Bendmaster 60

Operator's manual
BendMaster
TruBend Cell 5000
Operator's manual
BendMaster
TruBend Cell 5000
Original operator's manual

Edition 2015-06-01
Order Information Please specify when ordering this document:
Operator's manual
BendMaster
Edition 2015-06-01
Document number B579EN
TRUMPF Maschinen Austria GmbH + Co. KG

Address for orders Technische Redaktion
Industriepark 24
A-4061 Pasching
Fon: +43 7221 603 - 0
Fax: +43 7221 603 - 50
Internet: http://www.at.trumpf.com
E-Mail: [email protected]
For "partly completed machinery" in accordance with the EC

Machinery Directive, this document corresponds to the
assembly instructions.
© TRUMPF Maschinen Austria GmbH + Co. KG

Before you proceed ...
This operator's manual documents the automation components
BendMaster (60) and BendMaster (150) in the TruBend Cell
5000 bending cell for the automatic handling of sheets on the
press brakes of the TruBend Series 5000.
The machine documentation includes:

■ Spare parts catalog.
■ Circuit diagrams.
■ TruBend Series 5000 operator's manual.
■ TruTops Bend software manual.
■ Handling equipment operator's manual
B579EN 2015-06-01 Before you proceed ... I

II Before you proceed ... 2015-06-01 B579EN
Table of contents
Chapter 1 Safety
1 For your safety 1‐3
2 Operational safety 1‐5

2.1 Intended use 1‐5
2.2 Authorized personnel 1‐6
3 Hazards 1‐7
3.1 Dangers due to the switch cabinet 1‐7
3.2 Hazards due to laser radiation 1‐7
3.3 Dangers from magnetic fields 1‐8
Mobile fanning magnet (option) 1‐8
3.4 Hazards when dealing with workpieces 1‐9
Sharp-edged workpieces 1‐9
Dangers due to floating loads 1‐9
3.5 Danger due to increased movement dynam- 1‐11
ics (optional productivity package)
3.6 Dangers due to unexpected movements 1‐12
3.7 Dangers due to Teleservice 1‐12
4 Measures to be taken by the manufacturer 1‐13

4.1 Danger zones and safeguarding device 1‐13
4.2 Danger signs on the machine 1‐16
5 Organizational measures to be taken by 1‐20

the user
5.1 Observing warnings and danger signs 1‐20
5.2 Training and instructing operators 1‐20
Measures applicable worldwide 1‐20
5.3 Adhering to the duty of care when handling 1‐20
the machine
5.4 Pay attention to water protection 1‐21
5.5 Using spare parts, accessories, software and 1‐22
operating materials
B579EN 2015-06-01 Table of contents 0‐1

6 Overview of residual risks 1‐24
7 Disassembly and disposal 1‐26
Chapter 2 BendMaster installation conditions

(60)/(150)
Who does what? 2‐3
1 Planning aid 2‐4
2 Installation site 2‐6

2.1 Space requirements 2‐6
2.2 Floor requirements 2‐6
Surface 2‐6
Floor quality 2‐8
2.3 Weight load 2‐10
2.4 Stress due to vibration 2‐11
2.5 Ambient conditions 2‐11
3 Compressed air supply 2‐13
4 Electrics 2‐14
4.1 Electrical power supply 2‐14
Connected loads 2‐14
Connecting cables 2‐15
4.2 Power supply 2‐15
Residual current device (RCD) 2‐15
Line structures 2‐16
4.3 Network link 2‐17
5 Transport 2‐18
5.1 Preparing transport 2‐18
Transport dimensions 2‐18
5.2 Permitted auxiliary tools 2‐18
5.3 Checking, unloading and transporting the 2‐20
machine
On delivery: check the machine 2‐20
0‐2 Table of contents 2015-06-01 B579EN

Unloading and transporting the machine 2‐20
Chapter 3 Description
1 Machine concept 3‐3
2 Technical data 3‐4

2.1 BendMaster 3‐4
2.2 BendMaster axes 3‐5
3 The most important assemblies 3‐6

3.1 Nameplate 3‐6
3.2 Floor lane 3‐7
3.3 Arm 3‐7
3.4 BendMaster switch cabinet 3‐7
3.5 Sheet sensor 3‐8
3.6 Rotational transformer 3‐9
3.7 Safety fencing 3‐9
3.8 Control panel 3‐9
3.9 Easy operation 3‐10
3.10 Sensor gauge fingers at the TruBend Series 3‐11
5000
4-axis sensor gauge finger 3‐12
6-axis sensor gauge finger (optional) 3‐13
Backstop resistor 3‐14
4 Options 3‐15
4.1 Extendable floor lane 3‐15
4.2 Gripper 3‐15
Vacuum gripper 3‐15
Multi-gripper 3‐17
Multiple-circuit suction cups 3‐17
Gripper construction kit 3‐18
4.3 Special gripper 3‐19
Magnetic gripper 3‐19
Linear gripper 3‐19
Pivoted-jaw gripper and pivoted-jaw grip- 3‐20
per with turning axis
4.4 Sheet removal station 3‐21

4.5 Double sheet recognition and double sheet 3‐22
separation
Double sheet recognition 3‐23
Double sheet separation 3‐24
4.6 Regripping station 3‐24
4.7 Gripper changing console 3‐25
4.8 Backlighting table 3‐25
4.9 Productivity package 3‐26
4.10 Mobile fanning magnet 3‐27
4.11 Handling equipment 3‐27
4.12 Store connection 3‐28
4.13 TruTops°Bend 3‐29
5 Options at the TruBend 3‐30
Chapter 4 Operation
1 Description of the operating elements 4‐6

1.1 Portable manual control unit 4‐6
Operating elements 4‐6
Menus and submenus 4‐7
1.3 Stationary 19" screen 4‐10
2 Operating the BendMaster 4‐11

2.1 Safety information 4‐11
2.2 Status display 4‐11
2.3 Software versions view 4‐13
2.4 User settings 4‐13
Changing settings 4‐13
Creating BIO (BendMaster Information 4‐15
Object)
Creating and modifying users 4‐15
2.5 Operating modes 4‐16
Selecting operating modes 4‐17
Enabling conditions for operation modes 4‐17
2.6 Moving axes of the BendMaster manually 4‐22
2.7 Displaying axis positions 4‐26
2.8 Gripper service 4‐27

2.9 Automatic gripper change (option) 4‐28
Picking up a gripper 4‐28
Lay down gripper 4‐31
2.10 Regripping station (option) 4‐32
Moving the axes of the regripping station 4‐32
manually
Setting up the regripping station 4‐33
Removing the regripping station 4‐35
2.11 Setting the backstop resistor regardless of 4‐36
the program
3 Switching on and referencing the Bend- 4‐38

Master
3.1 Switching on the BendMaster 4‐38
3.2 Referencing the BendMaster 4‐39
Referencing the Z, A, B, C, Z1, Z2 axes 4‐40
Referencing the D axis 4‐41
3.3 Referencing TruBend 4‐42
4 Switching off the BendMaster 4‐46

4.1 Stopping BendMaster and TruBend in any 4‐46
emergency or after a malfunction
4.2 BendMaster, switching off 4‐46
5 Travel functions 4‐48

5.1 Executing travel functions 4‐48
6 Running in a TruTops program 4‐50

6.1 From BendMaster control V7.0 and higher: 4‐50
Settings in TruTops Bend
6.2 Procedure for productivity package option 4‐50
Checking the productivity package 4‐50
Calculating suction cup capacities 4‐51
Determining the reduction of the robot 4‐52
speed
6.3 Overview, loading a program 4‐52
6.4 Creating a new BendMaster job from the Tru- 4‐53
Tops Bend program
6.5 Archiving, restoring or deleting jobs 4‐55
Filing away a job 4‐56
Restoring an order 4‐56
Deleting a job 4‐57

Changing the backup directory path on 4‐58
the user interface
6.6 Defining job details 4‐59
Defining exposure details 4‐59
Editing the gripper weight 4‐61
6.7 Loading and unloading areas 4‐62
Load job 4‐64
Adjusting an area 4‐64
Copying an area 4‐67
Deleting an area 4‐68
Displaying the area position 4‐68
Defining area details 4‐69
6.8 Performing the rough recognition process 4‐72
(Search within area)
Searching for an area 4‐72
Searching for further loading stacks 4‐76
Intermediate layer, searching for 4‐77
Procedure in the event of problems with 4‐77
the rough recognition
6.9 Defining stacks 4‐78
6.10 Processing stacks 4‐80
6.11 Creating a tooling plan 4‐84
Checking the TruTops tooling plan 4‐84
Selecting a separation method 4‐85
Selecting double sheet recognition 4‐87
6.12 Setting bending parameters 4‐88
Opening bending parameters 4‐89
Selecting bending support 4‐90
Setting the backgauge sensor system 4‐90
Setting the approach strategy 4‐91
Setting the backstop resistor for single 4‐92
bending operations
6.13 Program, loading 4‐92
Opening the running in program 4‐92
Program steps for running in 4‐93
Selecting an execution method 4‐94
Running in procedure 4‐94
Teaching a point 4‐96
Points, editing 4‐96
Setting the main run indicator manually 4‐98
Deleting a point 4‐99

Displaying axis positions 4‐100
6.14 Starting a run-in program 4‐100
6.15 Production planning 4‐102
Creating or modifying a production plan 4‐102
Setting the speed and required number 4‐103
Executing the production plan 4‐104
6.16 Connection to storage (option) 4‐105
Defining parts data 4‐105
Defining loading and unloading areas of 4‐105
the storage stations
Moving a storage cart manually 4‐106
Moving the BendMaster semi-automati- 4‐106
cally
Moving a storage cart in automatic mode 4‐108
7 Working at the press brake without Bend- 4‐110

Master
7.1 Working at the press brake without Bend- 4‐110
Master
8 Errors and Messages 4‐111

8.1 Displaying and acknowledging errors and 4‐111
messages
8.2 Troubleshoot an error 4‐111
9 Error handling 4‐113

9.1 Jumpering the sensor finger 4‐113
9.2 Image processing diagnostics 4‐113
Opening the diagnostics tool 4‐119
Recording with Vision Diagnostics 4‐121
Saving the image recorded last 4‐124
Restarting the program 4‐125
9.3 Teleservice 4‐125
10 Solving problems and troubleshooting 4‐126

10.1 Problem: no part recognized 4‐126
Solution: no part identified 4‐127
10.2 Problem: Part underneath detected 4‐128
Solution: part underneath detected 4‐129
10.3 Problem: part interference contour recognized 4‐130
Solution: interference contour recognized 4‐131

Chapter 5 Maintenance (customer)
1 General guidelines 5‐3
2 Maintenance Overview 5‐5
3 Lubrication 5‐6
3.1 Overview 5‐6
3.2 Maintenance Instructions 5‐7
BendMaster: Z slide 5‐7
Regripping station (option) 5‐8
4 Mechanical elements 5‐10

Safety fencing 5‐10
Lift gate 5‐10
Transport equipment (option): transport 5‐11
belt
BendMaster: Z axis 5‐11
Regripping station 5‐12
Sheet removal station 5‐13
Press brake: sensor gauge finger 5‐13
Gripper changing console (option) 5‐14
BendMaster: pivoted-jaw gripper (option) 5‐15
5 Electrical components 5‐16

5.1 Overview 5‐16
BendMaster: control cabinet 5‐17
BendMaster: switch cabinet 5‐18
BendMaster: fan in the C arm 5‐20
BendMaster: fan, Z slide 5‐21
6 Optical components 5‐22

6.1 Overview 5‐22
BendMaster: sheet sensor 5‐22

7 Pneumatic components 5‐24
Press brake: compressed air supply 5‐24
Chapter 6 Maintenance (Technical Service)
1 Maintenance overview 6‐2
Chapter 7 Index

Chapter 1
Safety
1 For your safety 1‐3
2 Operational safety 1‐5

2.1 Intended use 1‐5
2.2 Authorized personnel 1‐6
3 Hazards 1‐7
3.1 Dangers due to the switch cabinet 1‐7
3.2 Hazards due to laser radiation 1‐7
3.3 Dangers from magnetic fields 1‐8
Mobile fanning magnet (option) 1‐8
3.4 Hazards when dealing with workpieces 1‐9
Sharp-edged workpieces 1‐9
Dangers due to floating loads 1‐9
3.5 Danger due to increased movement dynam- 1‐11
ics (optional productivity package)
3.6 Dangers due to unexpected movements 1‐12
3.7 Dangers due to Teleservice 1‐12
B579EN 2015-06-01 Safety 1‐1

4 Measures to be taken by the manufacturer 1‐13
4.1 Danger zones and safeguarding device 1‐13
4.2 Danger signs on the machine 1‐16
5 Organizational measures to be taken by 1‐20

the user
5.1 Observing warnings and danger signs 1‐20
5.2 Training and instructing operators 1‐20
Measures applicable worldwide 1‐20
5.3 Adhering to the duty of care when handling 1‐20
the machine
5.4 Pay attention to water protection 1‐21
5.5 Using spare parts, accessories, software and 1‐22
operating materials
6 Overview of residual risks 1‐24
7 Disassembly and disposal 1‐26
1‐2 Safety 2015-06-01 B579EN

1. For your safety
Regulations and guidelines With the CE marking and the EC Declaration of Conformity,
TRUMPF confirms that the machine meets the basic health and
safety requirements of the EC Machinery Directive.
The CE marking is located on the nameplate of the machine.
The EC Declaration of Conformity is delivered along with the
machine.
The machine meets the requirements of safety standard ANSI
B11.3.
Chapter Safety This chapter describes the safety concept. The chapter describes
how potential dangers can be avoided. The overview of residual
risks contains measures to be taken by the operator in order to
reduce the residual risks.
Notes
■ The operator must adhere to the valid safety and accident
prevention regulations of the respective country and the
safety laws of the state and of the region!
■ USA and Canada: TRUMPF also recommends compliance
with the ANSI safety regulations for press brakes.
■ Observe the operator's manual for the press brake.
Warnings and danger signs Certain operations can be a source of danger during operation.
The documentation contains warnings before the instructions for
these activities. There are danger signs on the machine.
A warning contains signaling words that have been explained in

the following table:
Signaling word Description

DANGER ... refers to great dangers. If not avoided, it can result
in death and serious injuries.
WARNING ... refers to a dangerous situation. It could lead to seri-
ous injuries, if it is not avoided.
CAUTION ... indicates a potentially dangerous situation. It could
lead to injuries, if it is not avoided.
NOTICE If such a situation is not observed, it can lead to dam-
age to property.
Tab. 1-1
B579EN 2015-06-01 For your safety 1‐3

Example of a warning:
Suspended load!
DANGER
Falling loads could lead to severe bodily injury or even
death.
Ø Observe safety regulations for the handling of heavy loads.
Ø Never walk under a suspended load.
Ø Use tested and appropriately sized tackle and means of
transportation.
Ø Employ qualified technicians to transport the machine.
Ø Carry out transport in accordance with the transport regula-
tions.
1‐4 For your safety 2015-06-01 B579EN

2. Operational safety
The machine can become a source of danger if it is used inap-

propriately or for purposes other than those intended:
■ Dangers to the safety of the operator.
■ Damage to the machine and other material assets of the
operator.
■ Negative effect on the effective functioning of the machine.
2.1 Intended use
The user may use the machine only in the industrial sector.
The installation, operating and transport conditions prescribed by
TRUMPF must be adhered to and the maintenance work must
be performed. The installation and operation must comply with
the relevant national regulations that are valid in the country of
operation. The user must adhere to the national regulations.
The user may only manipulate cold sheets using the machine.
The sheets are taken from the loading or unloading position,
bent on the press brake according to the machining cycle and
then, depending on the design version, either set down at the
loading or unloading position or transported onwards from the
unloading position.
The following is not allowed:

■ Unauthorized alteration or conversion of the machine by the
user or personnel.
■ Any working procedure that impairs the safety.
■ The machining of hot, splintering or brittle materials.
■ Use of tools from other manufacturers without consultation
with and release by TRUMPF.
■ Misuse of press beams for storing unused tools.
■ The machining of scarred or sandblasted sheets (does not
apply to machining with the pivoted-jaw gripper).
■ The machining of sheets with unsuitable gripper technology
(e.g. perforated sheets with suction cups).
■ Exceeding the maximum workpiece dimensions of:
− 2000 x 1000 mm with BendMaster (60).
− 3000 x 1500 mm with BendMaster (150).
− Profiles: 2500 x 1000 mm with BendMaster (60).
− Profiles: 4000 x 500 mm with BendMaster (150).
■ Exceeding the maximum workpiece weight of:
− 40 kg with BendMaster (60).
B579EN 2015-06-01 Operational safety 1‐5

■ Exceeding the maximum load capacity (workpiece and grip-
per weight) of:
■ Use outdoors.
■ Utilization of the portable manual control unit in the vicinity of
heat sources or direct sunlight.
Exemption from liability Any other form of use is considered unauthorized use. TRUMPF
is not liable for any damage, especially personnel injuries and
production failures resulting from this. The risk is borne solely by
the operator. The warranty will be voided.
TRUMPF assumes no liability for material damage or personal
injury caused by gripper elements and peripheral equipment built
by the user himself (e. g. conveyor systems for the workpieces,
sheet thickness measurement devices). The user bears sole
responsibility for using self-built gripper elements.
2.2 Authorized personnel
■ Operation, setting and maintenance work may only be

carried out by authorized, trained and instructed personnel.
■ Qualified personnel may:
− Transporting the machine to the installation site.
− Carry out work at the hydraulic, pneumatic and electrical
modules.
− Disassembling the machine.
1‐6 Operational safety 2015-06-01 B579EN

3. Hazards
3.1 Dangers due to the switch cabinet
The switch cabinet may be opened only by a specialist electri-

cian.
Electrical voltage!
DANGER
Electric shock!
Ø Keep switch cabinet closed.
Ø Before opening the switch cabinet: switch off the main
switch and secure against switching back on. Wait for the
discharging time (at least 5 minutes).
Hot components!
CAUTION
Burns!
Ø Keep switch cabinet closed.
Ø Before opening the switch cabinet: switch off the main
switch and secure against being switched back on. Wait for
the correct cooling phase (at least 5 minutes).
3.2 Hazards due to laser radiation
Laser systems are classified into laser classes as per the Euro-
pean Standard EN 60825-1 (USA: ANSI Z136.1, ANSI B11.21).
The laser class corresponds to the hazard level of the laser light
emitted.
B579EN 2015-06-01 Hazards 1‐7

Assembly Laser class Description
Diode lasers on the sheet sensor for 2M The accessible laser radiation lies in the visible spectral
height measurement range of 400 nm to 700 nm. It is not dangerous for
eyes in the case of short exposure time (up to 0.25 s)
Wavelength 535 nm.
as long as the beam is not observed through optical
instruments (magnifying glass, lens, telescope). Addi-
tional radiation parts outside the wavelength spectrum of
400-700 nm fulfill the conditions of class 1M.
Eyes are normally protected from the laser light by turn-
ing away and closing the eyelids.
Four diode flashes on the sheet 2M The accessible laser radiation lies in the visible spectral
sensor for fine exposure range of 400 nm to 700 nm. It is not dangerous for
eyes in the case of short exposure time (up to 0.25 s)
Wavelength 532 nm.
as long as the beam is not observed through optical
instruments (magnifying glass, lens, telescope). Addi-
tional radiation parts outside the wavelength spectrum of
400-700 nm fulfill the conditions of class 1M.
Eyes are normally protected from the laser light by turn-
ing away and closing the eyelids.
Tab. 1-2
Eye injury due to laser radiation!

WARNING
Laser radiation damages the eyes permanently.
Ø Do not look directly into the beam.
3.3 Dangers from magnetic fields
Mobile fanning magnet (option)
A mobile fanning magnet can be used to separate ferromagnetic

sheets.
The fanning magnet is a permanent magnet which creates a
strong magnetic field. The magnetic field and the high attractive
ferromagnetic force are constant.
Magnetic flux density The magnetic flux density is at its highest of about 180 mT (milli
tesla) at the front surfaces of the fanning magnets. The value is
about 0.7 mT at a distance of 60 cm.
1‐8 Hazards 2015-06-01 B579EN

Health risk and damage to property due to strong magnetic
WARNING fields of the expanding magnets!
Ø Persons with pacemakers: maintain a distance of at least
1 m.
Ø Notify personnel, visitors, or visiting personnel of the dan-
gers to persons with pacemakers.
Ø Do not reach between the fanning magnet and the sheet
metal stack with parts of the body.
Ø Only place the fanning magnet on the sheet metal stack or
remove it from the sheet metal stack in its retracted normal
state.
Ø Do not hold any heavy ferromagnetic parts (sheets, tools) in
your hands in the proximity of fanning magnets (<1 m).
Ø Keep watches and magnetic storage media (diskettes, credit
cards) away.
3.4 Hazards when dealing with

workpieces
Processing workpieces can be dangerous. These dangers and

measures are different for every workpiece.
Sharp-edged workpieces
Workpieces have sharp edges!

