial flow CO2

laser with wear-free gas circulation and radio-frequency excitation.

CO2 SLAB laser. Extremely high quality beam with considerable maintenance reduction.

Every one of our machines is made using technologies that better meet expectations and ensure the quality of the provided service.

We have established collaborations with the world's major laser manufacturers, and this exchange of experience adds value at the disposal of our clients.

This is the prerequisite that allows us to manufacture a system that better solves the client's issues.

Assessing the best CO2 or high brightness laser source is not enough: nowadays it is essential to know how to choose the optimal type of process.

TTM provides pure laser (LW) welding with no filler material, the ideal solution for welds of high aesthetic quality that minimises thermal deformations.

We can also integrate hybrid processes, ranging from L-GMAW (laser-MAG) to L-GTAW (laser-TIG), particularly indicated in the event of large variability in joint geometry or of special hardness requirements, especially in the shipbuilding industry.

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FEAsIBILITY sTUDIEsAND r&D TEsTING

DEsIGN, sImULATION AND TEsTING

TTM has with specific equipment for continuous studies on CO2 and high brightness laser cutting and welding processes (solid-state and fibre lasers).

TTM uses this equipment during specific stages of process parameter studies carefully following the client's guidelines before proceeding with the design stage. This is possible also thanks to the collaboration of research institutes in national and international projects.

Our welding solutions aim at obtaining fully automated systems and processes.

The mechanical features and the state of the art control systems ensure maximum precision on very wide working ranges.

TTM's know-how allows acquiring the welding path and stages through a system based on high resolution laser triangulators (teaching).

A critical factor in the welding process is the increase in hardness values. To limit such values, TTM makes use of controlled induction systems with pre-heating and cooling curve management algorithms.

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FULLY AUTOmATED cLAmPING AND LOADING/UNLOADING sYsTEms

WELDING OPTIcs

All TTM systems provide for the full automation of the process during the material loading, positioning, processing and discharging phases.

This ensures maximum efficiency, reduction of overall management costs, and maximum safety for operators, thanks to the reduction of human intervention in potentially hazardous areas.

The welding heads are normally supplied by PRECITEC or TRUMPF. The laser beam is steered to the site of use through the process fibre or a mirror optical path.

A PUSH-PUSH welding wire supply system can be installed on both for CO2 and high brightness solutions, to ensure the highest performance in terms of precision and responsiveness of the feed rate control system.

Special applications, such as wobbling mirrors and twin-spot optical systems are also possible.

These solutions originate from the need to broaden the beam transversally with respect to the weld or to pre-heat the material. Their use is specifically tested during the R&D phases.

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cOAXIAL VIsION sYsTEm WELDING JOINT DETEcTION, mEAsUrEmENT, AND TrAcKING sYsTEms

The welding heads normally use can have a CCD camera installed for a coaxial vision of the welding area.

This function is useful for the correct alignment of the welding head during the robot setup phases, with the presence of an He/Ne Laser pointer coaxial to the beam.

Moreover, the camera allows for in-process welding monitoring by displaying the image or the next application of welding process monitors.

TTM can install special infrared pulsed laser lighting systems on the welding head to filter the plasma components and the fumes normally generated during welding operations.

One of the latest systems is based on the 690 nm CAVITAR CAVILUX hardware.

The obtained images are processed by dedicated software that can analyse and control the quality of the process itself.

TTM integrates real time joint tracking and off-line joint mapping sensors in its welding systems by means of a coaxial camera installed on the welding head or by using external laser sensors.

The trajectory is reconstructed by means of numerical image processing managed by a control unit. The use of extremely fast real-time hardware, such as FPGA or multi-processor systems, ensure the computational power required to analyse a large amount of data.

For stringent applications, which require an accurate evaluation of the geometrical features of the joint (such as

position, width, presence of even very narrow gaps) before welding, TTM has developed mapping software based on bidimensional high-precision laser triangulators to detect the shape of the profile orthogonally to the welding line.

This way, the system can automatically modify the theoretical welding trajectory according to the actual position of the workpiece and vary the main process parameters (laser power, welding speed, amount of filler material) in real time, depending on the actual size of the joint.

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OFF-LINE PrOGrAmmING sYsTEms

sYsTEm cONTrOL AND hUmAN-mAchINE INTErFAcE

NONDEsTrUcTIVE cONTrOL sYsTEms

TTM also provides the software to automatically generate cutting and welding programs, thereby avoiding consuming machine self-learning sessions.

The software can reside in a Windows PC as a stand-alone application or integrated in the system monitoring software.