WARNING
Risk of injury!
Ø Wear personal protective gear.
Dangers due to floating loads
The BendMaster moves with suspended loads during loading

and unloading.
B579EN 2015-06-01 Hazards 1‐9

Unexpected vacuum loss in case of a suctioned workpiece!
DANGER
Risk of fatal injury due to workpiece crashing!
Ø No permanent workplace is permitted outside the safety
fencing within the swivel range of the BendMaster.
Ø Follow the safety regulations for handling heavy loads.
Ø Do not enter the danger zone when a workpiece is attached
by suction.
Ø Do not fail to follow any of the following instructions.
In manual and automatic ■ Never manually guide a load suspended from the BendMas-
mode ter out of the danger zone or manually guide it into the dan-
ger zone.
■ In the event of a power failure:
− Wait until the power supply has been restored.
− Securely deposit the workpiece on a pallet.
■ If there is a defect directly at the BendMaster that requires
repair work in the danger zone:
− Secure the suspended load from above using a crane
and remove it.
or
− Drop the suspended load with the safety doors closed
before entering the danger zone.
■ If there is a defect to the system outside the danger zone:
− Eliminate the defect.
− Deposit the suspended load on a pallet.
■ Do not move the BendMaster with suspended loads into the
home position in order to enter the danger zone afterwards.
Set down the workpiece first.
Additionally, in manual mode In manual mode (for example, teach mode), the operator may be
within the safety fencing to move the axes of the robot and the
press brake.
If the compressed air fails, an acoustic warning signal is emitted
in manual mode and a cyclic error message is displayed at the
HMI. The BendMaster stops and can no longer be moved in
manual mode.
Unexpected drop in pressure at the BendMaster gripper

WARNING while a workpiece is clamped!
Risk of injury due to workpiece falling down.
Ø If an acoustic warning signal is emitted, exit the automation
cell immediately and close the safety doors.
Ø Acknowledge the message.
Ø Before entering the safety cabin: move the BendMaster
manually and set down the clamped workpiece safely.
1‐10 Hazards 2015-06-01 B579EN

Pressure drop at the BendMaster gripper while a workpiece
WARNING is clamped caused by switching off the compressed air
supply.
Ø Only turn off the MAIN SWITCH and the compressed air
supply if no workpiece is gripped by the BendMaster's vac-
uum gripper.
The safety doors are not monitored in manual mode.
Risk of injury and damage to property due to suspended

WARNING load in manual mode.
Ø Move the BendMaster only if no other persons are in the
danger zone.
Ø Only perform overhead movements with suspended loads
from a safe distance.
Ø Make sure that the suspended load does not collide with the
safety fencing or other parts in the danger zone.
When programming of ■ Do not modify automatically generated traverse points such

traverse points that the risk of workpiece loss is increased.
3.5 Danger due to increased movement

dynamics (optional productivity
package)
When the productivity package option is activated, the movement

dynamics of the BendMaster are doubled.
Increased movement dynamics due to productivity package

WARNING
The workpiece may fall out or be ejected! Risk of injury!
Ø Before starting an older project, check the holding force and
stability of the corresponding gripper and confirm the respec-
tive dialog.
Ø Calculate the suction cup capacity (see "Calculating suction
cup capacities", pg. 4‐51).
Ø Adapt the number of suction cups to the gripper.
Ø If the number of suction cups cannot be increased: reduce
the speed of the travel points (see "Points, editing", pg.
4‐96).
Ø For magnet gripper: reduce the robot speed (override) to
50% (see "Determining the reduction of the robot speed",
pg. 4‐52).
B579EN 2015-06-01 Hazards 1‐11

3.6 Dangers due to unexpected
movements
Unexpected movements of the robot!

WARNING
Risk of crushing.
Ø When working inside the safety cabin: Maintain a sufficient
distance from moving assemblies.
Ø Do not stand under the BendMaster.
Unexpected movements of linear or pivoted-jaw gripper

WARNING (option)
Risk of crushing.
Ø Before starting set up or maintenance work, close the shut-
off valve on the pivoted-jaw gripper.
Ø Take special care when you open the shut-off valve,
because the suction cup slat will start to move immediately.
3.7 Dangers due to Teleservice
Teleservice is used to establish a connection between the

machine and Technical Service.
The service engineer can access the user interface to analyze
problems and in some cases to eliminate them directly.
Teleservice activated!
WARNING
Injury and damage to property.
Ø Only persons trained by TRUMPF may take part in a Tele-
service session.
Ø If doubts arise regarding the qualifications of the persons
involved or if comprehension issues arise, TRUMPF can
refuse Teleservice or terminate the Teleservice session.
1‐12 Hazards 2015-06-01 B579EN

4. Measures to be taken by the
manufacturer
The danger zone of the machine is safeguarded by safety equip-

ment. The machine may only be operated with these safety devi-
ces.
4.1 Danger zones and safeguarding

device
1 EMERGENCY STOP impact 4 EMERGENCY STOP impact 7 EMERGENCY STOP impact

button button on the outside at posts 1 button on the inside on post 4
2 Key-operated switch operating to 4 8 Safety fence
mode 5 TruBend 5000 9 Main switch
3 EMERGENCY STOP impact 6 BendMaster
button
Danger zones and safeguarding device TruBend Cell 5000 Fig. 59198
In teach mode (setup mode) of the BendMaster, the BendMaster

is moved with suctioned part while the operator can be within
the protective fence. The danger zone in teach mode is in the
B579EN 2015-06-01 Measures to be taken by the manufacturer 1‐13

entire swiveling range of the BendMaster as well as 2000 mm to
the left and to the right of the suctioned workpiece.
TruBend Cell 5000 danger zone (gray) in teach mode with suctioned workpiece Fig. 71402
Safety fence The danger zone is completely or partially secured with a safety
fence depending on the installation. It can be accessed through
one or more safety doors.
The safety fence prevents persons from entering the system in
automatic mode or manual press mode. It prevents workpieces
from falling out of the system. The safety doors are monitored
and enable controlled access to the system.
Restricted work area The work area of the robot is restricted at the individual motion
axes of the robot using soft and hardware end stops. The robot
can only be moved within the defined work area.
The work area is defined such that the robot cannot move
against the safety cabin or other static collision contours (e.g.
switch cabinet within the safety cabin).
Main switch The machine is switched on and off via the main switch. The
main switch can be secured against being switched on again
using a padlock.
1‐14 Measures to be taken by the manufacturer 2015-06-01 B579EN

The main switch has the following positions:
Position Description
0 The machine is switched off and the voltage supply of the
machine is interrupted .
I The machine is switched on.
Tab. 1-3
EMERGENCY STOP impact Note

button
The Emergency stop function for the press brake is integrated in
the BendMaster control.
EMERGENCY STOP impact buttons are located at the following

points on the machine:
■ On the portable manual control unit.
■ On the support for the portable manual control unit.
■ On each corner post of the safety fencing.
■ Within the protective fence at Column 4.
An EMERGENCY STOP leads to the following:

■ All axis motions stop.
■ All drives are switched off electrically.
■ The power supply of all safety doors is interrupted.
■ The 24 V control voltage is maintained.
■ Vacuum remains.
Pulse trigger switch In manual mode, the enable key on the portable manual control
unit is pressed into the neutral position in order that the axes
can be moved.
In Manual mode, the user may be within the safety fencing. For
that reason, the travel motions of the machine must be
observed.
The pulse trigger switch has the following positions:
Position Description
Not pressed It is not possible to move the axes.
Pressed The axes can be moved.
All axis movement stops when the pulse trigger switch
is released.
Pushed through EMERGENCY STOP is triggered.
Tab. 1-4
OPERATING MODE key The machine can be operated in various operating modes. The
switch operating mode is selected using the OPERATING MODE key
switch.

The key must be removed and kept safely.
The key switch is located on the mounting device for the porta-
ble manual control unit and has the following positions (see "Fig.
46231", pg. 4‐17):
Switch setting Description
(zero position) None of the axes can be moved.
(TruBend manual) Press brake can be operated without BendMaster. The BendMaster is in home
position.
(Manual mode) Only the axes of the BendMaster can be moved at reduced speed.
The ENABLE KEY on the portable manual control unit must be pressed the
whole time.
(Automatic mode) All axes move at the programmed speed.

The program is started using the START button on the portable manual control
unit.
The operator must be outside the safety cabin.
Tab. 1-5
Reduced speed in manual The traveling speed of the axes is reduced automatically in man-
mode ual mode. The maximum traveling speed at the center of the
gripper is 250 mm/s.
4.2 Danger signs on the machine
Danger signs indicate dangers when operating the machine.

1 Gripper 4 BendMaster switch cabinet
2 Sheet sensor 5 Motors between A, B and Z
3 Sheet sensor axes
6 BendMaster (150): Under the
cover of the Z axis
Danger signs BendMaster Fig. 59196

7 EMERGENCY STOP impact 8 Warning sign above every
buttons on the corner posts, safety door
inside and outside
Danger signs TruBend Cell 5000 Fig. 59274
Pos. Danger sign Description

1 Risk of crushing.
2 Danger due to laser radiation..

Caution - radiation, light
emitting diodes, class 2M.
Do not look into the beam or
view directly with optical instru-
ments when the cover is
opened.
2 Danger due to laser radiation..

Caution - laser radiation, class
2M.
Do not look into the beam or
view directly with optical instru-
ments when the cover is
opened.

Pos. Danger sign Description
3 Laser radiation: do not look into
the beam or view directly with
optical instruments
Laser class 2M
Wavelength 532 nm.
Max. output power <1 nW
4 Danger due to electrical voltage.

(BendMaster switch cabinet)
5 Danger due to hot surfaces.
6 Danger due to electrical voltage.

(Under cover, Z axis BendMas-
ter (150))
7 Freeing of clamped persons.
8 Only trained personnel are per-

mitted to enter the bending cell.
Danger from suspended load!
Do not reach through the safety
fencing!
Danger from attached sheet
metal parts!
Tab. 1-6

5. Organizational measures to be taken
by the user
5.1 Observing warnings and danger

signs
Certain activities can be a source of danger during the operation.

The documentation contains warnings before the instructions for
these activities and danger signs are provided on the machine.
5.2 Training and instructing operators
Measures applicable worldwide
The user must take the following measures before the personnel
start working on the machine:
■ Train personnel appropriately.
■ Inform the personnel about the possible dangers and the
safety measures.
■ Keep personal protective gear ready.
■ As far as possible, ensure personnel wear protective gear
(e.g. gloves, safety shoes, hearing protection, safety
glasses...).
■ Define responsibilities for safety, operation, maintenance, set-
ting work and service.
■ Require that personnel read the technical documentation of
the machine. Recommendation: obtain written confirmation
from the personnel.
■ For fault diagnosis and error correction, a connection will be
made via Teleservice by TRUMPF between the machine and
Technical Service. When the machine is commissioned the
user will be informed about the sequence and possible risks
of the Teleservice. The user must provide safety instruction
to operators who are involved in the Teleservice.
5.3 Adhering to the duty of care when

handling the machine
Checking the danger zone The operator must always make sure that nobody is within the
and safety devices danger zone before starting up the machine.
The operator may only operate the machine using safety devi-
ces. Safety devices may not be removed or put out of operation,
except when performing maintenance and service work. The
1‐20 Organizational measures to be taken by the user 2015-06-01 B579EN

operator must replace and put the safety devices into operation
after completing work.
Once per shift, preferably before starting the production:

■ Check the safety devices for proper function.
Ensuring the perfect User:

working order ■ The user must ensure that the machine is installed as per
the installation plan and installation conditions.
■ The user must ensure that only authorized personnel works
at the machine.
■ The operator must ensure that damaged or missing danger
signs on the machine are replaced.
■ The user or the persons appointed by him/her must operate
the machine when it is in perfect working order.
■ The user must ensure that the work station is kept clean and
tidy by issuing appropriate instructions and conducting
inspections.
■ The user must ensure that the working areas are supplied
with sufficient fresh air.
Operator:
■ The operator must immediately report changes (including the
operating performance) occurring in the machine to the oper-
ator. The machine must be checked for externally visible
defects and damage at least once per shift.
■ The machine must be checked for externally visible defects
and damage at least once per shift.
■ The operator must check the tooling status prior to operation
of the machine to avoid any risks due to an incorrect tooling
status.
■ Before starting the machine, the operator must always make
sure that nobody is within the danger zone.
Observing the shutdown The prescribed shutdown procedures must be adhered to during
procedure all operations (e.g. setting and maintenance work).
5.4 Pay attention to water protection
Water-pollutant substances (e.g. oil) should not enter the ground

or into water bodies.
The Federal Republic of The principle of precaution is applicable for machines in the Fed-
Germany eral Republic of Germany: water should not become contami-
nated when using water-pollutant substances (Federal Water Act
WHG).
B579EN 2015-06-01 Organizational measures to be taken by the user 1‐21

The plant decree and the administrative regulations of the Fed-
eral states explain how this principle of precaution should be
adhered to.
Water-pollutant materials ■ Lubricants

Water Hazard Class 1 or 2
Volume of water-pollutant materi- ≤ 5 l (≤ 1.32 gal)
als
Hazard level of the machine A
Water protection specifications Tab. 1-7
Outside the Federal Outside the Federal Republic of Germany, the respective
Republic of Germany national regulations as regards water protection must be adhered
to.
5.5 Using spare parts, accessories,

software and operating materials
Using spare parts, Spare parts and accessories that have not been released by
accessories and software TRUMPF (in the following: "External parts and accessories") are
not checked. Installing and using external parts and accessories
can change design-related properties of the machine and
weaken the safety.
Only software that has been approved for installation by
TRUMPF may be installed.
Liability disclaimer ■ TRUMPF is not liable for damage if external parts and
accessories are used or if spare parts and accessories
approved by TRUMPF are not installed or replaced properly.
■ TRUMPF cannot be held liable for damages resulting from
the installation or operation of software which is not
approved by TRUMPF.
Using permissible operating The permissible operating materials (especially lubricating and
materials as per the cleaning agents) must be used as per the regulations. If a safety
regulations data sheet has been prescribed for the manufacturer of the oper-
ating material (European Directive 1907/2006 REACH), the
instructions in it must be followed, such as:
■ Chemical properties.
■ Physical and safety-related specifications.
■ transport.
■ Regulations
■ Safety measures, storage, and handling.
■ Procedures in the event of accidents or fires.
1‐22 Organizational measures to be taken by the user 2015-06-01 B579EN

■ Specifications for toxicology and ecology.
■ Waste code with prescribed disposal method for the operat-
ing materials.
Note
Safety data sheets can be obtained from the manufacturers of
the respective operating materials.
B579EN 2015-06-01 Organizational measures to be taken by the user 1‐23

6. Overview of residual risks
The machine has residual risks in spite of its safety devices and
construction type.
The following overview of residual risks is a summary of the
main potential threats to life and limb posed by the machine.
Any additional precautions that can be taken by the machine
owner to reduce residual risks are specified in the overview of
residual risks.
For detailed descriptions of the measures: (see "Hazards", pg.
1‐7).
Residual risk Dangerous point Type of danger Measure to be taken by

the operator
Mechanical elements
Crushing, striking, shear- ■ Sharp-edged workpie- Risk of injury Wear protective clothing
ing or cutting. ces.
Operation by trained and
■ Movement of the arm instructed personnel.
with or without a work-
piece. When working inside the
safety cabin:
■ Moving the machine on
Maintain a sufficient dis-
the floor lane.
tance from moving assem-
■ Unexpected movement blies (BendMaster, press
of linear or pivoted-jaw beam, backgauge). It is
grippers (option). forbidden to go beneath
the BendMaster or
between the BendMaster
and the bending machine.
Crushing, hitting, shearing Falling loads: Risk of injury Wear protective clothing
■ Releasing the work- Wear safety shoes.
piece after bending.
Operation by trained and
■ Workpiece falling due instructed personnel.
to loss of vacuum.
Before entering the safety
cabin: manually move the
BendMaster and safely
place the workpiece down
or drop it, for example, in
the area on the right, next
to the press brake.
Stumbling Stumbling within the floor Risk of injury -
lane area.
Gripping or retracting Expected movement of Risk of injury Maintain sufficient dis-
the conveyor band tance to the conveyor
(option). belt.
Do not lean or support
yourself on the conveyor
belt.
Malfunction or incorrect The BendMaster collides Risk of injury There must be no perma-
function with the safety fencing. nent workplace outside of
the safety cabin within the
swiveling range of the
BendMaster.
Electrics
1‐24 Overview of residual risks 2015-06-01 B579EN

Residual risk Dangerous point Type of danger Measure to be taken by
the operator
Electrical contact and ■ Direct contact with nor- Risk of fatal injury Maintenance/servicing/
proximity to parts under mally live parts. repairs by specially
high voltage, electric ■ Indirect contact with trained personnel.
shock parts that are live due
to an error.
Teleservice
Crushing, cutting, separat- Movements of the Risk of injury Have Teleservice per-
ing, impacting machine formed only by persons
who have been trained by
TRUMPF.
Residual risks Tab. 1-8
B579EN 2015-06-01 Overview of residual risks 1‐25

7. Disassembly and disposal
TRUMPF recommends that TRUMPF machine tools be disas-

sembled and disposed of by Technical Customer Support or a
specialist disposal company. The following notes are to be
passed on to the specialist disposal company performing the dis-
posal work, to guarantee fast, environmentally sound and safe
disposal.
Preparing disassembly ■ Contamination, in particular types of dust which can be stir-

red up or which be hazardous during disassembly are to be
removed.
■ Close off the disassembly and storage area over a wide
area.
■ Move down movable parts and suspended loads as far as
possible. Secure or support suspended loads in the event of
a defective machine.
■ Have the machine disconnected from the power supply by a
trained electrician.
■ If present: Close the compressed air supply and separate it
from the machine.
■ Depressurize components under pressure (e.g. compressed
air line).
■ Wait at least an hour to allow any residual voltage in the
machine to dissipate and hot components to cool down. All
assemblies/components can then be touched.
Dismantling ■ Poisonous vapors can result when thermally cutting painted

components or components made out of composite materials!
− Select a suitable cutting process.
or
− Wear a suitable protective mask and ensure there is a
sufficient supply of fresh air.
■ Secure top-heavy assemblies to prevent them from tipping
over and carefully put them in a good transport position (cen-
ter of gravity down).
■ Moving assemblies may be unbraked after being discon-
nected from the power supply!
− Fix movable assemblies prior to disassembly/transport, so
that the center of gravity cannot move in an uncontrolled
manner.
■ Mechanical stresses can be released when undoing chains,
ropes and steel constructions!
− Wear suitable protective gear and close off the area over
a wide area.
1‐26 Disassembly and disposal 2015-06-01 B579EN

Transporting assemblies ■ Close off transport routes and storage positions over a wide
area.
■ Use suitable lifting gear. See installation conditions.
■ Fasten assemblies above the center of gravity as far as pos-
sible.
B579EN 2015-06-01 Disassembly and disposal 1‐27

1‐28 Disassembly and disposal 2015-06-01 B579EN
Chapter 2
BendMaster installation
conditions (60)/(150)
Who does what? 2‐3
1 Planning aid 2‐4
2 Installation site 2‐6

2.1 Space requirements 2‐6
2.2 Floor requirements 2‐6
Surface 2‐6
Floor quality 2‐8
2.3 Weight load 2‐10
2.4 Stress due to vibration 2‐11
2.5 Ambient conditions 2‐11
3 Compressed air supply 2‐13
4 Electrics 2‐14
4.1 Electrical power supply 2‐14
B579EN BendMaster installation conditions (60)/(150) - 2‐1

Version 10
Connected loads 2‐14
Connecting cables 2‐15
4.2 Power supply 2‐15
Residual current device (RCD) 2‐15
Line structures 2‐16
4.3 Network link 2‐17
5 Transport 2‐18
5.1 Preparing transport 2‐18
Transport dimensions 2‐18
5.2 Permitted auxiliary tools 2‐18
5.3 Checking, unloading and transporting the 2‐20
machine
On delivery: check the machine 2‐20
Unloading and transporting the machine 2‐20
2‐2 BendMaster installation conditions (60)/(150) - B579EN

Version 10
Who does what?
Customer All the conditions described in this chapter must be fulfilled

before the machine is delivered.
If this is not the case, Technical Service will not be able to put
the machine into service.
Note
During start-up, the main switch on the machine may only be
switched on by Technical Service.
Technical Service The machine is put into service by Technical Service.
Start-up includes:
■ Installing, aligning, leveling and securing the machine.
■ Connecting the machine to the supplies (with the exception
of the electrical power supply).
■ Putting the machine into service.
■ Performing a functional test.
■ Instructing personnel.
B579EN BendMaster installation conditions (60)/(150) - 2‐3

Version 10
1. Planning aid
The planning aid provides an overview of the measures to be

taken and preparations to be made.
For details, refer to the corresponding sections of these installa-
tion conditions.
Time before the delivery Planning criterion Measures

of the machine
10 weeks Personnel and training ■ Appoint a member of staff to be responsible for
preparations for the delivery of the machine.
■ Appoint operating and service personnel and pro-
grammers.
■ Arrange training schedules for specialist personnel.
10 weeks Installation site ■ Determine the installation site of the machine, taking
into account the space requirements according to
the installation plan.
■ Check floor requirements:
− Floor quality.
− Evenness.
− Oil-resistant floor without expansion joints.
■ Take the weight and dimensions of the machine into
account.
■ Check the requirements for ambient conditions:
− Room temperature.
− Exposure to sunlight.
− Purity of the ambient air.
■ Check transport route, e.g.:
− Gateway openings.
− Header heights.
− Cable rack heights.
− Shunting areas around corners.
At least 8 weeks Installation plan Confirm the final installation plan by signing it and
send back to TRUMPF.
8 weeks Electrical system ■ Install electrical connections at the installation site.
■ Lay the conductor cross-section and fuse protection
according to the legal requirements.
■ Have the work required for Teleservice carried out:
− Install a telephone connection at the installation
site.
■ For network connection: install the network connec-
tion at the installation site.
6 weeks Compressed air supply ■ Arrange for the installation of the compressed air
supply at the installation site.
− Take into account connection, purity, com-
pressed air requirements.
3 weeks Transport Provide auxiliary transport equipment.
Note: If the machine is conveyed to the customer's site
by Technical Service, the required means of transporta-
tion and auxiliary transport equipment is provided by
them.
2‐4 Planning aid - Version 10 B579EN

Time before the delivery Planning criterion Measures
of the machine
2-3 weeks Feedback ■ Provide TRUMPF with feedback to confirm that the
requirements of the installation conditions have been
implemented.
During installation and Electrical installation ■ At the start of the installation process: have the sys-
start-up tem connected by a professional electrician.
Planning aid Tab. 2-1
B579EN Planning aid - Version 10 2‐5

2. Installation site
What does the customer Please consult a structural analyst for professional support, par-
need to do? ticularly in the context of the topic of floor requirements. Hand
over the "Installation site" section and the installation plan to the
structural analyst.
2.1 Space requirements
The following is documented in the TRUMPF installation:

■ Arrangement of components.
■ Space requirements for installation.
■ Space requirements of the system.
■ Space requirements for opening all doors.
■ Electric power supply.
■ Compressed air supply.
Hall height ■ TruBend Cell 5000 with BendMaster (60): at least 4000 mm
(at least 157 in).
■ TruBend Cell 5000 with BendMaster (150): at least 5000 mm
(at least 197 in).
2.2 Floor requirements
The quality of the prepared parts can be guaranteed only when

the floor conditions meet TRUMPF requirements.
Surface
Flatness The floor on which the machine stands must be even.
Permissible deviation from flatness (flatness tolerance):

■ Footprint range: max. 12 mm (½ in) per 10 m (33 ft).
■ Load-bearing points range: max. 2 mm (0.08 in) per 0.5 m
(1.64 ft).
The flatness tolerance can be determined for different measuring
point distances from the following diagram.
2‐6 Installation site - Version 10 B579EN

A Flatness tolerance B Measuring point distance l1
Tolerance for evenness depending on the measuring point distance Fig. 65278
Measuring point distance Flatness tolerance Department

0.5 m (1.64 ft) 2 mm (0.08 in) Load-bearing points.
10 m (33 ft) 12 mm (½ in) Installation surface.
Reading examples Tab. 2-2
Measuring procedure:
The straight edge is placed on the high points of the surface and
determines the depth gauge at the lowest point. For the selected
measuring point distance the depth gauge may not be greater
than the tolerance for evenness.
1 Straightedge l1 Measuring point distance

2 Vanishing line of the straight- t1 Depth gauge
edge
3 Surface
Measuring procedure for determination of the depth gauge Fig. 65581
B579EN Installation site - Version 10 2‐7

Expansion joints ■ The entire installation surface must consist of a continuous
base plate with a smooth surface in the area of the load-
bearing points.
■ The distance of the plug bore holes to the edge of the base
plate must be at least 200 mm (8 in).
■ If foundations are present, the arrangement of the expansion
joints must be paid attention to.
A Joint arrangement permissible B Joint arrangement not permissible

Expansion joints, top view Fig. 58390
Floor quality
Note
The floor must be oil-proof.
Elastically cushioned base Possible combinations in the bending cell:

plate ■ BendMaster (60) with TruBend 5085 to TruBend 5230 (S).
■ BendMaster (150) with TruBend 5130 to TruBend 5320.