The functions range from typical flat cutting with nesting and offcut optimisation to the automatic generation of cutting and welding sequences for combined systems.

The size and large number of moving elements of TTM systems make the development of human-machine interfaces (HMI) dedicated to specific applications indispensable. The experience in tube and sheet cutting and welding applications allows TTM to optimise the HMI to make the management of the system and process parameters easier for the operator.

Every HMI integrates an advanced multilingual diagnostics system through the connection to the TTM remote assistance service.

TTM also provides a series of additional network-based services, which allow clients to access a technological parameter database, as well as quotation and predictive diagnostic services by accessing the dedicated server.

The full automation of TTM systems can be extended to production quality control by means of the integration of off-line systems, such as ultrasounds and eddy-current.

The automatic generation of analysis reports allows continuously monitoring the quality of the welded joints.

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ORDERED BY INDIAN RAILWAYS, TSL 2.5-25 IS A STATE OF THE ART SYSTEM FOR MANUFACTURING THE SIDE WALLS AND ROOFS OF PASSENGER RAILWAY CARS.

CASE HISTORY

TSL 2.5-25

FULLY AUTOMATED LASER CUTTING ANDWELDING SYSTEMFOR MANUFACTURINGSIDE WALLS ANDROOFS

TSL STANDS FOR "TAGLIA SALDA LAMIERE" (SHEET CUTTING AND WELDING):2.5 METRES IS THE MAXIMUM WELDING LENGTH 25 METRES IS THE MAXIMUM LENGTH OF THE PIECES THAT CAN BE MADE USING THE SYSTEM.

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CASE HISTORY

TSL 2.5-25

OrThOGONAL FLAPsAND NO BUrrs

TECHNICAL DATA

MAXIMUM PROCESSABLE FORMAT

width • 2500 mm maxlength • 25000 mm max

TSL 2.5-25 IS A STATE OF THE ART SYSTEM DESIGNED BY TTM TO MEET THE SPECIFIC REQUIREMENTS OF INDIAN RAILWAYS, WHICH HAS CERTIFIED TTM AS MANUFACTURER OF HIGHLY RELIABLE AND EASY TO USE CUSTOMISED AND DEDICATED SYSTEMS.

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By welding together sheets of commercial sizes, the TSL system makes sheets of sizes not available on the market and completes the processing by cutting the perimeter and all the openings for doors and windows to obtain roofs, floors and side walls for railway cars.

TSL 2.5-25

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THE TSL 3.3-26.5 SYSTEM HAS BEEN DESIGNED AND MANUFACTURED FOR RAILWAY CAR BUILDING WORKS TVER JSC (RUSSIA), TO MANUFACTURE THE STAINLESS STEEL SIDE WALLS FOR RAILWAY CARS UP TO 26.5 METRES LONG.THIS SYSTEM, EQUIPPED WITH 3D CUTTING HEAD, ALSO ALLOWS PROCESSING SPECIAL NON-FLAT PROFILES, SUCH AS CORRUGATED SHEETS AND PERFORMING CRIMPED CUTS.

CASE HISTORY

TSL 3.3-26.5

FULLY AUTOMATED LASER CUTTING ANDWELDING SYSTEM WITH 3D CUTTING HEAD

THE TSL SYSTEM PROVIDES FOR THE USE OF A GANTRY TO AUTOMATICALLY DISCHARGE THE OFFCUTS REMOVED BY SUCTION CUPS AND PLACED ON CONVEYOR BELTS. THESE OPERATIONS OCCUR IN A FULLY MASKED TIME UPON WELDING THE NEXT SIDE WALL.

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CASE HISTORY

TSL 3.3-26.5

larghezza • 3300 mm maxlunghezza • 26500 mm max

LAsEr sOUrcE ON BOArD ThE mAIN GANTrY

THE MAIN GANTRY MOVES THE CUTTING AND WELDING HEADS, THE TRUMPF CO2 TLF4000 LASER RESONATORAND THE RELATIVE ELECTRICAL EQUIPMENT. THIS SOLUTION ENSURES A HIGH DYNAMIC RANGE AND MINIMISES MAINTENANCE OF THE OPTICAL PATH.

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TSL 3.3-26.5

The modularity of the safety systems allows for safe intervention in the loading/unloading areas by operators without having to interrupt cutting and welding operations.