■ Carrying capacity of the subsurface at least ks = 5000
kN/m2.
■ Minimum thickness:
− TruBend 5085 - 5230: 200 mm / 7.87 in.
− TruBend 5230 (S): 230 mm / 9.05 in.
− TruBend 5320: 250 mm / 9.84 in.
■ Concrete quality (equivalent to tensile strength C 25/30).
■ The reinforcement of the base plate should meet or exceed
the following specifications. The specifications apply to the
reconstruction of the base.
5050 5085 5085 (S) 5130

Top lengthwise (xsi) cm2/m 3.20 3.20 3.20 3.24
Top transverse (eta) cm2/m 3.20 3.20 3.20 3.20
Below lengthwise (xsi) cm2/m 3.20 3.20 3.20 3.20
Below transverse (eta) cm2/m 3.20 3.20 3.20 3.72
Reinforcement in the base plate Tab. 2-3
Version with greater installation height:
5085 (X 5085 5130 5170 5170 5230 5230 5320

) (SX) (X) (X) (SX) (X) (SX) (X)
Top lengthwise cm2/m 3.20 3.20 3.24 3.62 6.55 4.90 7.18 7.94
(xsi)
Top transverse cm2/m 3.20 3.20 3.20 3.20 3.20 3.20 3.80 4.20
(eta)
Below lengthwise cm2/m 3.20 3.20 3.20 3.53 4.83 4.92 5.04 5.33
(xsi)
Below transverse cm2/m 3.20 3.20 3.72 4.24 5.83 5.84 6.24 6.22
(eta)
Reinforcement in the base plate with increased installation height Tab. 2-4
US specification: rebar spaced 12 in on center, on both the top

and bottom faces and oriented in both the longitudinal and trans-
verse directions.
■ < 4.30 cm2/m: 2 layers of #4 rebar
■ 4.30 - 6.66 cm2/m: 2 layers of #5 rebar
■ > 6.66 cm2/m: 2 layers of #6 rebar
Ceiling plate/free span base ■ Effective load 15 kN/m2 (2.2 psi).

plate ■ Minimum thickness:
− TruBend 5085 - 5230: 200 mm / 7.87 in.
− TruBend 5230 (S): 230 mm / 9.05 in.
− TruBend 5320: 250 mm / 9.84 in.

■ Concrete quality (corresponding to Class C 25/30 tensile
strength): cylinder compressive strength ≥25 N/mm2
(3700 psi).
■ Multiple span girders.
When is a structural analyst A structural analyst must be consulted under the following condi-
generally required? tions:
■ The previously named requirements for an elastically embed-
ded base plate are not met.
■ The system is to be set up on a ceiling plate/free-span base
plate.
■ The system is to be set up on fiber-reinforced concrete or
roller-compacted concrete.
■ The system is to be installed on a floor other than the one
named above.
Vibration damping The machine must be damped against oscillations if other sensi-
tive machines are located directly next to the machine or if the
machine is located on a free-span surface which cannot tolerate
these oscillations.
Vibration damping can be implemented by the following meas-

ures:
■ Use Sylomer mats to isolate the machine; thickness 12 mm
(0.47 in), quality SR 1200, violet color, base plate to the sub-
surface and on the side.
■ Structure of the floor (from the bottom to the top):
− A layer of construction mat.
− At least 300 mm (11.8 in) gravel layer with compaction.
− 120 mm (4.72 in) underbody C12/15 reinforced with 1
mild steel grid layer (steel cross-section lengthwise/cross-
wise 1.96 cm²/m, mesh width lengthwise/crosswise
100 mm, wire thickness lengthwise/crosswise 5 mm).
2.3 Weight load
Structural analysis ■ Perform a structural stress analysis of the load-bearing

capacity of the floor surface prior to installation.
■ Take into account the weights of the relevant components
and the load on the support points.
Note
If the concrete floor has the minimum thickness and quality, it
will not have to be subject to a structural check.

Weights of the relevant machine parts:
BendMaster (60) BendMaster (150)

BendMaster weight 620 kg (1367 lb) 784 kg (1728 lb)
Floor lane of each 2000 mm element (79 in) 310 kg (683 lb) 310 kg (683 lb)
Complete weight with 4 m floor lane (158 in) 1240 kg (2734 lb) -
Complete weight with 6 m floor lane (236 in) 1550 kg (3417 lb) 1714 kg (3779 lb)
Complete weight with 16 m floor lane (630 in) - 3264 kg (7196 lb)
Tab. 2-5
2.4 Stress due to vibration
In the immediate area around the system, external influences

can lead to vibration loads. Vibration loads can effect the quality
of workpieces.
External influences are e.g.:

■ Fork lifts, industrial trucks, etc.
■ The installation or removal of other machines in the immedi-
ate vicinity of the system.
■ Machines which excite vibrations during operation, such as
punch presses etc.
2.5 Ambient conditions
Machine ambient conditions Notes

■ One-sided exposure to direct sunlight and unidirectional
drafts must be avoided (e.g. with Venetian blinds if installed
near a window).
■ The switch cabinet must be air-conditioned at temperatures
of above +30 °C (+86°F).
Machine status Temperature

Operation +10°C ... +40°C
(+50°F ... +104°F)
Machine ambient conditions Tab. 2-6

Ambient conditions for the Control status Temperature Humidity
control system Transport or switched- –20 °C ... +70 °C 20 to 75 % relative
off machine (–4°F ... +158°F) humidity
90 % temporarily, but
non-condensing
Ambient conditions for the control system Tab. 2-7
Brightness Bright light impairs the sheet sensor of the BendMaster:
■ The sheet sensor may not be exposed to direct sunshine.

■ No halogen lamps may be installed over the machine.

3. Compressed air supply
Note
The connection point is indicated on the installation plan using
this symbol.
Compressed air supply The BendMaster needs a separate compressed air supply. The
compressed air connection may be flexible or may consist of a
fixed pipe to the BendMaster's optional switch cabinet.
Compressed air supply Property Requirement

connected loads Required pressure 6±1 bar (87±15 psi)
Air consumption (required volume Average: 2 - 8 m3/h (1.18 -
rate of flow according to ISO 1217 4.71 cfm)
or DIN 1945)
Compressed air supply connected loads Tab. 2-8
Supply lines compressed air Property Requirement

supply Min. nominal diameter of the sup- 13 mm (1/2")
ply line
Min. nominal diameter of the main 13 mm (1/2")
line
Length of the connecting line No limit
Supply lines compressed air supply Tab. 2-9
Compressed air properties Property Requirement Quality Recommendation

at the tapping point class1
Dust-free Maximum particle size: 4 Air filter in front of the
15 µm system
Conden- Cooled down to +7°C 5 Cold dryer
sate-free (+44.6°F) pressure
dew point
Oil-free Maximum oil content: 4 Oil-free sealing screw-
5 mg/m3 type compressor with
active carbon filter
Compressed air properties at the tapping point Tab. 2-10
1 ISO°8573-1; 2010 edition
B579EN Compressed air supply - Version 10 2‐13

4. Electrics
Target group The requirements specified in the "Electrical" section must be

met by a company which specializes in electrical installations.
IEC/NEC conditions The IEC conditions apply worldwide, the NEC conditions apply
only for Canada and the USA.
4.1 Electrical power supply
Note
The central connection point is on the switch cabinet and is
shown on the installation plan with the illustrated symbol.
Connected loads
Note
Impermissible voltage fluctuations endanger the faultless opera-
tion of the machines and reduce their performance. A voltage
stabilizer is necessary. Otherwise a regulated isolating trans-
former can be used.
Before shipping, the system is set to the power supply voltage

and frequency specified by the customer.
Property Value
Line voltage at 50 Hz ± 1% V 400 ±5%
Line voltage at 60 Hz ± 1% V 460 ±5%
Frequency tolerance - ±2%
Control voltage V 24
Connected load kVA 7.5
Fuse protection at 400 V A 16
Maximum interruption time - 10 ms/10 s
Tab. 2-11
NEC conditions for fuses The use of slow-blow fuses is preferred. If these fuses are also
used for branch circuits, an ETI type fuse must be used to pro-
tect the machine from current peaks when switching the machine
on.
2‐14 Electrics - Version 10 B579EN

Connecting cables
Establish the electric power supply in accordance with DIN EN

60204-1/4.3.1:
IEC
Cable Copper cable, four-core minimum (L1, L2, L3, PE)
Cable cross-section Designed according to:
VDE 0100, part 430 (IEC 364-4-47)
■ TruBend 5050: at least 6 mm2 (single-core: 10 mm2)
■ TruBend 5085 / 5130 / 5170: at least 10 mm2 (single-core: 16 mm2)
■ TruBend 5230 / 5320: at least 35 mm2
Ground wires Designed according to:
VDE 0100, part 540 (IEC 364-5-54)
Cross-section of the entire Designed according to:
ground wire EN 60204-1, section 8.2.8.
Requirements for the connecting cable Tab. 2-12
NEC
Cable ■ Copper cable, four-core (L1, L2, L3, PE).
■ THHN copper or equivalent is recommended (2000 V test voltage) designed
for a maximum temperature of 90° C (194° F).
■ No aluminum cables may be used to connect the machine.
Cable cross-section ■ The cable cross-section must comply with NEC 670-4 (a). The cable cross-
section must be designed for at least 125 % of the nominal current. The
nominal current is specified on the nameplate.
■ To ensure voltage stability and rating, the line dimension should be larger
than specified in the NEC table 310-16.
Requirements for the connecting cable Tab. 2-13
4.2 Power supply
Residual current device (RCD)
Notes
■ Whether a residual current circuit breaker has to be used
depends upon the local electricity company.
■ On the line side, only residual current circuit breakers of type
B (sensitive to all types of fault current, EN 50178/5.2.11.2;
VDE 0160) are approved.
A residual current circuit breaker provides protection from fault

currents due to directly or indirectly touching live parts.
B579EN Electrics - Version 10 2‐15

Residual current circuit If a residual current circuit breaker is used to provide protection
breaker for direct contact from direct contact, an unregulated isolating transformer must
be used (EN 50178 section 5.2.11.1, VDE 0160). This is
because the fault current resulting from the design is >30 mA.
Residual current circuit If a residual current circuit breaker is to be used to provide pro-
breaker for indirect contact tection from indirect contact, this must be selected depending on
the machine's fault current.
Note
In rare cases, customer-side voltage fluctuations on the
machine's power input filter may lead to higher fault currents
than the typical value specified. The main electricity supply and
the machine must then be separated by an unregulated isolat-
ing transformer.
If a residual current circuit breaker is used, observe the following

requirements:
BendMaster (60) BendMaster (150) BendMaster with handling equip-

ment
Type S Type S Type S
Selective Selective Selective
Sensitive to all types of current + Sensitive to all types of current + Sensitive to all types of current +
resistant to current surges resistant to current surges resistant to current surges
5 kA 5 kA 5 kA
Tripping current of 300 mA Tripping current of 300 mA Tripping current of 300 mA
Values for residual current circuit breaker Tab. 2-14
Line structures
Power supply with grounded outer conductor (corner-

grounded delta network)
When connecting the machine to a power supply with a

grounded outer conductor, an unregulated isolating transformer
must be used.
NEC conditions Power supply configuration:

■ A power supply in star connection and with a grounded star
point (solidly grounded wye) is required.
■ If the existing power supply is in delta connection (corner
grounded delta), the customer must install a grounded
unregulated isolating transformer in star connection (with
grounded star point) (see NEC item 450-5).
2‐16 Electrics - Version 10 B579EN

Grounding:
■ The machine and power distributor system must be equipped
with a grounding line in accordance with NEC article 150,
"Grounding".
■ For details on grounding power distributor systems and
industrial plants, refer to the NEC standards or consult an
electrician or the power station.
IT network
A surge diverter is required if the machine is connected to an IT

network.
TRUMPF recommends surge diverters from the following manu-

facturers:
■ Phoenix Contact GmbH & Co. KG, Flachsmarktstraße 8,
D-32825 Blomberg, E-mail: [email protected].
■ Dehn+Söhne, PO Box No. 1640, D-92306 Neumarkt, E-mail:
[email protected].
4.3 Network link
TRUMPF provides the following interfaces for the network (e.g.

connection to a programming system) in the switch cabinet of
the machine:
■ RJ 45 plugs for customers with shielded-twisted pair network
cabling.
B579EN Electrics - Version 10 2‐17

5. Transport
The arrangements and transport of the system from the truck to

its final installation site need to be prepared and carried out.
Machine conveyance to In some countries the customer can have TRUMPF transport the
customer's site by TRUMPF system from the truck to the final installation site, the so-called
"Machine conveyance to customer's site". The transport route
may not exceed the length contractually agreed to. The transport
route must be flat, with no steps or ramps.
If the customer has assigned TRUMPF with conveying the
machine to the customer's site, the customer must only ensure
that the transport route satisfies the requirements mentioned
below. TRUMPF will deal with all the other points mentioned in
the following, including auxiliary tools and means of transporta-
tion.
5.1 Preparing transport
Before the machine is delivered, check the following:

■ Is there sufficient space for transport to the installation site?
■ Can the floor can be crossed with armored rollers, etc.?
■ Are the gateway openings, header heights and cable rack
heights sufficient?
Transport dimensions
BendMaster (60) BendMaster

(150)
Max. part size 3000 mm (118 in) 3000 mm (118 in)
Max. weight incl. packaging 700 kg (1543 lb) 864 kg (1905 lb)
Floor lane dimensions of each 310 kg (683 lb) 310 kg (683 lb)
2000 mm element (79 in)
Dimensions and weight Tab. 2-15
5.2 Permitted auxiliary tools
If the machine is conveyed to the customer's site by Technical

Service, the required means of transportation and auxiliary trans-
port equipment is provided by them.
2‐18 Transport - Version 10 B579EN

Note
The carrying capacity of the authorized auxiliary equipment must
be selected in such a way that the maximum load can be trans-
ported safely.

Authorized additional equipment Carrying capacity Carrying capacity
Crane truck for unloading the truck At least 1 t (2205 lb) At least 1 t (2205 lb)
Indoor crane for transporting the Recommendation:At least 1 t At least 1 t (2205 lb)
machine (2205 lb)
When transporting with a crane: two According to the machine weight According to the machine weight
type A shackles (DIN 82101)
For transport with a crane: adjusta- According to the machine weight According to the machine weight
ble crane chain
Lifting belt According to the machine weight According to the machine weight
Permitted auxiliary tools Tab. 2-16
Shackle When transporting the machine with a crane: use two type A
shackles (DIN 82101):
Type A shackle Fig. 52814
BendMaster (150): TruBend In combination with the BendMaster (150), the press brake (Tru-
on a platform Bend 5000 series) must be put on a platform.
Notes
■ The TruBend may only be lifted on to the platform using an
indoor crane or mobile crane or a hydraulic hoisting jack. All
other methods are not permissible.
■ If a mobile crane is also not possible for space reasons, then
the customer must organize this activity himself, e.g. by
assigning a local installation company. Information on this
can be requested from TRUMPF Maschinen Austria.
B579EN Transport - Version 10 2‐19

■ The TruBend is normally lifted with hydraulic hoisting jacks
and the pedestal bases installed under the press brake. If
the customer is not able to put the TruBend on a pedestal,
an external installation company can be called in to do this.
Information about this can be requested from TRUMPF
Maschinen Austria.
5.3 Checking, unloading and transporting

the machine
On delivery: check the machine
1. Examine all components for any transport damage.

2. Record visible damage caused during transport on the cargo
note and have the record countersigned by the truck driver.
3. Report any hidden transport damage to the insurance com-
pany and TRUMPF within six days.
Unloading and transporting the machine
Suspended load!
DANGER
Falling loads could lead to severe bodily injury or even
death.
Ø Observe safety regulations for the handling of heavy loads.
Ø Never walk under a suspended load.
Ø Use tested and appropriately sized tackle and means of
transportation.
Ø Employ qualified technicians to transport the machine.
Ø Carry out transport in accordance with the transport regula-
tions.
1. Remove the packaging.

2. Unload the BendMaster with a crane.
3. Remove securing devices for shipping.
4. Transport the accompanying accessories box and any acces-
sory parts that may be separately packaged directly from the
truck to the installation site with a forklift.
5. Transport the BendMaster to the installation site using an
indoor crane with sufficient carrying capacity.
2‐20 Transport - Version 10 B579EN

Chapter 3
Description
1 Machine concept 3‐3
2 Technical data 3‐4

2.1 BendMaster 3‐4
2.2 BendMaster axes 3‐5
3 The most important assemblies 3‐6

3.1 Nameplate 3‐6
3.2 Floor lane 3‐7
3.3 Arm 3‐7
3.4 BendMaster switch cabinet 3‐7
3.5 Sheet sensor 3‐8
3.6 Rotational transformer 3‐9
3.7 Safety fencing 3‐9
3.9 Easy operation 3‐10
3.10 Sensor gauge fingers at the TruBend Series 3‐11
5000
B579EN 2015-06-01 Description 3‐1

4-axis sensor gauge finger 3‐12
6-axis sensor gauge finger (optional) 3‐13
Backstop resistor 3‐14
4 Options 3‐15
4.1 Extendable floor lane 3‐15
4.2 Gripper 3‐15
Vacuum gripper 3‐15
Multi-gripper 3‐17
Multiple-circuit suction cups 3‐17
Gripper construction kit 3‐18
4.3 Special gripper 3‐19
Magnetic gripper 3‐19
Linear gripper 3‐19
Pivoted-jaw gripper and pivoted-jaw grip- 3‐20
per with turning axis
4.4 Sheet removal station 3‐21
4.5 Double sheet recognition and double sheet 3‐22
separation
Double sheet recognition 3‐23
Double sheet separation 3‐24
4.6 Regripping station 3‐24
4.7 Gripper changing console 3‐25
4.8 Backlighting table 3‐25
4.9 Productivity package 3‐26
4.10 Mobile fanning magnet 3‐27
4.11 Handling equipment 3‐27
4.12 Store connection 3‐28
4.13 TruTops°Bend 3‐29
5 Options at the TruBend 3‐30
3‐2 Description 2015-06-01 B579EN

1. Machine concept
Within the TruBend Cell 5000 bending cell, the bending process
at the press brake can be performed fully automatically using the
BendMaster handling system. The BendMaster has the following
features:
■ Four rotational axes and a linear axis as floor lane
■ Sheet sensor for workpiece recognition.
■ Offline programming with TruTops Bend.
■ Very high flexibility due to the option of configuring the load-
ing and unloading positions, the length of the floor lane, grip-
per changes and the regripping unit as desired, as well as
due to a sheet removal station for small parts automation
and conveyor belts for transfer out of the cell.
■ Suitable both for automatic, unmanned operation as well as
for manual operation with BendMaster in home position and
with the safety fencing closed.
■ BendMaster (60) or BendMaster (150) for different load
capacities.
B579EN 2015-06-01 Machine concept 3‐3

2. Technical data
2.1 BendMaster

services Max. load capacity [kg] 60 150
Max. workpiece weight [kg] 40 110
Max. workpiece dimen- [mm] 1000 x 2000 3000 x 1500
sions
Min. workpiece thick- [mm] 0.7 0.7
ness
Max. workpiece thick- [mm] Specified by max. Specified by max.
ness workpiece weight workpiece weight
Max. working range of [mm] 2600 4600
the Z axis (standard
version)
Dimensions (space in Wide standard version [mm] 4725 8160
front of the press
brake)
Depth from TruBend [mm] 5395 5395
bending line
Distance between [mm] 1270 (TruBend 5050 to 1650
BendMaster and Tru- 5130)
Bend
1230 (TruBend 5170 to
5320)
Weight [kg] 620 784
Floor lane [m] 4 6
Extendable up to 14 m Extendable up to 16 m
in steps of 2 m in steps of 2 m
Floor lane weight per [kg] 310 310
2000 mm element
Control station Height [mm] 1020 1020
dimensions (outside
the safety fencing)
Width [mm] 870 870
Depth [mm] 650 650
Speeds Floor lane (Z axis) [mm/s] 2000 2000
A axis [rpm] 20 20
B axis [rpm] 25 25
C axis [rpm] 45 45
Rotary table (D axis) [rpm] 45 45
Positioning accuracy Z direction [mm] ± 0.5 ± 0.5
Coupling center abso- [mm] < 0.1 < 0.1
lute
Connected loads Electrics [V] 3 x 400 at 50 Hz 3 x 460 at 60 Hz
[A] 16 16
Pneumatics [bar] 6 (dynamic pressure) 6 ±1 (dynamic pres-
sure)
24 m³/h temporarily
42 m³/h temporarily
3‐4 Technical data 2015-06-01 B579EN

Control system TRUMPF CNC
Technical data Tab. 3-1
2.2 BendMaster axes
Axes of the BendMaster Fig. 58860
Axis Description Drive

Z axis Floor lane Belt drive via synchronous
motor and omega drive
A axis Rail interpolation for arm Drive via synchronous
movement motor, eccentric gear
B axis Rail interpolation for arm Drive via synchronous
C axis Rail interpolation for arm Drive via synchronous
D axis Rotary table without end Drive via synchronous
position motor, eccentric gear
BendMaster axes Tab. 3-2
B579EN 2015-06-01 Technical data 3‐5

3. The most important assemblies
1 Gripper 4 Sheet sensor 7 BendMaster arm

2 Rotational transformer 5 Z slide 8 BendMaster switch cabinet with
3 Integrated double sheet recogni- 6 TruBend press brake nameplate
tion 9 Floor lane
The most important assemblies Fig. 58810
3.1 Nameplate
The nameplate with the CE marking is located on the rear side

of the switch cabinet and on the inside right of the switch cabi-
net.
3‐6 The most important assemblies 2015-06-01 B579EN

3.2 Floor lane
The floor lane is a linear guide system with belt drive. The Bend-
Master is moved on it in lateral direction.
Modularly extendable The floor lane is the connection to the factory floor. It can be
modularly extended with 2000 mm elements. The maximum
length is 14000 mm (BendMaster (60)) or 16000 mm (BendMas-
ter (150)).
The covering of the floor lane is not designed for standing

NOTICE on or storing parts on it!
Damage to the floor lane.
Ø Do not step on the covering.
Ø Do not deposit any workpieces on the covering.
3.3 Arm
The arm consists of three individual parts, which are connected

to each other with joints. The arm is moved by the rail interpola-
tion of three drives.
Loading/unloading and Turned away from the press brake, the arm is used to load and
bending unload the BendMaster. The arm faces the press brake during
the bending process.
The loading and unloading area may also be positioned next to
the press brake. In this case, the arm also faces the brake press
during loading and unloading.
A BendMaster with conveyor system enables loading and
unloading from all sides.
Additional functions next to Additional functions are possible in addition to the press brake,
the press brake e.g. backlighting table, if the floor lane is of sufficient length.
3.4 BendMaster switch cabinet
Traveling version The BendMaster switch cabinet travels along the machine body
of the BendMaster. It is equipped with the controllers for the
servo-drives, an industrial PC and the control and power elec-
tronics for the sheet sensor.
This industrial PC controls the drive axes and evaluates the data
of the sheet sensor. The industrial PC is connected to the porta-
B579EN 2015-06-01 The most important assemblies 3‐7

ble manual control unit and the press brake in real time and
linked to the control cabinet of the BendMaster.
3.5 Sheet sensor
The BendMaster is operated with a sheet sensor used to identify

the position of the workpieces.
Sensor head The sensor head consists of two CCD cameras (rough and fine
recognition), four diodes that collectively generate a green flash
and a green diode laser for height measurements.
Signal processor The performance data is recorded and evaluated by an industrial

PC in the switch cabinet of the BendMaster.
Sheet sensor functions The sheet sensor performs the following three functions one
after another:
■ Rough recognition of the workpiece stack.
■ Height measurement of the workpiece stack.
■ Fine recognition of the workpiece.
Rough recognition of the The camera takes a picture of the pallet with workpiece stacks.
workpiece stack It may be composed of several individual images. The working
area lighting of the BendMaster is used for this purpose.
CAD data of the workpiece is saved in the computer. This data
is used to create reference models. The respective pattern is
searched for in the recorded image and the position of the work-
piece is determined if the pattern is found.
This position data is used to bring the sensor head into the right
position for height measurement and/or fine position recognition
of the workpiece.
The rough recognition process only has to be performed once
for each loading cycle, since the pallet with the workpiece stacks
can no longer be moved after loading the bending cell.
Measurement of the The precise distance between the workpiece and the gripper
workpiece stack height must be determined. A diode laser projects a laser cross into the
camera vision range for this purpose. The distance is calculated
by means of triangulation.
The height of each workpiece stack is measured once by
default. The BendMaster automatically calculates the height of
the remaining workpiece stack since it knows the sheet thickness
of the workpiece.
The height of the workpiece stack can be measured after every
xth workpiece. Potential errors due to inaccuracies of the sheet
thickness are compensated for in this way.

Fine recognition of the The precise position of the workpiece is determined (±0.2 mm) in
workpiece order to position the gripper properly. To avoid daylight influen-
ces, narrowband flash lighting (green LED flash) is used for the
fine recognition process.
This process can be carried out twice at different points of long
components to avoid angle errors.
The workpiece can be picked up after it has been positioned
precisely. If Backlighting table "load mode" was selected, fine
recognition is carried out on the separately installed backlighting
table without a diode flash.
3.6 Rotational transformer
A continuous rotational transformer is integrated in the D axis,

which allows the D axis to be rotated without an end position.
The rotational transformer transfers compressed air, vacuum, AS-
i bus signals and 24 V DC for the vacuum gripper.
It is driven by an attached servomotor.
3.7 Safety fencing
The safety fencing prevents access of persons in automatic and

manual press mode and also prevents workpieces from falling
out of the machine.
Monitored sliding doors allow controlled access in order to load,
unload and refit the machine.
3.8 Control panel
There is a control panel outside the safety fencing. A portable

manual control unit with 8.4" screen is also there. A stationary
19" screen can be optionally connected.
The control panel can be integrated in a corporate network
which can be used for offline programming.
The control panel is connected to the traveling control unit in the
switch cabinet of the BendMaster and to the control of the press
brake via a local network.

1 Pulse trigger switch 8 Screen
2 Red LED for "indication of error 9 Emergency stop IMPACT BUT-
messages" TON
3 Green LED "Ready for opera- 10 SPEED BUTTON
tion" 11 Traverse buttons
4 Button array 12 Button for DISPLAYED COOR-
5 Menu selection button DINATE SYSTEM
6 START 13 Button for MOVE COORDI-
7 STOP NATE SYSTEM
Portable manual control unit Fig. 39796
Tip
Reset the program at the manual control unit:
■ Press the following keys simultaneously:
<Robot> menu, <Position> menu, <V+>.
The control panel also contains the visualization computer and
the control cabinet of the BendMaster. The main switch is on the
front side.
The visualization computer is connected via the local network to
the industrial PC in the switch cabinet of the BendMaster.
3.9 Easy operation
A stationary 19" screen can be set up on the control panel in

addition to the portable manual control unit with 8.4" screen. A
keyboard and mouse are also provided with the screen.

Fig. 68676
3.10 Sensor gauge fingers at the

TruBend Series 5000
If the BendMaster is used, the standard equipment of the Tru-

Bend Series 5000 includes sensor gauge fingers. The sensors
recognize automatically when the sheet is up against or on
gauge fingers.

4-axis sensor gauge finger
Sensor gauge finger on 4-axis backgauge Fig. 59277
The middle part of the gauge finger protrudes slightly on the

face side and at the bottom support and can be pressed in.
The BendMaster presses the workpiece to be bent against the
sensor gauge finger. The control releases the press beam for
bending only once the workpiece rests properly against the sen-
sor finger.
It cannot be positioned against the top support of the gauge fin-
ger in BendMaster mode.

6-axis sensor gauge finger (optional)
Fig. 41696
The linear movement in X direction and the stopping process in

Z direction are identified by inductive path measurement sensors
and transferred to the control system.
The control system releases the press beam for bending only
once the workpiece rests properly against the sensor finger.
Stop block for small parts The stop block for small parts is screwed on to the existing
(optional) gauge fingers. Small parts on both the sensor fingers can thus
be stopped.

1 Bending line A Part too small for gauge finger B Gauge finger with installed stop
2 Installed stop block block
Fig. 54688
Backstop resistor
Magnets that can be cut in are located on the sensor gauge fin-
gers which may form an additional backstop resistor:
■ Backstop resistor is cut in:
Thick workpieces must overcome the spring force of the sen-
sor gauge and the magnetic force of the backstop resistor
when stopping. This ensures that the workpiece weight does
not trigger a backstop travel motion prematurely.
■ Backstop resistor is not switched:
Thin sheets need only overcome the spring force of the
gauge sensor when stopping.

4. Options
4.1 Extendable floor lane
The floor lane can be modularly extended up to 14,000 mm

(BendMaster (60)) or 16,000 mm (BendMaster (150)) using
2000 mm elements. They allow the BendMaster to be adapted
individually to any production site.
4.2 Gripper
The "Robot in tool change position" travel function can be used

to move the BendMaster to the manual tool change position in
order that the gripper can be changed manually (see "Gripper
service", pg. 4‐27).
If a gripper changing console is present, then a change of grip-
per can be carried out automatically (see "Automatic gripper
change (option)", pg. 4‐28).
Vacuum gripper
Vacuum grippers are operated with vacuum. They are suitable

for all materials in sheet machining and for smooth sheet surfa-
ces. No holes are permitted in the workpiece within the suction
cup area.
Setup Vacuum grippers consist of up to five parts:

■ Gripper changing plate.
■ Base plate.
■ Suction cups.
■ AS-i module for separating.
■ Pneumatic cylinders for the separation process.
The coupling is used to connect the vacuum gripper (and any
other grippers) to the gripper changer of the BendMaster.
B579EN 2015-06-01 Options 3‐15

1 Suction cup 3 Gripper quick-change adapter
2 Base plate
Fig. 41774
1 Pneumatic cylinder for sheet 2 AS-i module

separation
Fig. 41775
3‐16 Options 2015-06-01 B579EN

Multi-gripper
The multi-gripper is a multifunctional gripper tool which can be

used to pick up sheets of various sizes, depending on the
weight:
Multi-gripper Fig. 43875
■ Minimum size: from 900 x 200 mm to 700 x 700 mm.

■ Maximum size: from 1350 x 200 mm to 1000 x 1000 mm.
Not only can each of the four inner and outer suction cups be
adjusted on the multigripper, the arms with the suction cups can
also be moved to the left and right.
Their individual activation allows individual vacuum circuits to be
switched on or off separately (see multi-gripper operator's man-
ual).
Multiple-circuit suction cups
Multiple-circuit suction cups are multifunctional gripper tools of

which the shape can be adapted to the customer's part.
B579EN 2015-06-01 Options 3‐17

Fig. 51329
They are suitable in particular for components which become

increasingly smaller, since the individual suction cup circuits can
be switched on or off separately due to the individual suction cup
activation.
Gripper construction kit
The gripper construction kit is a modular system which consists

of various gripper components, such as coupling, valves and
suction cups.
Fig. 43874
3‐18 Options 2015-06-01 B579EN

The construction kit contains components for three grippers;
optionally with separation.
4.3 Special gripper
Magnetic gripper
The magnet gripper has two pneumatically adjustable magnets.

This means that magnetic workpieces which have e.g. many
recesses or which are made of perforated sheets can still be reli-
ably gripped.
Fig. 58424
Linear gripper
The linear gripper is a vacuum gripper used preferably for profile

parts. Excess regripping is prevented by the eccentricity of the
suction bar.
The gripper consists of a travel path, onto which a pneumatically
displaceable suction cup slat is placed. The suction cups can be
manually displaced on the travel path.
B579EN 2015-06-01 Options 3‐19

Linear gripper at the BendMaster Fig. 61839
The suction bar can approach two positions: left end position
and right end position. Both positions are monitored by proximity
switches.
Traverse path between the end positions: 316 mm
Note
For operation, see the supplement to the BendMaster operator's
manual "Linear Gripper Option".
Pivoted-jaw gripper and pivoted-jaw gripper

with turning axis
In case of small sheets, the pivoted-jaw gripper is used together

with a sheet removal station.
Pivoted-jaw gripper Fig. 49441
3‐20 Options 2015-06-01 B579EN

Note
The software version TruTops Bend 5.0 or higher is required for
programming the pivoted-jaw gripper.
Maximum weight 1.5 kg

Maximum size 210 x 297 mm (A4 format)
Sheet thickness 0.75 - 6 mm
Technical data of the workpiece Tab. 3-3
The pivoted-jaw gripper is placed on a linear slide which can

approach two positions from the middle of the coupling: either
160 mm to the left or 160 mm to the right.
The eccentricity of the pivoted-jaw gripper that is thus achieved
prevents frequent re-gripping which would be required due to the
collision contour of the BendMaster.
Many different parts geometries can be machined with different
gripper jaws.
A pneumatically driven turning axis (option) can rotate the grip-
per through 180°. The number of regripping operations can thus
be further reduced.
4.4 Sheet removal station
Small parts are separated from the sheet stack and transferred
to the pivoted-jaw gripper at the sheet removal station.
There are two sheet removal station variants:

■ Sheet removal station without a linear axis, where the sheets
can be separated and removed from a pallet.
■ Sheet removal station with a linear axis, where the blanks
can be separated and removed from two pallets.
■ Sheet removal station with rotary pallet with which sheets
can be separated and removed from four pallets.
B579EN 2015-06-01 Options 3‐21

1 Sheet removal station without 2 Sheet removal station with 3 Sheet removal station with rotat-
linear axis linear axis ing plate
Sheet removal station Fig. 54689
Maximum sheet weight 1.5 kg

Maximum sheet size 210 x 297 mm (A4 format)
Maximum sheet thickness 0.75 - 6 mm
Tab. 3-4
The suction cups of the sheet removal station pick up the sheet.
At the same time, double sheet recognition and if required, dou-
ble sheet separation can be carried out.
The sheet removal station prepares the next sheet during Bend-
Master operation.
Note
For operation, see Supplement to the BendMaster Operator's
Manual, "Option for small parts (pivoted-jaw gripper)".
4.5 Double sheet recognition and double

sheet separation
Slightly oiled sheets stick together easily. For this reason or

other reasons, the BendMaster may pick up two or more work-
pieces at the same time. Two systems are available to prevent
this:
■ Double sheet recognition
■ Double sheet separation
3‐22 Options 2015-06-01 B579EN

Double sheet recognition
Integrated double sheet The double sheet recognition process is performed by means of
recognition three sensors in the C arm of the BendMaster.
When a part is picked up, its weight is measured and compared
with the reference value from TruTops Bend.
Each time a workpiece is picked up by the BendMaster, its
weight is measured and compared to the reference value so that
it does not go unnoticed if a double-sheet is picked up.
The minimum permissible weight of a sheet is 400 g.
With pallet scale Note

Double sheet recognition with a pallet scale is carried out on
BendMaster systems which do not have the integrated double
sheet recognition option.
Pallet scales for double sheet recognition Fig. 38423
Double sheet recognition is carried out using pallet scales. When

a part is picked up, its weight is measured and compared with
the reference value from TruTops Bend.
You can tell whether one or more workpieces have been picked
up by the BendMaster each time a workpiece is picked up by
the reduction in weight on the pallet scales.
The measurement range of the pallet scales is 0 to 1500 kg.
The maximum load must not exceed 3000 kg (e.g. when using a
stacker for loading). The minimum permitted weight of a blank is
200 g.
B579EN 2015-06-01 Options 3‐23

Double sheet separation
If several workpieces are picked up by the BendMaster, they can

be separated mechanically by the double sheet separation sys-
tem.
Gripper The gripper is used to bend the workpieces. The workpieces

bend easily, however the degree of bending is always within the
elastic range. This bending process exerts a force on the two
workpieces, resulting in a peeling effect.
Travel movement The BendMaster performs a travel movement. The workpieces

bend easily, however the degree of bending must always lie
within the elastic range. This bending process exerts a force on
the two workpieces resulting in a peeling movement.
4.6 Regripping station
The regripping station is used if it is not possible to re-grip the

workpiece by clamping it between the upper and lower tool.
The regripping station is programmed in the TruTops Bend pro-
gramming system. The designation of the gripper is Z3 for the
left gripper side and Z4 for the right gripper side.
The gripper arm positions to be set are displayed in the tooling
plan along with the angle and length of the suction cup exten-
sion.
1 Angle setting 2 Length setting

Regripping station Fig. 41347
3‐24 Options 2015-06-01 B579EN

4.7 Gripper changing console
An automatic gripper change is possible with a gripper changing

console. Two grippers (three with BendMaster (150) per gripper
changing console can be deposited inside. Modular extension of
up to four gripper changing consoles is possible.
1 Upper gripper deposit station 2 Lower gripper deposit station

with gripper
Gripper changing console Fig. 53017
4.8 Backlighting table
A backlighting table must be used for the fine recognition of

workpieces with critical surfaces (e.g. galvanized, glossy).
B579EN 2015-06-01 Options 3‐25

Backlighting table Fig. 38422
The workpiece is picked up and set down on the backlighting

table on the basis of the data acquired by the BendMaster from
the rough recognition process and the measurement of the work-
piece stack height.
The fine recognition process is performed on the backlighting
table. The backlighting for image recording makes it easier to
identify the contours of the workpiece.
4.9 Productivity package
The productivity package can, depending on the gripper and the

part geometry, be used to increase productivity from 15 to 25 %.
The productivity increase is achieved via synchronized travel

motions and optimized continuous path control of the robot:
■ Axes control optimization:
− Torque pre-control: exact pre-calculation of the necessary
drive torque and drive force.
− Torque limiting: makes it possible to follow robot paths
quickly and precisely, since the maximum possible torque
and drive torque is calculated while the process is being
carried out and thus can be optimized.
■ Gripper movements can be run in parallel.
■ Optimization of regripping operations during bending.
■ Optimized traverse paths of the backgauge:
− X axis withdrawal takes place at the same time as bend-
ing operation.
− The backgauges are equipped with magnets.
■ Faster data exchange between press brake and BendMaster.
3‐26 Options 2015-06-01 B579EN

System requirements:
■ TruTops Bend V2.9 or higher.
■ TASC6000 V8.2 or higher.
■ TruBend Cell 5000 V07.00.07 or higher.
4.10 Mobile fanning magnet
The mobile fanning magnet can be used to separate oiled, ferro-

magnetic sheets that have become stuck together.
The fanning magnet is positioned at the sheet metal stack.
There it creates several magnetic poles which repel each other.
This effect causes to the separation of the sheets that have
become stuck together.
1 Sheet metal stack to be sepa- 3 Transport equipment

rated
2 Setting wheel for extending and
retracting the fanning magnet
Fig. 67036
Note
For operation, see the "Fanning magnet" operator's manual.
4.11 Handling equipment
The material feed and part removal processes can be automated

by means of a conveyor system.
B579EN 2015-06-01 Options 3‐27

Pallet conveyors with rollers transport pallets or boxes; conveyor
belts transport finished single parts, that are hard to stack for
example.
1 Handling equipment control 3 Press brake 5 Pallet conveyor

panel with portable manual con- 4 Conveyor belt
trol unit for BendMaster
2 BendMaster
Handling equipment for the BendMaster Fig. 61948
Note
For operation, see Operator's manual for transport equipment
4.12 Store connection
The TruBend Cell 5000 can be linked to a storage system. The

interface with the storage system is established by means of a
storage cart. The parts are booked using the TruTops Fab soft-
ware, Storage module.
The BendMaster can not only request raw material from the stor-
age system, it can also return finished parts to the storage sys-
tem.
3‐28 Options 2015-06-01 B579EN

TruBend Cell 5130 with connection to storage Fig. 59979
Note
For operation, see "Supplement to the BendMaster Operator's
Manual, Connection to storage (option)".
4.13 TruTops°Bend
TruTops Bend is the programming system for the bending tech-

nology. There is an additional module for TruToPs Bend, which
can be used to program the BendMaster. This allows two NC
programs (TruBend and BendMaster) to be created with a single
program.
Operation See "TruTops Bend Software Manual".
B579EN 2015-06-01 Options 3‐29

5. Options at the TruBend
The following TruBend options must be available if work on the

TruBend is to be automated with a BendMaster:
■ CNC-crowning.
■ Hydraulic tool clamping.
■ BendMaster interface.
■ Sensor gauge finger.
TRUMPF BendGuard No optoelectronic protective devices are required for manual

press brake bending if the BendMaster is used on the TruBend.
It is sufficient to use operating station 1 in two-hand operating
mode.
The BendMaster must be in home position when operating the
bending cell manually. All doors must be closed. The operator is
locked in within the safety fencing.
Unavailable options in Some of the options of the TruBend must not be available when
combination with using the BendMaster. These are:
BendMaster ■ Bending aid.
■ Additional backgauge finger.
■ Upholding device.
■ Light curtain.
■ Second operating station.
The following modules must be removed from the TruBend

before using the BendMaster:
■ BendGuard.
■ Support brackets.
3‐30 Options at the TruBend 2015-06-01 B579EN

Chapter 4
Operation
1 Description of the operating elements 4‐6

1.1 Portable manual control unit 4‐6
Operating elements 4‐6
Menus and submenus 4‐7
1.3 Stationary 19" screen 4‐10
2 Operating the BendMaster 4‐11

2.1 Safety information 4‐11
2.2 Status display 4‐11
2.3 Software versions view 4‐13
2.4 User settings 4‐13
Changing settings 4‐13
Creating BIO (BendMaster Information 4‐15
Object)
Creating and modifying users 4‐15
2.5 Operating modes 4‐16
Selecting operating modes 4‐17
B579EN 2015-06-01 Operation 4‐1

Enabling conditions for operation modes 4‐17
2.6 Moving axes of the BendMaster manually 4‐22
2.7 Displaying axis positions 4‐26
2.8 Gripper service 4‐27
2.9 Automatic gripper change (option) 4‐28
Picking up a gripper 4‐28
Lay down gripper 4‐31
2.10 Regripping station (option) 4‐32
Moving the axes of the regripping station 4‐32
manually
Setting up the regripping station 4‐33
Removing the regripping station 4‐35
2.11 Setting the backstop resistor regardless of 4‐36
the program
3 Switching on and referencing the Bend- 4‐38

Master
3.1 Switching on the BendMaster 4‐38
3.2 Referencing the BendMaster 4‐39
Referencing the Z, A, B, C, Z1, Z2 axes 4‐40
Referencing the D axis 4‐41
3.3 Referencing TruBend 4‐42
4 Switching off the BendMaster 4‐46

4.1 Stopping BendMaster and TruBend in any 4‐46
emergency or after a malfunction
4.2 BendMaster, switching off 4‐46
5 Travel functions 4‐48

5.1 Executing travel functions 4‐48
6 Running in a TruTops program 4‐50

6.1 From BendMaster control V7.0 and higher: 4‐50
Settings in TruTops Bend
6.2 Procedure for productivity package option 4‐50
Checking the productivity package 4‐50
Calculating suction cup capacities 4‐51
Determining the reduction of the robot 4‐52
speed
6.3 Overview, loading a program 4‐52
6.4 Creating a new BendMaster job from the Tru- 4‐53
Tops Bend program
6.5 Archiving, restoring or deleting jobs 4‐55
4‐2 Operation 2015-06-01 B579EN

Filing away a job 4‐56
Restoring an order 4‐56
Deleting a job 4‐57
Changing the backup directory path on 4‐58
the user interface
6.6 Defining job details 4‐59
Defining exposure details 4‐59
Editing the gripper weight 4‐61
6.7 Loading and unloading areas 4‐62
Load job 4‐64
Adjusting an area 4‐64
Copying an area 4‐67
Deleting an area 4‐68
Defining area details 4‐69
6.8 Performing the rough recognition process 4‐72
(Search within area)
Searching for an area 4‐72
Searching for further loading stacks 4‐76
Intermediate layer, searching for 4‐77
Procedure in the event of problems with 4‐77
6.9 Defining stacks 4‐78
6.10 Processing stacks 4‐80
6.11 Creating a tooling plan 4‐84
Checking the TruTops tooling plan 4‐84
Selecting a separation method 4‐85
Selecting double sheet recognition 4‐87
6.12 Setting bending parameters 4‐88
Opening bending parameters 4‐89
Selecting bending support 4‐90
Setting the backgauge sensor system 4‐90
Setting the approach strategy 4‐91
Setting the backstop resistor for single 4‐92
bending operations
6.13 Program, loading 4‐92
Opening the running in program 4‐92
Program steps for running in 4‐93
Selecting an execution method 4‐94
Running in procedure 4‐94
Teaching a point 4‐96
B579EN 2015-06-01 Operation 4‐3

Points, editing 4‐96
Setting the main run indicator manually 4‐98
Deleting a point 4‐99
Displaying axis positions 4‐100
6.14 Starting a run-in program 4‐100
6.15 Production planning 4‐102
Creating or modifying a production plan 4‐102
Setting the speed and required number 4‐103
Executing the production plan 4‐104
6.16 Connection to storage (option) 4‐105
Defining parts data 4‐105
Defining loading and unloading areas of 4‐105
Moving a storage cart manually 4‐106
Moving the BendMaster semi-automati- 4‐106
cally
Moving a storage cart in automatic mode 4‐108
7 Working at the press brake without Bend- 4‐110

Master
7.1 Working at the press brake without Bend- 4‐110
Master
8 Errors and Messages 4‐111

8.1 Displaying and acknowledging errors and 4‐111
messages
8.2 Troubleshoot an error 4‐111
9 Error handling 4‐113

9.1 Jumpering the sensor finger 4‐113
9.2 Image processing diagnostics 4‐113
Opening the diagnostics tool 4‐119
Recording with Vision Diagnostics 4‐121
Saving the image recorded last 4‐124
Restarting the program 4‐125
9.3 Teleservice 4‐125
10 Solving problems and troubleshooting 4‐126

10.1 Problem: no part recognized 4‐126
Solution: no part identified 4‐127
10.2 Problem: Part underneath detected 4‐128
Solution: part underneath detected 4‐129
4‐4 Operation 2015-06-01 B579EN

10.3 Problem: part interference contour recognized 4‐130
Solution: interference contour recognized 4‐131
B579EN 2015-06-01 Operation 4‐5

1. Description of the operating elements
1.1 Portable manual control unit
The portable manual control unit is used to control the BendMas-

ter.
In manual mode, the operator can operate the BendMaster at
reduced speed from within the safety fencing with the enable key
actuated (in neutral position).
Operating elements
■ Button array for various functions.