TECHNICAL DATA

MAXIMUM PROCESSABLE FORMAT

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TS 4.20, ORDERED BY GÖECKE UMFORMTECHNIK GMBH (GERMANY), ALLOWS OBTAINING SEMIFINISHED LARGE SIZED SHEETS, USED IN THE TRANSPORTATION INDUSTRY. WITH THIS SYSTEM, THE COMPANY HAS OBTAINED THE TÜV NORD ISO 15085 CERTIFICATION IN 2010 FOR WELDING PROCESSES IN THE RAILWAY INDUSTRY.

TRANSVERSAL LASER CUTTING AND WELDING FOR MANUFACTURING METAL SHEETS WITH DIMENSIONS NOT AVAILABLE ON THE MARKET FOR THE RAILWAY INDUSTRY

CASE HISTORY

TS4.20

AS FOR ALL THE MODELS OF THE TS AND TSL SERIES, THE TS 4.20 SYSTEM CAN BE EQUIPPED WITH BOTH CO2 AND HIGH BRIGHTNESS LASER RESONATOR (FIBRE OR DISK).

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width • 4000 mm maxlength • ∞ mm

CASE HISTORY

TS 4.20

sHeets to Be WelDeDdimensions 1000x2000 mm mindimensions 2000x4000 mm max

WelDeD sHeetsdimensions 2000x2000 mm mindimensions 4000x∞ mm max

max ∞ mm

min

200

0 m

m

max

400

0 m

m

CUTT

ING

AN

DW

ELD

ING

AR

EA

THE SYSTEM IS INCLUDED IN AN AUTOMATED LINEFOR MANUFACTURING CARBON AND STAINLESS STEEL SIDE WALLS OF URBAN TRANSPORT COACHES WITH THICKNESS BETWEEN 1 AND 8 MM

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TS4.20

TECHNICAL DATA

MAXIMUM PROCESSABLE FORMAT

THE SYSTEM INSTALLED AT GÖECKE MAKES USE OF A TRUMPF TLF5000 STATIONARY SOURCE, WHICH ALLOWS WELDING CARBON AND STAINLESS STEEL WITH THICKNESS UP TO 8 MM.

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CASE HISTORY

TS5.12

LONGITUDINAL CUTTING AND WELDING.THE FULLY AUTOMATED LINEFOR MANUFACTURING LARGE FORMATS EVEN WITH DIFFERENT THICKNESS

THE TS 5.12 SYSTEM HAS FULLY MET THE MANUFACTURING REQUIREMENTS OF GÖECKE UMFORMTECHNIK GMBH (GERMANY). TS 5.12 CAN LONGITUDINALLY JOIN SHEETS UP TO 12 METRES LONG OF DIFFERENT MATERIAL AND THICKNESS.

THE TYPICAL TS 5.12 SYSTEM APPLICATIONS INCLUDE LONGITUDINAL WELDING OF HIGH MECHANICAL PROPERTY SHEETS, SUCH AS HIGH-RESISTANCE STEEL SHEETS.THIS TYPE OF APPLICATION REQUIRES PRE AND POST-HEATING SYSTEMS

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CASE HISTORY

TS 5.12

width • 5000 mm maxlength • 12000 mm max

sHeets to Be WelDeDdimensions 600x3000 mm mindimensions 2500x12000 mm max

WelDeD sHeetsdimensions 1200x3000 mm mindimensions 5000x12000 mm max

max 12000

min

120

0

min

600

max

500

0

CUTTING ANDWELDING AREA

max 12000

min 3000

min 3000

max

250

0

THE TS 5.12 SYSTEM AUTOMATICALLY LOADS TWO OR MORE SHEETS UP TO 12 METRES LONG. IT CAN COMBINE SEVERAL TRIMMING AND WELDING PROCEDURES TO OBTAIN A SEMIFINISHED PRODUCT IN VARIOUS CONFIGURATIONS, JOINING TOGETHER EVEN SEVERAL SHEETS OF DIFFERENT LENGTH, WIDTH, MATERIAL AND THICKNESS.

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TS5.12

WITH COOLING CURVE CONTROL TO LIMIT THE HARDNESS IN THE MOLTEN AREA AND IN THE THERMALLY ALTERED AREA. EVEN FOR THIS SYSTEM, THE ACCURATE MECHANICAL DESIGN HAS ALLOWED PLACING THE MAIN CARRIAGE OF THE TRUMPF TLF5000 CO2 SOURCE ON BOARD.

TECHNICAL DATA

MAXIMUM PROCESSABLE FORMAT

The components welded using the CRPLW system represent the core of the ITER Tokamak, the first industrial-scale nuclear fusion reactor.