■ PULSE TRIGGER SWITCH.
■ EMERGENCY STOP impact button.
1 Pulse trigger switch 8 Screen

2 Red LED for "indication of error 9 Emergency stop IMPACT BUT-
messages" TON
3 Green LED "Ready for opera- 10 SPEED BUTTON
tion" 11 Traverse buttons
4 Button array 12 Button for DISPLAYED COOR-
5 Menu selection button DINATE SYSTEM
6 START 13 Button for MOVE COORDI-
7 STOP NATE SYSTEM
Portable manual control unit Fig. 39796
4‐6 Description of the operating elements 2015-06-01 B579EN

Menus and submenus
Which menus are available depends on the enabled user levels.

Menus which are not enabled are displayed in gray.
Operating element Submenus / description

Diagnostics menu:
■ Existing messages: Information, warnings and messages are displayed and can
be acknowledged.
■ Info: main screen.
■ Version: Display installed software versions, user logon, language options, write
BIO.
■ BV diagnostics: Display image recorded last, restart image processing software,
save recorded image.
Setup menu:
■ Job: Create new job from TruTops program or select existing job for execution.
Furthermore, select lot size and fine recognition (up to Software V5) as well as
archive and delete jobs.
■ Job details: (from software V6 and higher): Define fine recognition, height meas-
urement and error strategies.
■ Areas: Adapt (add or move) loading and unloading areas defined in TruTops, exe-
cute rough recognition process, display the area position using the image recog-
nition laser.
■ Stack layout: Process stack assignment (activate, disable, delete loading or
unloading stack).
■ Tool setup plan: Display bending machine, regripping station and gripper setup
plans specified by TruTops Bend. The system must be appropriately loaded.
■ Separation method: Select double sheet recognition and the separation method.
■ Bending parameters: (from software version 5.0 and higher): Setting of parame-
ters for the bending support, for the backgauge sensor system, for approaching
backgauges and for actuating the backgauge resistance for each bending step.
■ Loading: Start loading program, teach or process points, set main run indicator.
Position menu:
■ Position: Reference or master BendMaster. Display the axis positions in the
desired coordinate system:
Reference or master the regripping station (generation 2 from software version
4.0 and higher). Control the regripping station manually.
■ Automatic: Interrupt program execution. Then restart program or stop it com-
pletely. Start travel function; for example, home position.
■ Production package: (from software version 4.0 and higher): Execute several jobs
in one production cycle.
Service menu:
■ Calibrate: Start calibration for camera and height measurement.
■ More: Open, load and deselect projects manually. Process versions manually.
■ Service functions: Execute sequence routines manually.
■ Configuration: Modify configuration of connection to visual PC.
■ CAN Service: Read out and modify parameters of LENZE drives.
■ ASI Service: Read out the existing slaves at the respective AS-i circuit. Read-
dress slaves.
■ User configuration: Edit existing users, e.g. language for logon. Create new
users.
B579EN 2015-06-01 Description of the operating elements 4‐7

Operating element Submenus / description
Press menu:
■ Press servicing: Start bending machine (hydraulics, CNC, tool clamping).
■ Regripping station (generation 1): Reference or master the regripping station.
Control the regripping station manually.
■ Sensors for press: Display position of sensor gauge finger. Teach the sensor
gauge finger. Starting with Software version 5.0: Activation, setup as well as dis-
play of the backstop resistor.
Robot menu:
■ Gripper servicing: Clamp or loosen gripper, manual suction or blasting of sheet,
manual separation at gripper.
■ Gripper deposit position: Pick up or deposit the gripper at the gripper deposit sta-
tion. Teach the gripper deposit.
■ Sheet sensor: Record images with coarse and fine camera.
■ Variables: Only for personnel of TRUMPF's Service Department: view or edit var-
iables.
User key 1:
Key for acknowledging all errors, warnings and information (for TRUMPF Service
only).
User key 2 (for TRUMPF Service only):

Input key during start-up for the calibration of the sensor gauge fingers, the fine
position camera and for mastering the regripping station.
User key 3:
■ Press 1x: Display of the speed in mm/s.
■ Press twice: the acceleration is indicated in mm/s2
■ Press 3 x: the jerk is indicated in mm/s3 (the smaller it is, the smoother the
acceleration is)
MOVE COORDINATE SYSTEM button:
This button is used to select the coordinate system in which the axes of the Bend-
Master are moved.
■ For regripping station Generation 1: 5 coordinate systems are available.
Displayed coordinate system button:
This button is used to select the coordinate system to be displayed on the screen of
the portable manual control unit or on the stationary 19" screen (option).
Description of the menus with submenus Tab. 4-1
Enable key The ENABLE KEY on the rear side of the portable manual con-
trol unit can be set to three positions in order to switch the
BendMaster operational readiness in manual mode:
■ Not pressed: BendMaster not ready for operation.
■ Pressed halfway: BendMaster ready for operation.
■ Fully pressed: BendMaster not ready for operation.

1.2 Control panel
The portable manual control unit is connected to the control

panel. The mounting device for the portable manual control unit
is mounted on the control panel. If a stationary 18" screen is
used, it is also mounted on the control panel.
Operating elements
1 Operation mode selection key 4 RED button3

switch
5 EMERGENCY STOP impact
2 GREEN button2 button
3 Bending cell lighting 6 BendMaster main switch
Control panel with 19" screen, mouse, and keyboard Fig. 41798
On the control panel:

■ Main switch
On the support of the portable manual control unit:

■ Operating mode key switch.
■ EMERGENCY STOP impact button.
■ GREEN button: description of (see "Enabling conditions for
operation modes", pg. 4‐17).
2 Activate safety fencing catch or switch BendMaster to operational readi-

ness.
3 Deactivate operational readiness or deactivate registration for access or
deactivate catch.
B579EN 2015-06-01 Description of the operating elements 4‐9

■ RED button: description of (see "Enabling conditions for oper-
ation modes", pg. 4‐17).
■ WHITE button: illumination of bending cell
1.3 Stationary 19" screen
The same user interface is used on the stationary 19" screen

(option) as for the portable manual control unit.
A keyboard and mouse are available for operation.
Only the user interface with write permission set may be the
active interface.

2. Operating the BendMaster
2.1 Safety information
Workpiece is suspended from the suction cup of the

WARNING BendMaster!
The workpiece can fall down if the power supply is discon-
nected or if the vacuum is reduced.
Ø Only turn off the MAIN SWITCH and the compressed air
supply if no workpiece is suspended from the vacuum grip-
per of the BendMaster.

HMI. If a sheet is gripped, the operator must exit the automation
cell immediately and close the safety doors, because the blank
could be released from the gripper.
Workpiece is suspended from the suction cup of the

WARNING BendMaster!
The workpiece may fall down if the vacuum is reduced.
Ø If the warning signal is emitted, exit the bending cell immedi-
ately and close the safety doors.
2.2 Status display
The different statuses of the control are indicated by symbols at

the top left of the HMI user interface.
Icons Status
■ Green padlock, open: write permission granted.
■ Red padlock, closed: no write permission.
Hand: manual operating mode is active.
Arrow: automatic operating mode is active.
Circle: zero position operating mode is active.
TruBend manual operating mode (without BendMas-

ter).
BendMaster/regripping station ready for operation

(green).
B579EN 2015-06-01 Operating the BendMaster 4‐11

Icons Status
BendMaster/regripping station not ready for operation
(red).
No connection (TruBend communication).
TruBend not ready for operation (red).
TruBend CNC stop (blue).
TruBend CNC start (green).
Green: pallet scales connected to control system.
Red: pallet scales not connected to control system.
Gray: pallet scales switched off or not configured.
Green with cross: pallet scales with error, e.g. COM

port used.
Green with check mark: pallet scales connected to

control system and used in the current project.
■ Green triangle: job is currently being executed.

■ Red square: job execution has been stopped.
■ Yellow double line: execution of program is inter-
rupted.
Name of loaded job.
Single job SO (Single Order mode): Default process-

ing mode. Is activated as soon as a job is selected in
the job page or carried out in the >Setup menu.
Production plan mode: Execution mode if a job pack-
age or production list is started in the >Production
plan menu
Tab. 4-2
Indicator light on safety ■ Red: an error is present. Read out, eliminate and acknowl-
fencingLamp edge the error in the menu >Diagnostics >Existing mes-
sages. The indicator light then turns orange.
■ Orange: BendMaster is ready. It can be operated in the
desired operating mode after meeting the respective enabling
conditions.
4‐12 Operating the BendMaster 2015-06-01 B579EN

■ Green: job is processed.
■ White: No function.
2.3 Software versions view
1. Menu: >Diagnostics > >Version

The control software and visualization software are both div-
ided into system software and application software.
Fig. 39914
2. Double-click on the desired software area. The software ver-
sions are displayed.
2.4 User settings
Changing settings
Disabling the touchscreen in 1. Press >Diagnostics > >Version menu.

order to clean it

Fig. 59594
2. Press >Lock. The touchscreen is deactivated for 20 seconds.

The screen can be cleaned within this period without trigger-
ing any functions.
Registering other users Note

Various functions of the BendMaster can be used, depending
on the user rights.
3. Press User. The logon window appears. The user can log
on.
Changing the language 4. Press Language. The language can be changed on the
"Choose Languages" mask.
Restarting the portable 5. Press Restart. Works only for a user with the corresponding
manual control unit authorization (see "Creating and modifying users", pg. 4‐15).
Setting write permission 6. Press Release write permission. The write permissions for
the operating unit used are deactivated.
The operating units which can be used are the portable man-
ual control unit and the optional monitor on the visualization
computer.
The BendMaster can only be operated from one user inter-
face, notably the one with write permission (you can tell by
the green icon).
Write permission can be requested in order to change the
user interface. Write permission can be forced if it has not
been enabled.

Creating BIO (BendMaster Information
Object)
After system crashes, collisions and fatal errors, a BIO file

should be created, which can be used by the Development
department to draw conclusions regarding the cause of an error.
Not only the control data is saved to a BIO file, but all machine-
relevant data for the purpose of fault analysis.
Ø Press Write BIO.

The BIO file is saved to the visual PC in the released direc-
tory: 'C:\xChange\BIO' as a ZIP file. The file name consists
of the date and time of creation. BIO files no longer required
should be deleted.
Creating and modifying users
Creating a new user 1. In the menu, select >Service > >User configuration. The fol-
lowing mask appears.
Fig. 51840
2. Press New. The "User configuration" mask appears.
3. Define the settings:
− "User": enter the name of the new user.
− "Default user" (only for the operator user group): The
user is automatically logged on after a delay time of 10 s
if the check mark is set.
− "Password": enter twice to avoid input errors.

− "Language": select the language for the user interface.
− "User group": defines the user rights. The following user
levels are possible (in ascending order according to prior-
ity): operator, programmer, administrator, service, devel-
oper.
Note
A logged on user can create new users up to his own user
level. Users with the operator user level cannot create new
users.
4. Press OK
Edit user 5. Mark the user to be edited.
6. No. The "User configuration" mask appears.
7. Make the changes.
Delete user 8. Mark the user to be edited.
9. Press Delete. The "User configuration" mask appears.
10. Confirm the query.
2.5 Operating modes
The BendMaster has four different operating modes:
■ Automatic mode:
In automatic mode the BendMaster is controlled automatically
by programs.
■ Manual mode:
In manual mode, the BendMaster is moved manually at
reduced speed. The enable key on the portable manual con-
trol unit must be pressed in neutral position.
■ TruBend manual:
The TruBend can be moved manually, i.e. without the Bend-
Master, in TruBend manual operating mode. The BendMaster
must first be moved into the home position.
■ Zero position:
TruBend and BendMaster are not active in the zero position.

Selecting operating modes
1 Zero position 4 Manual operation

2 TruBend manual 5 Automatic mode
3 Key switchOPERATION
MODE SELECTION
Fig. 46231
Ø Set the OPERATING MODE key switch for operating mode

selection to the desired operating mode.
Enabling conditions for operation modes
Enabling conditions for All EMERGENCY STOPs released:

manual mode ■ At TruBend (control system and control panel).
■ On all posts of the safety fencing.
TruBend:
■ CONTROL key switch is set to ON.
■ Press beam not in sloping position.
■ Rear protective cover is closed.
BendMaster:
■ Manual operating mode is active.
■ The ENABLE KEY of the portable manual control unit is
pressed in the neutral position.
Tip
To deactivate an activated catch, press the RED button on the
mounting device for the portable manual control unit.

Note
(for optional store connection)
The BendMaster will stop at once if it is not in parking position
when the lift gate is opened.

automatic mode ■ At TruBend (control system and control panel).
■ On all posts of the safety fencing.
At the TruBend:
BendMaster:
■ Automatic operating mode is set.
■ All doors of the safety fencing are closed.
■ All lift gates are closed.
■ The GREEN button on the mounting device of the portable
manual control unit has been pressed once (BendMaster is
ready for operation).
Notes
■ Lift gates can be opened only when the safety doors are
released.
■ If the RED button flashes rapidly, this means that not all
doors of the safety fencing are closed.
■ With store connection option: The BendMaster stops
immediately if it is not in the parking position when the lift
gate is opened.
■ With handling equipment option: No impermissible inter-
ruption of the palletizer's protected field.
Tip
Press the GREEN button twice if the BendMaster is in the park-
ing position.

Function button on the But- Operating How often should it be Consequences
portable manual control unit tons mode pressed?
GRE Automatic 1. Press once. ■ The catch is acti-
EN vated if it was pre-
viously deactivated.
■ The RED button
goes out.
2. Press it a second ■ The BendMaster is
time. switched to ready
for operation.
■ The GREEN button
lights up.
RED Automatic, 1. Press once. ■ Operational readi-
BendMaster in ness of the Bend-
home posi- Master is deacti-
tion vated.
goes out.
2. Press it a second ■ The catch is deacti-
time. vated.
■ The RED button
lights up.
Automatic, 1. Press once. ■ Deactivation of the
during the catch is reported.
execution of ■ The RED button
a job flashes slowly. The
current workpiece
is finished.
2. Press the START ■ BendMaster is
button on the portable moved into home
manual control unit position.
once. ■ Operational readi-
ness of the Bend-
Master is deacti-
vated.
goes out.
■ The catch is deacti-
vated.
■ The RED button
lights up.
3. Press the GREEN ■ The catch is reacti-
button once. vated.
■ The RED button
goes out.
4. Press the GREEN ■ The BendMaster is
button a second time. switched to ready
for operation.
lights up.
5. Press the START Execution of the job is
button on the portable resumed.
manual control unit
once.

Function button on the But- Operating How often should it be Consequences
portable manual control unit tons mode pressed?
Manual mode 1. Press once. ■ The active catch is
or TruBend deactivated.
manual ■ The RED button
lights up.
What happens if… Tab. 4-3
Note
If a person is still in the bending cell after starting the automatic
program:
■ Press the RED button on post 1 twice.

− Press once: the system stops.
− Press a second time: The catch is deactivated for 30 s.
− Exit the bending cell.
− To reset the deactivation of the 30-second catch:
Press the GREEN button in the mounting device of the
portable manual control unit for at least 3 seconds.
or
− Press any EMERGENCY STOP button and press the
RED button on post 1 twice to deactivate the catch for
30 seconds.
1 GREEN button (post 1) 2 RED button (post 1)

Post 1 Fig. 41776

manual press (TruBend ■ At TruBend (control system and control panel).
without BendMaster)

■ On all posts at the safety fencing.
At the TruBend:
■ For further conditions, refer to the TruBend operator's man-
ual.
BendMaster:
■ The BendMaster is in home position.
■ TrumaBend manual operating mode.
■ The operator is within the bending cell.
■ All doors of the safety fencing are closed.
■ All lift gates are closed.
■ In case of the conveyor technology option: No impermissible
interruption of the palletizing protected field.
■ GREEN button on post 1 has been pressed. The catch is
activated. The green key lights up.
Notes
■ Lift gates can be opened only when the safety doors are
released.
■ Deactivate the catch to exit the bending cell.
Deactivate the catch:

■ Press the RED button in post 1. The system stops and the
catch is deactivated. The bending cell can be exited.
or
■ Press the RED button on the mounting device of the portable
manual control unit.
or
■ Press any EMERGENCY STOP button (with the exception of
the two Emergency Stop buttons on the TruBend control and
control panel and the fully pressed foot switch at the control
panel. In this case the system stops, however the catch
remains active).

2.6 Moving axes of the BendMaster
manually
Automatic mode In automatic mode, all axes of the BendMaster can be moved at
reduced speed in the selected traverse coordinate system using
the traverse buttons if no program is currently being executed.
■ To move the axes of the BendMaster while executing a pro-

gram, interrupt the program with the red STOP key on the
portable manual control unit.
Note
When the program is restarted, make sure that the BendMaster
continues at precisely the position at which the program was
interrupted.
Manual mode In manual mode, all axes of the BendMaster can be moved at
reduced speed within the selected move coordinate system using
the traverse buttons.
The BendMaster can only be moved if the ENABLE KEY on the
portable manual control unit is pressed in neutral position, since
the operator may be within the safety fencing.
HMI. The BendMaster stops and can no longer be moved in
manual mode.
Unexpected drop in pressure at the BendMaster gripper

WARNING while a workpiece is clamped!
Ø If an acoustic warning signal is emitted, exit the automation
cell immediately and close the safety doors.
Ø Before entering the safety cabin: move the BendMaster
manually and deposit the clamped workpiece safely.
Conditions
■ Manual or automatic operating mode is active.
■ No error messages, i.e. green LED on the portable manual
control unit lights up (acknowledge error if red LED is on).
■ Manual mode: The BendMaster is ready for operation (pulse
trigger switch on the portable manual control unit has been
pressed, "BendMaster" icon is green).:

or
■ Automatic mode: BendMaster is ready for operation (the
GREEN button was pressed, and the "BendMaster“ icon is
green).
Translating axes
1 Axis or coordinate move 4 Traverse buttons

coordinate system 5 Button for DISPLAYED
2 MOVE COORDINATE SYS- COORDINATE SYSTEM
TEM button
3 Speed button
Fig. 33201
1. Press the MOVE COORDINATE SYSTEM button repeatedly

until the desired move coordinate system is set. The move
coordinate system currently set is displayed in the header.
There are six different move coordinate systems which can
be used to move the BendMaster axes (see "Tab. 4-4", pg.
4‐26).
2. Set coordinate system
Ø Press repeatedly until the desired displayed coordinate
system is set.
There are four different coordinate systems displayed
which can be used to display the axis positions of the
BendMaster in the Position menu.
or
Ø >Position Press >Position.
Ø Under "Coordinate system", press ▼.
Ø Select the desired coordinate system.

Fig. 39947
3. Select the speed using the speed buttons V- or V+.
The speed window is at the top right of the screen. The cur-
rent speeds in manual and automatic mode are displayed
there.
Switching between manual Pressing the velocity button always changes the velocity which is
and automatic mode displayed in large black letters in the velocity window.
Possible speeds in manual mode:

■ Incremental between 0.1 I and 1.0 I
(1 I corresponds to 0.1 mm/degrees or 1 mm/degree,
depending on which move coordinate system is set).
■ 2% to 5% in steps of 1%.
■ 10% to 100% in steps of 5% (at continuous pressure in
steps of 5%, and then 10%).
Speed in automatic mode:

■ 0.1% and from 1% to 100% in steps of 1% (at continuous
pressure in steps of 5%, and then in steps of 10%).
4. With write permission: press the speed window as required.
Manual speed is switched to automatic speed or vice versa.
5. Use the traverse buttons to move in the displayed direction.
The BendMaster is moved in the displayed direction as long
as the traverse button is pressed.
Coordinate systems for There are six traverse coordinate systems available to move the
displaying the axis positions axes. Four of them can also be used to display the axis posi-
tions on the screen (= displayed coordinate system):
■ Axis coordinate system ( = JOINTS).
■ Cartesian coordinate system ( = CART).
■ Mixed coordinate system ( = MIXED).
■ Auxiliary coordinate system (=AUX).

BendMaster axes Fig. 58860
Coordinate system Axis Movement of the BendMaster

Axis coordinates ( = Z To the right or left on the floor lane
JOINTS)
A Movement of the A axis
B Movement of the B axis
C Movement of the C axis
D Movement of the D axis
Cartesian ( = CART) X Towards or away from the press
brake
R Upwards or downwards
Z To the right or left on the floor lane
a Reorientation around the tool cen-
ter point: the center of the tool cen-
ter point stands still; the orientation
is changed.
The tool center point depends on
the tool, e. g. no gripper, gripper,
off-center gripper, sheet sensor.

Coordinate system Axis Movement of the BendMaster
Mixed X Towards or away from the press
brake
R Upwards or downwards
Z To the right or left on the floor lane
C Reorientation around the tool cen-
ter point: the center of the tool cen-
ter point stands still; the orientation
is changed.
The tool center point depends on
the tool, e. g. no gripper, gripper,
off-center gripper, sheet sensor.
D Movement of the D axis
Auxiliary coordinate Z3 Left regripping station to the right
system (= AUX) or to the left
Z4 Right regripping station to the right
or to the left.
Tab. 4-4
The two other coordinate systems are tool coordinate systems:

■ Tool coordinate system (= TOOL):
Coordinate system for the respective tool position. Corre-
sponds to the Cartesian coordinate system, CART.
■ Mixed tool coordinate system (= TOOL MIXED):
Mixed coordinate system for the respective tool position. Cor-
responds to the mixed coordinate system, MIXED.
Note
The coordinate system in which the axes of the BendMaster
are moved (= move coordinate system) can be selected in
the >Positionmenu (= displayed coordinate system) regard-
less of the displayed coordinate system.
6. Selecting the coordinate system
2.7 Displaying axis positions
1. Press >Position > >Position. The following mask appears.

Fig. 39951
The current axis positions are shown in the selected, dis-

played coordinate system in the "Axis values" window.
The displayed coordinate system is displayed in the "Coordi-
nate system" field from where it can be selected.
2. Selecting the displayed coordinate system
Ø Press the DISPLAYED COORDINATE SYSTEM button
on the portable manual control unit.
The coordinate system is changed each time the button
is pressed.
or
Ø Under "Coordinate system", press ▼.
Ø Select the desired coordinate system. The selected coor-
dinate system is displayed under "Coordinate system".
2.8 Gripper service
Open gripper servicing 1. Select >Robot >Gripper servicing menu. The following mask
appears.

Fig. 39949
Release gripper 2. Move BendMaster into gripper change position using the
"Move robot to tool change position" travel function.
3. Press the left Arrow.
4. Confirm question with OK.
The "Press the enable key to release gripper" operation mes-
sage is shown.
5. Press the ENABLE KEY within 10 seconds. The gripper
releases.
6. If the ENABLE KEY is not pressed within 10 seconds, then
press the Arrow again.
Gripping or depositing the 7. Picking up or depositing a gripper
board Ø In manual mode: press and hold manual mode.
Ø Press the middle Arrow.
or
Ø In automatic mode: lock the safety fencing.
Ø Press the middle Arrow.
The board is gripped or deposited with the gripper.
Performing sheet separation 8. Press the right Arrow. A suctioned double sheet will be sep-
(option) arated.
2.9 Automatic gripper change (option)
Picking up a gripper
Conditions

pressed, "BendMaster" icon is green).
or
green).
■ Gripper deposit station is occupied.
■ The gripper has a name.
Fig. 52484
1. Select >Robot >Gripper deposit station menu.
Note
A job must first be retracted with a gripper for this gripper to
be displayed.
2. Select a name in the drop-down menu. The last 25 used
grippers are listed.

Fig. 52485
3. Select Pick up gripper:
4. Select the number of the gripper deposit station from where
the gripper is to be picked up in "Parameter".
Symbol Description
Deposit station not taught.
Deposit station occupied; gripper unknown.
Deposit station occupied; gripper known.
Deposit station free.
Status of gripper changing console deposit station Tab. 4-5
5. Select Ok. The BendMaster picks up the selected gripper.

6. If the gripper is to be picked up automatically for the loaded
job, select Pick up job gripper.

Lay down gripper
Conditions
■ BendMaster is ready for operation:
− In manual mode: The enable key on the portable manual
control unit has been pressed, the "BendMaster“ icon is
green.
− In automatic mode: the GREEN BUTTON has been
pressed and the "BendMaster" icon is green.
■ A free deposit place is available at the gripper changing con-
sole.
■ The gripper is loaded at the BendMaster.
1. Select >Robot >Gripper deposit station menu.

2. Select Lay down gripper.
3. Select the number of the gripper deposit station where the
gripper is to be deposited in "Parameter".
Note
Only those stations on which there is no gripper can be
selected:
4. Select Ok. The gripper is set down.
5. Check whether the gripper name is correct. The gripper
name is only entered correctly if the gripper type has also
been loaded in the control.

2.10 Regripping station (option)
Moving the axes of the regripping station

manually
Conditions
■ The AUX move coordinate system is selected.
■ The regripping station has been referenced.
pressed, "BendMaster" icon is green).
green).
1. Select >Position >Position.
Fig. 52479
2. Select the AUX move coordinate system.
3. Use the Z3 move button for the left gripper arm and the Z4
move button for the right gripper arm to move the regripping
station to the desired position.
4. Select Suction cups On to activate the suction cups.
5. Select Suction cups Off to deactivate the suction cups.

Tip
The "Re-gripping unit in park position" travel function can be
used to move the gripper arms of the regripping station into
the parking position.
Setting up the regripping station
1. Select >Position >Position.

2. Select the AUX move coordinate system.
Note
The regripping station is integrated in TruTops. If no regrip-
ping station is used, the regripping consoles must be dis-
mounted.
Fig. 51842
3. Press Configuration. If a job with programmed regripping sta-
tion has been loaded, the tooling plan is displayed for the
regripping station.

1 Gripper arm 2 Slot for gripper arm
Fig. 54687
4. Screw the configured gripper arms onto the regripping con-
soles:
1 Angle setting 2 Length setting

Regripping station Fig. 41347
5. Set the position of the gripper arms according to the tooling
plan with the help of the angle scale and the snap-in length
adjustment:

1 Valve 2 Valve open 3 Valve closed
Fig. 54684
6. Open or close the valve at the suction cup of the gripper to
activate or deactivate the vacuum.
− I/O 1 = vacuum on.
− I/O 0 = vacuum off.
Removing the regripping station
1. Move the regripping station into the parking position with the
"Regripping unit in park position" travel function.
2. Undo the air hose at the bottom.

Fig. 54686
3. Undo the four fixing screws using the Allen key (5 mm).
4. Remove the regripping station.
2.11 Setting the backstop resistor

regardless of the program
The backstop resistor can be set at the programmer user level

(see "Fig. 51840", pg. 4‐15) or higher, regardless of the pro-
grams and jobs.
Condition
■ Backstop resistors have been activated by the TRUMPF
Service Department.
1. Open >Press >Sensors for press >Backstop resistor.

Fig. 43889
2. Mark "ON/OFF" with a checkmark to activate the backstop

resistor.
3. Activate "Normal-active" with a checkmark.
The backstop resistor is active while the backgauge
approaches its position.
The function corresponds to "When stopping" if the backstop
resistor is set for a single program (see "Setting the backstop
resistor for single bending operations", pg. 4‐92).
or
Ø Activate "Withdrawal active" with a checkmark.
The backstop resistor is active while the backgauge with-
draws from the workpiece.
The function corresponds to "When moving" if the back-
stop resistor is set for a single program (see "Setting the
backstop resistor for single bending operations", pg.
4‐92)).
4. Enter the strength of the backstop resistor between 0 and
100 %:
− "Left": actuation of the left backstop resistor.
− "Right": actuation of the right backstop resistor.
5. Deselect "ON/OFF" and then reselect it in order to apply the
change to the strength of the backstop resistor.

3. Switching on and referencing the
BendMaster
3.1 Switching on the BendMaster
Condition
■ The compressed air supply is switched on.
1. Turn on the BendMaster's main switch. The control starts up

automatically.
The TruBend has its own main switch, see TruBend opera-
tor's manual.
2. Wait for the control to start up.
3. Log on the user and request write permission. The following
preset users are available for selection:
− Operator.
− Programmer: operator (producing parts).
− Administrator: operator (retracting parts).
− Service. TRUMPF Service engineer.
− Developer.
Notes
The operator does not require a password. All other users
require the corresponding password.
Users can be created and existing users edited in the
">Service >User configuration menu (see "Creating and mod-
ifying users", pg. 4‐15).
4. Set the CONTROL ON key switch at the TruBend to 1.
5. Turn the BendMaster key switch on the mounting device for
the portable manual control unit to the desired operating
mode.
6. Release all EMERGENCY STOP buttons:
− EMERGENCY STOP on the control panel, on the porta-
ble manual control unit, on all posts of the safety fencing,
on the inside of post 4 and on the control and control
panel of the press brake.
− In automatic mode: close all doors of the safety fencing.
− In automatic operating mode: press the GREEN button
on the mounting device for the portable manual control
unit.
− In manual operating mode: press the ENABLE KEY but-
ton.
7. Referencing the BendMaster (see "Referencing the Bend-
Master", pg. 4‐39).
4‐38 Switching on and referencing the BendMaster 2015-06-01 B579EN

3.2 Referencing the BendMaster
If the BendMaster moves to the safe home position before

switching off with the "Robot in home position" travel function,
the axes do not have to be referenced again after being switch-
ing on again (see "Executing travel functions", pg. 4‐48).
The regripping station always has to be referenced.
If the BendMaster is not in the safe home position after switch-
ing off, the "Robot in zero position" travel function must be used
to manually move the "BendMaster to the reference position
after switching on and then referenced.
Display in the event of ■ "NRef" in the header of the speed window.

unreferenced axes ■ "!" status of the drive unknown, e.g. after restarting the con-
trol.
■ "N" drive not referenced.
1 Indication in the header in the 3 Indication of the axis values in

speed window if the BendMas- the displayed JOINTS coordi-
ter has not been referenced nate system under "POSITION"
2 Indication of the axis values in
the displayed AUX coordinate
system under "POSITION"
Fig. 54368
Note
Only the JOINTS movement type is possible if one of the axes
has not been referenced. Travel functions and program
execution are no longer possible.
B579EN 2015-06-01 Switching on and referencing the BendMaster 4‐39

Referencing the Z, A, B, C, Z1, Z2 axes
Conditions
(see "Enabling conditions for operation modes", pg. 4‐17).
■ The BendMaster is ready for operation (pulse trigger switch
on the portable manual control unit has been pressed,
"BendMaster" icon is green).
1. Select the >Position >Position menu on the portable manual

control unit.
2. Press Reference.
The axes to be referenced appear in the right-hand side of
the monitor screen against a blue background.
Fig. 40856
3. Move the axes until the reference marks are in alignment

with each other.

Fig. 41441
Note
Reference the D axis (see "Referencing the D axis", pg.
4‐41).
4. Press the blue button on the portable manual control unit for
the axis to be referenced.
5. Press the blue Z3 button on the portable manual control unit.
An automatic reference trip of the regripping station to the
left reference switch at the parking position is started.
6. Press the blue Z4 button on the portable manual control unit.
An automatic reference run of the regripping station to the
right-hand reference switch at the parking position is started.
Referencing the D axis
Conditions
■ The BendMaster is ready for operation (pulse trigger switch
on the portable manual control unit has been pressed,
"BendMaster" icon is green).
1. Select the >Position >Position menu on the portable manual

control unit.
2. Press Reference.

The axes to be referenced appear in the right-hand side of
the monitor screen against a blue background.
Fig. 49445
Rotational movement with loaded gripper can lead to

NOTICE collisions!
Ø Check for any risk of collision prior to the reference run of
the D axis.
3. BendMaster (60):
Move the D axis until the reference marks are in alignment
with each other.
or
Ø BendMaster (150):
Press the blue D button on the portable manual control
unit.
A reference trip of the D axis is carried out until the inte-
grated reference switch is actuated.
3.3 Referencing TruBend
If no manual reference trip is carried out with the TruBend, then

the reference trip will take place automatically prior to a program
start.

Conditions
■ In manual mode: The BendMaster is ready for operation
(pulse trigger switch on the portable manual control unit has
been pressed, "BendMaster" icon is green).
or
■ In automatic mode: BendMaster is ready for operation (the
green).
Referencing TruBend 1. Press the >Press >Press servicing menu on the portable
Fig. 46147
2. Starting referencing
Ø Manual mode: Press and hold the ENABLE KEY on the
Ø Press Start press.
or
Ø Automatic mode: Press the GREEN button.
Ø Press Start press.
The hydraulic unit is started. The upper and lower tools are
clamped. The press beam is referenced. The backgauge
moves into position.

Note
The CNC can only be started if the program is loaded.
After successfully starting the TruBend, the second icon in
the header switches to "TruBend CNC started":
1 Stop hydraulic unit 5 Clamp/release upper tool clamp 8 Approach mute point (in auto-
2 Start hydraulic unit 6 Clamp/release lower tool clamp matic mode only)
3 Stop CNC 7 Approach upper dead point 9 Approach clamping point
4 Start CNC 10 Approach lower dead point
Fig. 46148
Opening the press beam 3. Press Up.

Moving the backgauge to 4. Press Backgauge position.
the current bending step 5. Change to the TOS user interface with <Alt>+<Tab>.
Connecting to the TruBend
6. Press MMI:
control

Fig. 46150
7. Press TrumaBend connection.

The TruBend user interface is shown on the visualization PC.
Tip
If a VNC connection already exists, you can press <Alt>
+<Tab> to switch to the VPC connection.

4. Switching off the BendMaster
4.1 Stopping BendMaster and TruBend in

any emergency or after a malfunction
Ø Press EMERGENCY STOP on the control panel.

or
Ø Press EMERGENCY STOP on the portable manual con-
trol unit.
or
Ø Press EMERGENCY STOP on the outside of one of the
posts of the safety fencing.
or
Ø Press EMERGENCY STOP on the inside of post 4.
or
Ø In manual mode only:
− Release the ENABLE KEY on the portable manual con-
trol unit.
or
Ø In manual mode only:
− Fully press the ENABLE KEY on the portable manual
control unit.
4.2 BendMaster, switching off
Condition
■ The control is in the >Position >Automatic menu.
1. Press Stop to stop the program.

2. If there is a blank on the BendMaster, move into unloading
position and set down the blank.
3. Release and deposit the gripper.
4. Select Move, Robot in home position.
The safe home position must be approached so that the
BendMaster does not have to be referenced again after
switching on.
5. Change to the TOS user interface with <Alt>+<Tab>.
6. Press Exit, Exit control system.
7. Press Exit Windows XPe once the control has been shut
down.
8. Enter Yes. The visualization PC is shut down.
4‐46 Switching off the BendMaster 2015-06-01 B579EN

9. Turn off the main switch of the BendMaster.
Note
The TruBend has its own main switch. To switch off the Tru-
Bend, see the "Operator's manual for TruBend 5000 Series".
B579EN 2015-06-01 Switching off the BendMaster 4‐47

5. Travel functions
Travel functions are automatic programs used to approach posi-

tions or carry out processes which are frequently required, such
as approaching the home position.
5.1 Executing travel functions
Conditions
■ All axes have been referenced.
■ In manual mode: The BendMaster is ready for operation
(pulse trigger switch on the portable manual control unit has
been pressed, "BendMaster" icon is green).
or
■ In automatic mode: BendMaster is ready for operation (the
green).
1. Press >Position >Automatic.
Fig. 42643
2. Press Move. The travel functions are displayed.

3. Select the desired travel function:
4‐48 Travel functions 2015-06-01 B579EN

Travel function Description
Robot in initial position Moves the BendMaster into the initial position.
By default, the starting position corresponds to the 0 axis position.
The initial position can be customized by TRUMPF Service.
Robot in the tool change position Moves BendMaster into the manual gripper change position.
Robot in home position Moves the BendMaster in the safe home position. The BendMaster is col-
lapsed.
The home position can only be approached without gripper here.
■ The safe home position is approached:
− Before the manual press mode.
− When the machine is switched off.
Robot in parking position Moves the BendMaster into the parking position. The BendMaster is
extended.
■ The parking position is approached:
− For pallet change in automatic mode.
− For the store connection option for travel to storage (pallets or
parts exchange).
Regripping console in parking posi- Moves the regripping console into parking position.
tion
Robot in zero position Moves the BendMaster into the reference position (all axis positions = 0).
Travel functions Tab. 4-6
4. Confirm query with Yes.

5. To interrupt the travel function:
− Press STOP on the portable manual control unit.
6. To continue the travel function:
− Press START on the portable manual control unit.
7. To prematurely end the travel function:
− Press Stop at the HMI user interface.
B579EN 2015-06-01 Travel functions 4‐49

6. Running in a TruTops program
6.1 From BendMaster control V7.0 and

higher: Settings in TruTops Bend
Entering the control version The machine database of TruTops Bend has to be converted to
control version 7.0.
See the "Configuring BendMaster", "Entering the control version"
section in chapter 2 of the TruTops Bend software manual ver-
sion 3 for instructions.
Gripper weight The correct gripper weight must be entered in TruTops Bend.
This is the only way that the BendMaster can move with opti-
mized cycle time.
For the procedure, refer to the "TruTops Bend software manual
version 3", chapter 2, section: "Editing basic data", "Creating the
vacuum gripper (BendMaster option)".
Moving the transversing axis The BendMaster and the transversing axis can be moved in par-
and BendMaster in parallel allel. A start and end point must be set for the transversing axis,
which also serve as interpolation points for robot movement, so
that this procedure is taken into consideration during the collision
check.
For the procedure, refer to the "TruTops Bend software manual
version 3", chapter 8, section "Moving the cantilever parallel with
BendMaster".
Moving regripping consoles For the procedure, refer to the "TruTops Bend software manual
synchronously version 3", chapter 7, section: "Regripping", "TruBend Cell 5000:
Moving regripping consoles in synchronization with BendMaster".
6.2 Procedure for productivity package

option
Checking the productivity package
Checking if the productivity 1. Open >Diagnostics >Version >Cell options.

package exists
The productivity package is displayed.
Adjusting old projects For projects that were created before the installation of the pro-
ductivity package, the gripper and the travel speed of the robot
must be adjusted to the workpiece speed.
4‐50 Running in a TruTops program 2015-06-01 B579EN

Increased movement dynamics due to productivity package
WARNING
The workpiece may fall out or be ejected! Risk of injury!
Ø Before starting an older project, check the holding force and
stability of the corresponding gripper and confirm the respec-
tive dialog.
Ø Calculate the suction cup capacity (see "Calculating suction
cup capacities", pg. 4‐51).
Ø Adapt the number of suction cups to the gripper.
Ø If the number of suction cups cannot be increased: reduce
the speed of the travel points (see "Points, editing", pg.
4‐96).
Ø For magnet gripper: reduce the robot speed (override) to
50% (see "Determining the reduction of the robot speed",
pg. 4‐52).
2. Adjust the parameters to the weight of the workpiece. When

doing this, make sure that the center of gravity of the work-
piece is in the center of the suction cup arrangement.
Calculating suction cup capacities
Condition
■ The geometry of the workpiece is known.
1. Determine the weight of the workpiece.

2. Determine the number of required suction cups using the fol-
lowing table:
Nominal diameter in [mm] Carrying capacity [kg]

30 0.25
40 0.5
50 0.75
60 1
80 1.75
125 4
Suction cup diameter-carrying capacity for productivity pack- Tab. 4-7
age
Example:
A blank weighs 30 kg. Only suction cups with a diameter of
60 mm are available (load-bearing capacity 1 kg).
30 kg: 1 kg = 30.
Thirty suction cups are required.
B579EN 2015-06-01 Running in a TruTops program 4‐51

3. Arrange the suction cups in such a way that the center of
gravity of the workpiece is in the center of the suction cup
arrangement.
Determining the reduction of the robot

speed
When using the magnetic gripper in older programs with the pro-
ductivity package, the robot speed (override) must be reduced to
50%.
Ø Calculate the override. Examples:

■ Programmed speed: 100 %, reduced speed:
100 % x 0.5 = 50 %
■ Programmed speed: 80%, reduced speed:
80% x 0.5 = 40%
6.3 Overview, loading a program
Creating a job The BendMaster is controlled automatically in automatic mode.

To execute a program from TruTops Bend in automatic mode, a
job must first be set up in the>Setup menu and run in step-by-
step:
■ Create a job from the TruTops program or select a job which
has already been created.
■ Set job details such as fine recognition, height measurement
and error strategy.
■ Select areas where the BendMaster picks up workpieces or
sets them down.
■ Starting the rough recognition
■ Define the stack assignment.
■ Set up tools on the BendMaster, press brake.
■ Set up the regripping station.
■ Select double sheet recognition and the separation method.
■ Set the bending parameters for each bending operation, e.g.
bending support, bending sensors and, if available, backstop
resistor.
■ Load the job.
Input aid A numeric or alphanumeric keyboard appears as an input aid

after the respective field has been highlighted if values have to
be entered during the Enter values procedure.
If the comfort option is used, the entry can also be made using
the keyboard.

6.4 Creating a new BendMaster job from
the TruTops Bend program
Open order 1. Press >Set up >Job.
Fig. 59564
2. Press >Job >Build.

3. In the "Building project" window, select the TruTops Bend
program ('*.bnc') from the released directory 'C:\xChange
\parts', from a diskette or from an exchangeable USB storage
medium.
4. Press Open. The job is saved to the control.
The new job and the previously created jobs are displayed in
the "Selected Order" window.
5. Mark the job to be executed in "Selected Order". The
selected job is opened and graphically displayed.
The name of the selected job is displayed in the "Order
Name" field.
Tip
If the job is clicked on again, it is closed.
Defining the lot size 6. Click on the "Lot Size" field.
7. Enter the production quantity.
8. Press OK.
Enter the number of The number of successfully bent sheets is displayed.

completed, bent blanks
9. Click on the "Done" field.
10. Enter the quantity.
11. Press OK.

The "Ready" field is not reset to "0" after deselecting and
reloading the job. Jobs can thus be interrupted and resumed
at a later time with the last quantities.
Execution is finished when the finished items counter

reaches the defined lot size.
Setting the advance warning 12. Enter the number of blanks in the "Advance warning quan-
for quantities tity" field, above which the control displays the information for
every change in quantity: "Job X in Y blanks finished".
Entering the customer and The "Customer" and "Number" may be defined, but do not have
job number to be.
13. Click on the "Customer" or "Number" field.
14. Enter the customer name or job number.
15. Press OK.
The current project status is displayed under "Status":
Symbol Description
No job selected or error.
Job selected, without errors.
Stacks have been defined.
Job has been loaded.
Job is ready.
The job is available, but has not yet been selected for
automatic execution (gray).
Tab. 4-8
Updating the view 16. Press Update.