The inductors welded using the TTM system generate an intense magnetic field to confine the plasma in a precise space and protect the container against the temperatures at which fusion reaction occurs, close to those of the core of stars.

The Tokamak is one of the world's most complex machines and is the result of international cooperation with europe and italy playing a leading role in the project.

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THE CRPLW SYSTEM ORDERED BY ASG SUPERCONDUCTORS IS USED TO WELD, IN A FULLY AUTOMATED PROCESS, THE COVERS OF PLASMA CONFINEMENT INDUCTORS IN THE ITER EXPERIMENTAL FUSION REACTOR, THE MOST IMPORTANT SCIENTIFIC EXPERIMENT IN THE ENERGY FIELD.

CASE HISTORY

CRPLWSYSTEM

SYSTEM FOR ROBOT LASER WELDINGOF NUCLEAR FUSION INDUCTORS

The extreme complexity of the operations is fully managed by a control system that automates joint analysis, trajectory verifications, and the welds, coordinating the work of 3 robots.

The operator controls the entire process by means of a specially designed interface.

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TECHNICAL DATA

Dimensions of the

inductors to be welded:

Laser source Laser source

approx. 13000mm x 7000mmIPG YLS3000 with 3-way beam switch

ABB IRB4600 moving on linear runway and ground guide curves

CASE HISTORY

CRPLWSYSTEM

THE CRPLW SYSTEM MUST ENSURE THE PERFECT GEOMETRY OF THE WELDING BEADS AND ACCURATE PENETRATION CONTROL ON AISI 316 LN STEEL JOINTS WITH A GAP RANGING BETWEEN 0 AND 0.8 MM.UNDER THESE EXTREME CONDITIONS, THIS TTM SYSTEM DETECTS THE CORRECT POSITION OF THE JOINT FOR THE EXACT RECONSTRUCTION OF THE CURVED TRAJECTORY AND MODULATION OF PROCESS PARAMETRES, SUCH AS LASER POWER AND WELDING AND WIRE SPEED.THE EXTREME COMPLEXITY OF THE OPERATIONS IS ENTIRELY MANAGED BY A CONTROL SYSTEM, WHICH AUTOMATES JOINT ANALYSIS, TRAJECTORY VERIFICATION, AND THE WELDS, COORDINATING THE WORK OF 3 ROBOTS.

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CRPLWSYSTEM

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AN EssENTIAL AsPEcT Is rEPrEsENTED BY TrAINING ThE cLIENT's PErsONNEL IN chArGE OF OUr sYsTEms

The professionalism and competence of TTM technicians in training activities is fundamental to provide the knowledge of the process and the system necessary for a correct use.

This is an important added value that TTM guarantees to those who choose us as their partner.

TTmTrAINs YOU

TRAINING

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OUr cOmmITmENT cONTINUEs EVEN AFTErThE mAchINE hAs BEEN INsTALLED AND cOmmIssIONED

TTM presents itself as a true partner that considers the relationship between quality of the product and maintenance of optimal performance over time as indissoluble. Those who purchase a TTM system know that the after-sales service is as important and represents excellence even in terms of assistance and maintenance. A certainty that is backed up by the commitment of a dedicated service, close to its clients anywhere in the world.

AssIsTANcEsErVIcE

AFTER-SALES

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A cONTINUOUs AssIsTANcE sErVIcE IN rOUTINE AND PrEVENTIVE mAINTENANcE ALLOWs OUr cLIENTs TO mAINTAIN ThE sYsTEm AT ThE hIGhEsT EFFIcIENcY AND PrODUcTIVE LEVELs

Our spare parts are always ready and available, as is our after-sales service, to ensure our clients serenity in the investment and certainty over the years.

sPArE PArTssErVIcE

AFTER-SALES

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OUr mAIN GOAL Is OUr cLIENTs' sATIsFAcTION, FrOm WhIch WE OBTAIN OUr hIGhEsT GrATIFIcATION FOr ThE EFFOrT AND cOmmITmENT WE cONTINUE TO mAKE EVErY DAY.

The dedication, seriousness and professionalism of our group, together with the important results we continuously achieve, are our guarantee of the highest quality and reliability.

rELIABILITYAND QUALITYGUArANTEED

CUSTOMER SATISFACTION

TUBE TECH MACHINERY SRL

VIA BONFADINA, 3325046 CAZZAGO S. MARTINO

BS ITALIATEL. +39.030.7256.311FAX +39.030.7256.333INFO@TTMLASER.COM

WWW.TTMLASER.COM