The view is updated, e. g. after jobs have been deleted.
Having parts data displayed 17. Parts data
18. In the drop-down menu, press Unprocessed material, Fin-
ished part or, if available, Intermediate layer part.
The selected parts data is displayed:

Name Description
Material ID (store) ID number of the material with which it was
booked in the storage system. Only when a
storage system link is used.
Rotation to Geo Only when a storage system link is used and
up to TruTops Bend Software version 2.1:
If the part is is rotated in TruTops Bend in com-
parison with the geometry file, then this rotation
must be entered accordingly. The rotation to the
Geo drawing is possible only in 90° increments.
The rotation is carried out automatically starting
with TruTops Bend Software version 2.2.
Weight The sheet weight calculated by TruTops is dis-
played.
Layer thickness The layer thickness of the intermediate layer is
displayed and can be modified. A modification
of the sheet thickness has an effect only on the
calculation of the stack height.
Material The material programmed in TruTops Bend is
displayed.
Unprocessed material or intermediate layer part Tab. 4-9
Name Description
Material ID (store) ID number of the material with which it was
booked in the storage system. Only when a
storage system link is used.
Finished part Tab. 4-10
19. Press Back to return to the >Run in >Job menu.
Deleting a job Note

■ A job can be deleted only if it has not been opened or
loaded.
■ Deleted jobs can not longer be produced.
■ Jobs can be archived prior to deletion.
20. Press >Job >Delete.
21. Select the desired job .
22. Press OK. The selected job is deleted.
Loading a job 23. Press >Job >Load. The selected job is loaded and displayed
in the header.
Deselecting a job 24. Press >Job >Unload. The loaded job is deselected.
6.5 Archiving, restoring or deleting jobs
Notes
■ A job can be archived only if no other job has been transfer-
red or loaded.

■ the path for the backup directory is preset; it can however be
changed as necessary (see "Changing the backup directory
path on the user interface", pg. 4‐58).
Filing away a job
1. Press >Job >File away.
Fig. 76903
The orders saved on the BendMaster are displayed in the

left-hand window. The orders in the backup directory are dis-
played in the right-hand window.
2. Mark the orders to be archived in the left-hand window.
3. Press -->. The marked orders are noted for archiving in the
backup directory.
4. If the order is already in the backup directory, confirm the
corresponding query with OK.
5. Press OK. The marked orders are archived in the backup
directory.
Restoring an order

Fig. 76903

2. In the right-hand window, mark the orders that are to be
restored.
3. Press <--. The marked orders to be restored are noted.
4. If the order is already in the control, confirm the correspond-
ing query with OK.
5. Press OK. The marked orders are restored.
Deleting a job
Fig. 76903


2. In one of the two windows, mark the order that is to be
deleted.
3. Press .
4. Confirm the query with OK.
5. Press OK. The marked order is deleted.
Changing the backup directory path on the

user interface
The backup path changed on the user interface is stored in the

control and is displayed again when the system is next
accessed.
Fig. 76903

2. Press next to the backup directory path.
3. Press .
4. Press .
5. Selecting the drive.
6. Select or create a folder.
7. Press Press OK. twice

6.6 Defining job details
Notes
■ In order to be able to switch over directly into the job details,
a job must be opened or loaded. If this is not the case, then
the job is loaded directly.
■ All settings which are defined in the job details are stored in
the respective job and apply to all loading and unloading
areas.
■ The settings for individual areas can be modified in the "Area
details" mask
Defining exposure details
1. In the "Job" mask, press Continue.

or
Ø Press >Set up >Job details.
2. Press Details>Tool holder.
Fig. 76910
3. Define the parameters in the areas.

Name Description
"Fine recognition" "Basic setting":
■ No fine recognition.
■ Fine recognition on the stack, once.
Fine recognition is carried out once for each stack.
■ Fine recognition at the stack, periodic.
Fine recognition is carried out at defined intervals in the stack:
− "Period": number of blanks after which a fine recognition takes place. If, for
example, 3 pieces are entered, a fine recognition is carried out after every
third blank.
− "Tolerance position": specification of the maximum position deviation between
two fine recognition windows.
If the deviation too great, the stack is marked as locked. Depending on the
error strategy which has been set, a new rough or fine recognition process
can be carried out on the backlighting table.
− "Rotational position tolerance": maximum deviation of the rotational position
between two fine recognition windows.
If the deviation is too great, the stack is marked as locked. Depending on
the error strategy which has been set, a new rough or fine recognition proc-
ess can be carried out on the backlighting table.
■ Fine recognition on the backlighting table: : fine recognition is carried out on the
backlighting table (e.g. for strongly reflective parts). Can only be selected if a
backlighting table is available.
"Additional height meas- "Basic setting":
urement" ■ No height measurement.
■ Periodic height measurement.
Height measurement is carried out at defined intervals in the stack:
■ Fine recognition at the stack, periodic.
Fine recognition is carried out at defined intervals in the stack:
− "Period": number of blanks after which a height measurement takes place. If,
for example, 3 pieces are entered, a height measurement is carried out after
every third blank.
− "Height compensation": an exact height measurement is carried out prior to
the fine recognition process in order to compensate for the programmed
height during the fine recognition process. The determined difference (offset)
between the first and second fine recognition windows is displayed as "Offset
fine recognition 1" and "Offset fine recognition 2" in the Stack details window.
"Error strategy/recognition" "Basic setting":
■ No error processing: no action is performed after a faulty fine recognition.
■ New rough recognition: after a faulty fine recognition, first a rough recognition
and then a fine recognition are carried out.
■ Backlighting table: can only be selected if a backlighting table is available.
− For fine recognition with two fine recognition windows: if the two fine recog-
nition windows lie outside the previously entered "position"" or "rotational
position", tolerances, a fine recognition is carried out on the backlighting
table.
− For fine recognition with one fine recognition window: No action is carried
out after a faulty fine recognition, as sufficient position data is not available.
■ Rough recognition and backlighting table: Combination of the two strategies. First
a rough recognition is carried out. If the rough recognition fails, then a fine rec-
ognition is carried out on the backlighting table. Can only be selected if a back-
lighting table is available.

Name Description
"Height measurement in Active if an error strategy with rough recognition is defined. The height
case of error strategy" measurement is carried out on the material point used.
■ No height measurement: No height measurement is carried out during rough rec-
ognition.
■ Before approximate search: a height measurement is carried out before the
approximate search.
■ After approximate search: a height measurement is carried out after the approxi-
mate search.
■ Before and after approximate search: a height measurement is carried out before
and after the approximate search.
"Pre production in case of ■ Checkmark set:
full storage" The next part will still be produced, even if the shelf is full. The BendMaster
stops after the bending process if no free shelf is available at this time.
■ Checkmark not set:
The BendMaster stops after depositing the last part.
"Stack empty code" Defination above which quantity a loading stack in the selected area is marked
empty in the control.
■ Default setting: The control selects the mode.
■ through quantity: The stack is marked empty once the the quantity of 0 is
reached. If other blanks are still on this stack (e.g. due to incorrectly measured
stack height), then these will no longer be picked up.
■ through fine recognition: Once the quantity of 0 is reached, a fine recognition is
carried out with each additional sheet. If the fine recognition does not find any
more blanks, then the stack is marked as being empty.
■ through height measurement: Once the quantity of 0 is reached, a height meas-
urement is carried out with each additional sheet. If the result of the height meas-
urement is less than the thickness of the blank, then the stack is marked as
being empty.
"Position monitoring By default, the control monitors whether the surrounding rectangles of stacks posi-
active" tioned next to one another overlap when creating the loading stack.
■ Checkmark set:
Position monitoring active. Overlapping stacks are not created.
■ Checkmark not set:
Stacks are created, even if they overlap. This may result in collisions when
blanks are picked up.
"Approaching rotation Safe position for D axis rotary movement. In this position, it is possible to perform
position" the rotary movement without collision, even if the rotational position of a part devi-
ates from the program in TruTops.
■ Always approach: all rotary movements of the D axis are carried out at a safe
position.
■ Only after fine recognition: a rotary movement of the D axis to the safe position
is carried out before and after fine recognition. all other D axis rotary movements
take place while moving to the pick-up position.
Exposure details Tab. 4-11
Editing the gripper weight
If the gripper weight was not entered into the database when
TruTops Bend was programmed, then the control (starting from

software V7.0) will automatically set the gripper weight to the
maximum value. The gripper weight can be manually changed in
the program:
1. Details Press >Gripper weight.

2. Enter the correct gripper weight.
3. Press Continue.
6.7 Loading and unloading areas
When a job is set up, all loading and unloading areas need to
be set up. Selection:
Fig. 48245
Area types ■ Areas that cannot be changed.
Lines and areas Description

Lines, orange Fixed contours, e.g. bending cell or press brake.
Dotted area, white Working areas (unloading areas).
Thin lines, green Possible search area for the rough recognition
(loading areas).
Lines, white Sheet removal station or conveyor belts.
Plane, blue Loading area specified by TruTops Bend (cannot be
displaced).
(not displayed by
default)
Areas which cannot be changed Tab. 4-12
■ Loading areas(see "Tab. 4-16", pg. 4‐66):

Areas Description
Area, green Loading areas for sheets with the area type Load
Search M.
Area, red Loading areas for sheets with the area type Load
Search Automatic. Only in combination with the
optional storage system link. Only possible on one
storage station.
Area, blue Loading areas for blanks in case of area type Load
Precise.
Area, orange Sheet removal station or conveyor belts.
Area, pink Loading area for intermediate positions in case of Z
position exact.
Loading areas Tab. 4-13
■ Unloading areas (see "Tab. 4-17", pg. 4‐66):
Areas Description
Area, cyan Unloading areas for blanks in case of area type
Unload Precise.
Area, white Unloading area for blanks with Deposit quality area
type. The periods for depositing for quality assur-
ance are entered in the "Job details", "Storage
location settings" mask.
Area, red Unloading area for sheets with the area type
Deposit rejects.
Unloading area Tab. 4-14
Note
Loading and unloading areas are positioned in the same as they
have been programmed and simulated in TruTops. However,
they can be adapted to their actual position in the bending cell.
As a result, areas moved in the X direction might not be able to
be approached by the BendMaster.
Coordinate system and (see "Load job", pg. 4‐64)

starting point

1 Starting point 1 2 Starting point 2
Fig. 46232
Load job
Ø In the "Job details" mask, press Continue.

or
Ø Press >Set up >Job details. The job is loaded (see "Fig.
48245", pg. 4‐62).
Adjusting an area
1. Select the area to be changed

Ø Mark the area to be changed in the "Active Areas" list.
This area is displayed in bold in the graphic.

or
Ø Press the desired area in the graphic (see "Loading and
unloading areas", pg. 4‐62).
Do not confuse the loading and unloading areas!
2. Moving an area
Ø Press the value to be changed. The numeric keyboard
appears.
Ø Enter the value.
Ø Press OK.
or
Ø Move the area into the graphic using the drag & drop
method (see "Fig. 46232", pg. 4‐64).
Notes
− Moving unloading areas by means of drag & drop is only
possible in Z direction.
− The coordinate system in Z direction is stuck onto the
floor lane cover.
− The origin of the coordinate system in the X direction is
at the center of the shaft of the A axis. The coordinates
become positive in the direction of the TruBend and neg-
ative in the direction of the loading area.
− Moving unloading areas in X direction is only possible by
changing the starting point. However, it may be the case
that the BendMaster can no longer approach the unload-
ing positions.
− If the sheets of the loading stack are larger than the pal-
let, a larger loading area must be defined accordingly.
Name Description
Starting point X and Z coordinates of the bottom, left corner of
the area selected under active areas. This point is
displayed in red in the diagram (see "Fig. 46232",
pg. 4‐64).
"Length" Length of the area selected under "Active Areas" in
the Z direction in [mm].
"Width" Width of the area selected under "Active Areas" in
the X direction in [mm].
The length and width range can also be moved

using the drag & drop method:
■ Select an area.
■ Position the cursor at the corner diagonally
opposite the starting point.
■ Adapt the area.
"Pallet height" Height of the transport medium holding the work-
piece stack.

Name Description
"Area Types" The loading or unloading area function can be
defined using the different area types (see "Tab.
4-16", pg. 4‐66), (see "Tab. 4-17", pg. 4‐66).
Tab. 4-15
Area type Color Description

Load Search M Green ■ The approximate search must be started manually.
The number of recorded images which are joined to form
an overall image varies, depending on the size of the area.
The position of the stack in the overall image is determined
by means of the rough recognition process.
Load Search A Red ■ The approximate search is started automatically when a
storage system/pallet conveyor is used.
The number of recorded images which are joined to form
an overall image varies, depending on the size of the area.
The position of the stack in the overall image is determined
by means of the rough recognition process.
Load Search exact Blue The stack is positioned within this area as previously pro-
grammed in TruTops Bend.
Z position search A Orange The loading area is searched for a stack with intermediate
layers. The number of recorded images which are joined to
form an overall image varies, depending on the size of the
area. The position of the intermediate layer in the overall
image is determined by means of the rough recognition
process.
Intermediate layer search exact Pink The intermediate layer stack is positioned within this area
as previously programmed in TruTops Bend.
Area types, receiver Tab. 4-16
Area type Color Description

Unload Precise Cyan The stack is positioned within this area as previously pro-
grammed in TruTops.
Unload Precise White Parts for a quality check can be set down within this area
at periodic intervals.
Deposit rejects Red Parts for which the ACB angle detection sensor system has
indicated an error are deposited within this area.
Area types, unloading areas Tab. 4-17
■ Moving unloading areas by means of drag & drop is only

possible in Z direction.
■ Moving unloading areas in X direction is only possible by
changing the starting point. However, it may be the case
that the BendMaster can no longer approach the unload-
ing positions.
■ If the sheets of the loading stack are larger than the pal-
let, a larger loading area must be defined accordingly.
■ Do not confuse the loading and unloading areas.

Tip
The starting point for positioning a pallet can also be indicated
with the laser cross.
Copying an area
1. Select the area to be copied:

Ø Mark the area to be copied under "Active Areas".
or
Ø Press the desired area in the diagram.
2. Press Area, Copy.
The values of the selected area are adopted as proposal.
The following mask appears:
Fig. 35718
3. Enter "name".
Tip
Use descriptive names.
4. Enter the Z and X coordinates of the area's starting point

(bottom left) (see "Fig. 46232", pg. 4‐64).
Tip
If the sheets of the loading stack are larger than the pallet, a
larger loading area must be defined accordingly.

5. At "Mode" select the desired area type(see "Tab. 4-16", pg.
4‐66).
6. Press OK.
Deleting an area
Deleting individual areas 1. Mark the area to be deleted under "Active Areas".
2. Press Area, Delete.
All areas, deleting 3. Press Area, Delete all areas.
4. Press OK.
Displaying the area position
1. Press >Set up >Areas.

2. Press Area, Approach laser position.
The area positions are approached.
4. Press user key 2 to switch on the laser.
The point opposite the starting point of the selected area is
displayed (X) at the HMI user interface.
Fig. 49446
5. Position the pallet.

6. The opposite point of the starting point of the selected area
is displayed (X).

Displaying the area position
1. Press >Set up >Areas.

2. Press Area, Approach laser position.
The area positions are approached.
4. Press user key 2 to switch on the laser.
The point opposite the starting point of the selected area is
displayed (X) at the HMI user interface.
Fig. 49446
5. Position the pallet.

6. The opposite point of the starting point of the selected area
is displayed (X).
Defining area details
Opening area details 1. Press Display, Details to display the graphic again.

The settings which were made when the job was created
can be modified here for the selected area. The settings
apply to all stacks located in the selected area:
Fig. 68678
"Stack execution mode" Mode with which the loading stack in the selected area can be
processed. Can be defined only for the loading stack.
2. Select "Stack execution mode":
− by stacks (default value): a stack is processed completely
before beginning with the next stack.
− by layers: the highest stack is processed until another
stack has the same height. Once this occurs, processing
proceeds alternately, layer by layer, on all loading stacks
in the area.
"Height tolerance" The field is only active if by layers has been selected in the
"Stack execution mode" field. Can only be defined for loading
areas.
3. Enter the "height tolerance". Maximum difference in height
between the stacks which is still tolerated for the execution
by layers.
"Error strategy/recognition" Strategy as to how, after a failed fine recognition in the selected
area, work is to proceed. Can be defined only for loading areas.
4. Select "Error strategy / Recognition":
− As with job setting (default value): the job is resumed
with the programmed settings.
− No error processing: no action is performed after a faulty
fine recognition.
− New rough recognition: after a faulty fine recognition, first
a rough recognition and then a fine recognition are car-
ried out.

− Backlighting table: can only be selected if a backlighting
table is available.
For fine recognition with two fine recognition windows: if
the two fine recognition windows lie outside the previ-
ously entered "position"" or "rotational position", toleran-
ces, a fine recognition is carried out on the backlighting
table.
For fine recognition with one fine recognition window: No
action is carried out after a faulty fine recognition,
because there is not enough position data available.
− Rough recognition and backlighting table: Combination of
the two strategies. First a rough recognition is carried
out. If the rough recognition fails, then a fine recognition
is carried out on the backlighting table. Can only be
selected if a backlighting table is available.
"Height measurement mode" Strategy by which, after a failed fine recognition in the selected
area, work is to be congtinued with a rough recognition. Can be
defined only for loading areas.
5. Select "Height measurement mode":
− As with job setting (default value): the job is resumed
− No height measurement: no additional rough recognition
is carried out.
"Advance warning from" Determination of the minimum quantity of sheets in a stack in

the selected area at which an advance warning (message) is
issued.
6. Enter the quantity in the "Advance warning from" field.
"Stack empty code" Determination as to the number of pieces starting from which a
loading stack in the selected area will be marked "empty" in the
control. Can only be defined for loading areas.
7. Enter the stack height in the "Stack empty code" field.
or
Ø As with job setting (Default value): The job is resumed
"Sheet rotation" and "Offset Components with extrusions only on one side result in angled
in X" material stacks. With "Board rotation" and "Offset in X", every
part can be deposited rotated and/or offset from the previous
part.
8. Enter "Sheet rotation". Permitted values: 0° or 180°.
Rotation takes place around the center of the defining com-
ponent rectangle.
9. Enter "Offset in X".

"Deactivate vacuum When intermediate layers in the loading stack are used, vacuum
intermediate layer" monitoring can be deactivated for the selected area during the
time period from the loading to the unloading of the intermediate
layer.
10. Remove the checkmark from "Vacuum monitoring".
Note
The BendMaster is not stopped if no intermediate layer is
picked up or if it is lost during transport.
Redisplaying the diagram 11. Press Display, Overview to display the graphic again.
Viewing the approximate 12. Press Images of approximate search.
search for images
The recorded images already available can be viewed in
order that the rough recognition process does not have to be
repeated when searching for two or more loading stacks.
Adopt changes 13. Press Apply. The graphic is displayed again.
6.8 Performing the rough recognition

process (Search within area)
Searching for an area
Condition
■ All axes have been referenced.(see "Referencing the Bend-
Recording images 1. Press Search within area.

The loading area is searched. The number of recorded
images varies, depending on the size of the area. The first
image is displayed.

Fig. 39926
Note
"Image [1/4]" means the first of four recorded images is dis-
played.
2. Increase the size of the recorded image with Zoom if
desired:
− Activate zoom: A green window can be placed over the
area that is to be zoomed in. The zoomed in section is
displayed.
Activate zoom can be used to zoom in to the image
recording any number of times.
− Zoom out: image recording is reset from the currently
zoomed in section to the previous image detail.
The function can be repeated until the original size is
established.
− Zoom 100%: image recording size is reset to 100%.
− Deactivate zoom: Deactivates the activated zoom. The
green window is hidden.
3. Switch between the individual images using << and >> if
desired.
4. Position the blue cross-hairs from the top left corner of the
screen at the point where the height is to be measured and
the stack is to be searched for:

Fig. 59300
Note
Since the search results must include the height measuring
point, it must be positioned on the stack to be searched for.
Rough recognition in the Rough detection may be carried out both in a defined search
entire search area area and in the complete search area.
For a rough recognition in the complete search area, the com-
plete blank must be within the displayed search area.
5. Press Find stack.
6. Enter the approximate stack height ±50 mm (stack height
only, without transport medium).
7. Press OK.
The height is measured at the position previously defined.
The rough recognition process is then performed on the
stack. The search results found are displayed after the rough
recognition:

Fig. 54369
Note
There may be several search results. Image [1/2] means that
the first of the two permissible search results is displayed.
8. Press << and >> to switch back and forth between the per-
missible results.
9. Press Selection in the correct search result. The selected
search result is used as a loading stack. The "Stack layout"
mask appears.
Rough recognition in the Rough detection may be carried out both in a defined search
defined search area area and in the complete search area.
For a rough recognition in a search area, the blank may protrude
beyond the displayed search area in the X direction (see "Fig.
39926", pg. 4‐73).
10. Press Search area.
11. Enter the approximate stack height ±50 mm (stack height
only, without transport medium).
12. Press OK.
13. Drag the blue rectangle over the desired search area.
The defined search area may exceed the area covered by
the camera in the X direction:

Fig. 42936
14. Press Find stack.

The stack is subjected to the rough recognition process. The
found search results are displayed after rough recognition.
Note
There may be several search results. Image [1/2] means that
the first of the two permissible search results is displayed.
15. Press << and >> to switch back and forth between the per-
missible results.
16. Press Selection in the correct search result. The selected
search result is used as a loading stack. The "Stack layout"
mask appears.
Searching for further loading stacks
Condition
■ The rough recognition process is carried out.
1. Switch to the >Run in >Area menu.

2. Press Display, Images of approximate search.
the stack is to be searched for.
Note
Since the search results must include the height measuring
point, it must be positioned on the stack to be searched for.
4. Search for further loading stacks using one of the two rough
recognition options (see "Searching for an area", pg. 4‐72).

Intermediate layer, searching for
Condition
■ Intermediate store has been programmed in TruTops Bend
(function available from TruTops Bend V4.15).
1. Switch to the >Run in >Area menu.

2. Mark the loading area for the intermediate layer (orange).
3. Press Search within area.
The intermediate layer area is searched. Depending on the
size of the area, several images are recorded. The first
image is displayed.
the stack is to be searched for.
5. Press Find stack or Search within area to search for the
stack.
Procedure in the event of problems with

Incorrect area is scanned 1. In the >Set up menu, press Apply areas.

Stack not found ■ Height measuring point was not defined properly.
■ Stack is not entirely in the search area.
2. Use Search within area.
3. Search for several stacks with separate individual loading
areas.
Part of the composite image 4. Reduce the size of the loading area, if possible.
is overexposed or 5. Search for several stacks with separate individual loading
underexposed areas.
Stack is not found properly 6. Use Search within area.
7. Change the height measuring point.
Height measurement not ■ Height measuring point was not defined properly.
successful ■ The pallet height is incorrect in the >Set up >Areas menu.
■ An incorrect stack height was entered during rough recogni-
tion.
8. In the >Set up menu, press Apply areas.
Incorrect stack height The height measurement is a relative measurement between the
BendMaster and the highest blank. For this reason, minimum
deviations may occur between the actual and measured stack
heights.

The distance between the highest sheet and the cover for the
sensor system must be 333 mm during the fine recognition proc-
ess:
Fig. 51848
■ The pallet height is incorrect in the >Set upAreas menu.

9. In the >Set up menu, press Apply areas.
6.9 Defining stacks
Opening "Stack layout" Switching over to "Stack layout" user interface is performed
either automatically after the "find stack" process or as follows:
1. In the >Set up menu, press Areas, Continue.

or
Ø Press >Set up, Stack layout.

The loading stacks and unloading stacks found during the
rough recognition process are displayed in color.
Fig. 39931
2. Mark the desired stack in the "Stack" list. "Stack mode" is

displayed.
or
Ø Mark the desired stack in the graphic. "Stack mode" is
displayed.
Note
The coordinates of the starting point of the marked stack
are displayed at the coordinate arrows for the X and Z
directions.
Loading stack:
Stack mode Color

L stack active Blue
L height OK Gray
L coordinate OK Gray
L stack empty Red
L stack blocked Orange
L stack blocked Yellow
Tab. 4-18
Unloading stack:
Stack mode Color

A stack active Green
A stack ready Cyan

Stack mode Color
A stack full Red
A stack blocked Orange
Tab. 4-19
Displaying stacks 3. Press Display, Filter, All stacks. All stacks available in the
control are displayed.
or
Ø Press Display, Filter, Project stacks. The stacks of the
job opened on the Job page are displayed.
or
Ø Display Display, Filter, Running project stacks. The
stacks of the currently loaded job are displayed.
6.10 Processing stacks
Condition
■ A stack has been selected.
Risk of collision if the stacking mode is changed in an

NOTICE interrupted program!
Ø Before restarting the program, move the BendMaster man-
ually to a collision-free position (e.g. zero position).
Delete stack Loading or unloading stacks no longer used can be deleted.

Active stacks must first be deactivated before they can be
deleted.
1. Press Process, Delete stack.

or
Ø Press Process, Delete all stacks.
Enabling a stack Empty loading stacks and full unloading stacks are no longer
used by the control because no blanks can be picked up or set
down there. These stack statuses can be changed manually in
the control.
2. Press Process, Lock/unlock stack. The stack mode is
changed:
− At a stack height >0 mm: from L stack empty to L coordi-
nate OK.
− At a stack height >0 mm: from L stack empty to L no
coordinate.
− From A stack full to A stack ready.

Disabling a stack All stacks can be disabled apart from the stack modes L stack
empty, U stack (A stack) full and L no coordinate. The disabled
stacks are no longer used by the control system.
3. Press Process, Lock/unlock stack. The stack mode is
changed:
Changing the stack height The height of a loading stack can be changed manually. Since
the height measurement is a relative measurement between the
BendMaster and the highest blank, there may be minimum devi-
ations to the measured height.
4. Press Process, Change Height.
5. Enter the stack height.
6. Press OK. The height is changed.
If the stack does not have the L height OK status, the stack
mode is accordingly changed:
− From L no coordinate to L height OK.
Note
When the first blank is picked up from a stack in L height
OK stack mode, the BendMaster automatically measures the
height.
Activating/deactivating a Blanks can only be picked up from an active loading stack. Fin-
stack ished parts can only be deposited on an active unloading stack.
Only one loading and unloading stack can be active at a time.
If a loading stack is in L coordinate OK stack mode, sheets can
be picked up, since the BendMaster automatically measures the
height.
7. Press Process, Activate/deactivate. The stack mode changes:
− From L height OK to L stack active.
− From A stack ready to A stack active.
− Or vice versa.
In the standard sequence, the stacks are automatically acti-
vated according to their processing sequence. Manually acti-
vated stacks are processed first completely.
Turning a loading stack 90° This is practical for fine recognition to be able to rotate a sym-
metrical loading stack through 90° (e.g. if the first fine
recognition area of the BendMaster cannot be reached).
8. Press Process, Rotate stack 90°.
Turning a loading stack by x This is practical in order to be able to carry out fine recognition
° rotated at any angle between 0° and 180°.
9. Press Process, Rotate stack by x.
10. In "Parameters," enter the angle by which the loading stack
is to be rotated.

Emptying an unloading To reset the number of parts deposited on an unloading stack to
stack 0 and switch the stack mode back to A stack ready:
11. Press Process, Empty unloading area. The stack is emptied.
or
Ø Press Empty all unloading areas. All stacks are emptied.
Changing the number of The number of blanks in the loading stack or the number of fin-
finished sheets ished parts in the unloading stack can be increased or reduced
by pressing the button once. This is only possible with a loaded
job.
12. Press Sheet, Increment Sheet.
or
Ø Press Sheets, Decrement Sheet.
Note
This change also has an effect on the blank loading or part
depositing process. Note that there is a risk of collision!
Displaying stack details 13. Press Display, Details.
The details on the selected stack are displayed and can be
edited. Grayed out fields cannot be edited.
Name Description
Job Name of the job in which the stack was created.
Range Specifies whether the stack is a loading or unload-
ing stack.
Stack use Stacked = the blanks are picked up as
programmed in TruTops.
Number of layers Number of layers of the stack.
Current number of Number of sheets of sheets in the loading stack.
sheets Calculated on the basis of the stack height. Can be
changed by the thickness of a sheet with Sheet,
Increment Sheet or Sheet, Decrement Sheet.
Quantity intermedi- Number of intermediate layers in the unloading
ate layers stack. Calculated on the basis of the stack height.
Can be changed by the thickness of an intermedi-
ate layer with Sheet, Increment Sheet or Sheet,
Decrement Sheet.
Offset fine recogni- Indication of the offset value when using height
tion 1 compensation during the initial fine recognition proc-
ess.
Offset fine recogni- Indication of the offset value when using height
tion 2 compensation during the second fine recognition
process.
NoteThe height compensation is carried out during
a third fine recognition process, even if the corre-
sponding offset value is not displayed.
Details on the loading stack Tab. 4-20

Name Description
Job Name of the job in which the stack was created.
Range Specifies whether the stack is a loading or unload-
ing stack.
Stack use ■ Stacked = the blanks are picked up as program-
med in TruTops.
■ Box = the finished parts are placed in a box.
Number of layers Number of layers of the stack.
Current number of Number of finished parts in the unloading stack.
sheets Can be changed by a piece with Sheet, Increment
Sheet or Sheet, Decrement Sheet.
Quantity intermedi- Number of intermediate layers in the unloading
ate layers stack.
Max. sheets Maximum number of finished parts which can be
deposited on the unloading stack until A stack full
is established. The maximum number of finished
parts comes from TruTops and depends on the
simulated unloading stack. It can only be reduced,
not increased.
Details on the loading stack Tab. 4-21
Redisplaying the diagram 14. Press Display, Overview to display the graphic again.
Defining the stack The stack processing sequence can be adjusted both for loading
processing sequence and unloading stacks, e.g. when using eccentric grippers. This is
only possible with a loaded job:
Fig. 51855
15. Mark the desired stack under "Loading stack" or "Unloading

stack".
16. Move the marked stack up using ↑ or down using ↓.
The stack at the first position is executed first, the stack at
the second position is executed second, and so on.

17. If the processing sequence has been set, press Adopt.
The stack mode of the stack executed first is changed to L
stack active or A stack active.
Note
Manually activated stacks remain in L stack active or A stack
active stack mode.
6.11 Creating a tooling plan
Checking the TruTops tooling plan
1. In the "Stack layout" mask Press Continue..

or
Ø press >Set up >Tooling plan.
2. Press Setup plan. The setup plan created in TruTops Bend is
displayed:
Fig. 39936
3. Load the bending machine according to the tooling plan.

4. To display the gripper information: press Gripper. The gripper
plan is displayed:
5. To display the parts data: press Parts data drücken. The
data is displayed.
6. To display the original loading positions programmed in Tru-
Tops: press Load/unload. The information is displayed.

Selecting a separation method
1. In the "Tooling plan" mask,Press Continue.

or
Ø press >Set up >Separation method.
Fig. 51856
2. Under "Tool for", select Robot or Regripping station (if pro-

grammed in TruTops).
3. Select "Gripper" for the previously selected tool.
Note
At present, only the gripper used in TruTops can be selected.
4. Set the suction and blow-off times:
− "Timeout suction":
Delay until the vacuum switch is actuated.
− "Blow-off time": period during which the sheet is blasted
when deposited.
− "Blowing clean time":
Period after depositing the blank during which blasting is
continued during the travel motion up to the next interpo-
lation point. This prevents the blank from moving within
the stack or sticking to the gripper. In addition, the vac-
uum system is cleaned.
5. Set "Holder location":

− "No position":
If no gripper is set up, the BendMaster remains in the
current position for loading the gripper.
− "Tool-change height":
If no gripper is set up, the BendMaster moves into the
gripper changing position for loading the gripper.
− "Gripper deposit station":
If the required gripper is at the gripper deposit station,
the BendMaster picks this gripper up from there.
6. Set the "separation method" (sheet separation method used):
− No separation:
No separation is performed.
− Separation at the gripper:
Double sheet separation by activating the AS-i slave at
the gripper (peeling) (see "Tab. 4-22", pg. 4‐86).
− Separation by travel motion:
Double sheet separation by moving the C axis (see "Tab.
4-23", pg. 4‐86).
− Combined separation:
Combination of separation at the gripper and separation
by travel movement (see "Tab. 4-24", pg. 4‐87).
Name Description
Separating time Duration of the peeling movements
Delay time Time between two peeling movements
Cycles Number of peeling movements
Separation at gripper Tab. 4-22
Name Description
Peeling switched off Peeling is switched off
Peeling at close range The peeling movement is performed on the floor
lane side (only in combination with the Offset 1
and Angle 1 settings (see "Fig. 42938", pg.
4‐87)).
Peeling from a dis- The peeling movement is performed on the
tance safety fence side (only in combination with the
Offset 2 and Angle 2 settings (see "Fig. 42938",
pg. 4‐87)).
Peeling all points One peeling movement is performed at close
range and one at a distance.
Separation by moving Tab. 4-23
Name Description
Gripper, then travel First, separation at the gripper, then separation
motion by travel movement
Travel motion, then First, separation by travel movement, then sep-
gripper aration at the gripper

Name Description
Gripper and travel Simultaneous separation at the gripper and by
motion travel motion.
Combined separation Tab. 4-24
1 Offset 2 Bracket
Fig. 42938
7. Set a checkmark at "Fine recognition after separation" if an

additional fine recognition process is to be carried out after
the separation, regardless of the fine recognition set.
8. Set a checkmark at "Separate before measuring" if a peeling
cycle is to be carried out prior to the double sheet measure-
ment.
Note
Only peeling is possible at the gripper. Separation is not pos-
sible at the gripper (see "Tab. 4-23", pg. 4‐86).
Separation is recognized a cycle by the cycle counter.
Selecting double sheet recognition
1. In the "Tooling plan"Press Continue. mask,

or
Ø press >Set up >Separation method.
2. Press Recognition:

Fig. 52488
3. Define the Recognition selection:

− No recognition:
No double sheet recognition is performed. However, a
separation method can be selected which is executed
when picking up a blank, regardless of whether a double
sheet was picked up or not. Likewise, the execution of
the program is continued after the separation cycle.
− Pallet scale:
A double sheet recognition is performed using the pallet
scale. The loading stack must be on the pallet scale. The
separation process is performed according to the set sep-
aration cycle only after recognizing that a double sheet
has been picked up. The execution of the program is
resumed after successfully separating the double sheet.
− Integrated system:
A double sheet recognition is performed with the inte-
grated measurement system. The separation process is
performed according to the set separation cycle only after
recognizing that a double sheet has been picked up. The
execution of the program is resumed after successfully
separating the double sheet.
6.12 Setting bending parameters
Parameters for bending support, backgauge sensor system,

approaching the backgauges and the actuation of the backstop
resistors can be set for every bending step in the bending
parameters.

Note
When a program is run in, the parameters for bending support
and for approaching the backgauges are not yet defined. After
crossing the bend for the first time, the default parameters stored
in the control are entered. Due to the fact that the averaging fil-
ter cannot be adjusted by personnel, this parameter has no
default value even after crossing.
Opening bending parameters
1. On the "Separation method" screenPress Continue.

or
Ø press >Set up >Bending parameters.
Fig. 49448
Note
The Backstop resistor field is displayed only for activated
backstop resistors.
2. Use the following buttons to select the bending which is to
be modified:
Name Description
> Go forward one bending step from current bending
step.
>> Go to last bending step.
< Go back one bending step from current bending step.
<< Go to first bending step.
Tab. 4-25

Selecting bending support
Bending support is the movement of the BendMaster during the

bending process (tracking).
1. Select bending step.

2. Set the "low-pass filter":
− No filter:
During bending, the BendMaster moves exactly according
to the specified TruBend position. In some cases, this
can lead to abrupt BendMaster movements due to the
press beam regulation.
− Low:
The TruBend position settings are filtered somewhat to
ensure that the bending support proceeds less abruptly.
The movement of the BendMaster for moving the bend-
ing part is however slightly delayed in time, which
increases the possibility of a reverse bend on the bend-
ing part.
− Medium:
The TruBend position settings are filtered more strongly.
The bending support is smoothed to a greater extent and
the movements proceed more gently. The delay time of
the BendMaster compared to the bending part becomes
even longer.
− High:
The TruBend position settings are filtered to the maxi-
mum extent. The bending support is smoothed to the
maximum extent. The time delay of the BendMaster com-
pared to the bending part increases significantly. The
possibility of a reverse bend or of the cups being torn off
the sheet increases.
3. Press For all bendings if the settings are to apply to all bend-
ing operations..
Note
The averaging filter cannot be adjusted by personnel.
Setting the backgauge sensor system
The necessary backstop strategy can be set in the "Backgauge

sensor system" field. The default values originate from TruTops
Bend. The press beam is enabled for the bending motion once
the set parameters have been reached.

2. Setting "backgauge sensors":

− Without backgauge:
No sensor system is used.
− Alignment left:
The left backgauge sensor is active in the X direction.
− Alignment right:
The right sensor is active in the X direction.
− Alignment left and right:
Both sensors are active in the X direction.
− Clamp left:
The left sensor is active in the Z direction.
− Clamp right:
The right sensor is active in the Z direction.
− Align and clamp left:
The left and right sensors are active in the X direction.
The left sensor is active in the Z direction.
− Align and clamp right:
The left and right sensors are active in the X direction.
The right sensor is active in the Z direction.
Setting the approach strategy
The travel motion of the press beam during bending in combina-

tion with the search movement of the backgauge is set in the
"Approach strategy" field.

2. Set the "approach strategy":
− Backgauge and Y movement:
Travel motion and search movement run parallel. That is
the fastest method and therefore also the default value.
− Y movement before backgauge:
The travel motion of the press beam is carried out before
the search movement of the backgauge, e.g. when horn
tools are used.
− Backgauge before Y movement:
The search motion of the backgauge is carried out before
the travel motion of the press beam, e.g. for short side
lengths.

Setting the backstop resistor for single
bending operations
Condition
■ Backstop resistors have been activated by the TRUMPF
Service Department.
1. Press >Set up >Bending parameters.

2. Select "Bending number" if the backstop resistor is to be
adjusted for a single bending operation.
3. Select "When stopping" with a checkmark. The backstop
resistor is active while the backgauge approaches its posi-
tion.
or
Ø Select "When moving" with a checkmark. The backstop
resistor is active while the backgauge withdraws from the
workpiece.
4. Enter the strength of the backstop resistor between 0 and
100 %:
− "Left": actuation of the left backstop resistor.
− "Right": actuation of the right backstop resistor.
5. Press For all bendings if the backstop resistor setting is to
be applied for all bending operations in the program.
6.13 Program, loading
Opening the running in program
Conditions
■ The system is ready for operation in automatic mode.
■ BendMaster is ready for operation (the GREEN button was
pressed, and the "BendMaster“ icon is green).
■ No gripper set up.

or
■ The used gripper is set up.
■ Note
It is only checked whether a gripper has been set up at all
and not whether the correct gripper has been set up.
Ø In the "Separation method" mask, press Continue.

or
Ø Press >Setup >Run in.
Fig. 39942
The individual program steps are displayed. The green arrow

indicates the program step currently being executed.
Program steps for running in
Program step Description

SELECT TrumpfRobot Program reserves a robot. The robot can no
longer be used by any other program.
START_ORDER The robot gets ready for processing the
selected job.
CHECK_PRESSTOOL Starts the bending machine and the regripping
station for job processing
CHECK_ROBTOOL Checks whether the robot tool is fitted. The
robot is moved into tool change position if nec-
essary.
LOAD_SHEET Sheet pick-up subroutine.
LOAD_LAYER Intermediate store pick-up subroutine.
EXTERN_VISION_SH External fine recognition subroutine, e.g. at the
EET backlighting table.

Program step Description
BEND_SHEET Sheet bending subroutine.
UNLOAD_SHEET Store part subroutine.
Tab. 4-26
Selecting an execution method
Jobs can be loaded either in continuous operation mode or step-

by-step. Continuous operation is activated by default.
1. To run in the program step-by-step: press Stepping. The cur-

rent program step is displayed on a yellow background:
or
Ø Press Cont to return to continuous operation.
2. Press the green START key on the portable manual control
unit.
Note
When running in step-by-step, each program step must be
started using the green START key on the portable manual
control unit.
3. If a program is to be executed only up to a specific program
point:
− Interrupt the program at the portable manual control unit
using the red STOP key.
− Press Stepping.
− Mark the program point at which the program is to be
interrupted.
− Press Operation, Set Breakpoint.
− Press Operation, Activate/deactivate Breakpoint. The pro-
gram is only interrupted at the breakpoints indicated by
checkmarks.
− If required, press Set PC.
− Press Operation, Go to breakpoint. The program is exe-
cuted up to the active breakpoint.
− Press Operation, Remove all breakpoints to delete all
active breakpoints.
4. To interrupt the running-in process, press the red STOP key
on the portable manual control unit.
Running in procedure
■ The press brake is started.

■ The press program is loaded by the industrial PC.

■ The tools and backgauge of the TruBend are clamped and
positioned.
■ The gripper used is fitted on the BendMaster if it has not
been fitted yet.
■ Either the blank is picked up and transferred to the backlight-
ing table or a fine recognition is performed at the stack.
■ If double sheet recognition was activated, double sheet rec-
ognition and double sheet separation are performed.
■ The bending program is executed.
■ Finished sheets are set down on the unloading stack.
Interpolation points The points within a path that the BendMaster moves along when
approaching and traveling are referred to as calibration points
and programmed in TruToPs. There are two ways of editing such
calibration points:
■ To teach a point: the desired position of the marked point is

approached manually and saved as a new position.
■ To edit a point: the position is changed by changing the coor-
dinates manually in the respective coordinate system. In
addition, the interpolation type, the speed and the overlay
can also be changed if the respective user level is logged
on.
Overlay The path does not always need to be precisely complied with in
some travel motion sections. The cycle time can be reduced by
starting the next path early. This procedure is called overlaying:
P1 Interpolation point 1 (starting 1 Path length between starting

point) point and interpolation point
P2 Interpolation point point 2 (over- 2 Executed path (overlay)
lay point) 3 Path length between interpola-
P3 Interpolation point 3 (end point) tion point and end point
Overlaying calibration point Fig. 45198

The overlay can start at the earliest halfway up the shorter path.
Teaching a point
If the position of a point has to be corrected manually when run-

ning in a part, the point can be taught.
Notes
■ Taught points can not be reversed.
■ The current position of the regripping station is also taught.
1. Interrupt the program at the portable manual control unit

2. Approach the point to be taught step-by-step.
3. Approach the new position manually (make sure the correct
coordinate system is used).
4. Mark the program point to be taught. This program point is
displayed on a yellow background.
5. In the "Run in" mask, press Teach position.
Points, editing
1. Interrupt the program at the portable manual control unit

2. Mark the program point to be edited. It is displayed on a yel-
low background.
3. No.

Fig. 65022
4. Change the desired parameters (only parameters on a white

background can be changed).
Parameter Selection Description

Travel point Number in the program The travel point to be modified can be selected using
the arrow buttons.
Interpolation type LIN ■ Cartesian path.
■ The position is moved along a path.
■ The speed of the tool center point remains constant.
PTP ■ Point-to-point path.
■ The movement from the starting position to the end
position is as quick as possible, regardless of the
path.
■ No linear movement of the tool center point.
Speed Slow 20% of the max. speed
Reduced 30% of the max. speed
Medium 50% of the max. speed
Fast 75% of the max. speed
Maximum Maximum speed
User defined Entry in % of the maximum value

Parameter Selection Description
Overlay type Exact Point is approached exactly on the calculated path.
Length The overlay starts at one of the shorter path lengths
according to the stored radius of the programmed inter-
polation point (see "Fig. 45198", pg. 4‐95).
Percent The overlay starts at a percentage of the shorter path
length stored according to the size (see "Fig. 45198",
pg. 4‐95)).
Speed For TRUMPF Service only.
Overlay size Fine For Percent: 10%
At length of 3 mm
Reduced At percentage of 20%
At length of 20 mm
Medium For Percent: 40%
At length of 80 mm
Large At percentage of 70%
At length of 200 mm
Maximum Maximum possible position
At length of 600 mm
Position robot mPos[0] First coordinate axis in the right-hand (standard) coordi-
nate system
mPos[1] Second coordinate axis in the right-hand (standard)
coordinate system
mPos[2] Third coordinate axis in the right-hand (standard) coor-
dinate system
Position regripping station Z3 Position of the left regripping station
Z4 Position of the right regripping station
Pickup Gripper monitoring Starting with software V7.0, the linear axis and the
turning axis can be moved at the same time, both
travel motions must therefore be monitored.
Monitoring is programmed by TruTops Bend by default.
Tab. 4-27
5. Press OK.
The modifications are accepted.
Setting the main run indicator manually
The green arrow (main run indicator) indicates the current execu-
tion status of the automatic program. It can be set manually by
the operator.
When the automatic program is restarted, it is resumed at the
new position of the main run indicator. This point is approached
directly by the BendMaster.

Risk of collision when approaching the desired position!
NOTICE
Ø Watch out for possible collisions when approaching the
respective position after setting the main run indicator.
Ø Reduce the speed, if necessary.
1. To interrupt the program, press the red STOP key on the

portable manual control unit.
2. Mark the program line where the main run indicator is to be
set.
3. Select Operation, Set PC:
Fig. 39943
4. Press the green START key on the portable manual control

unit.
The automatic program is resumed at the marked line.
Deleting a point
Note
Program steps can be deleted only during step-by-step opera-
tion.
Program steps that have been deleted cannot be restored.
1. Press the red STOP key on the portable manual control unit.
2. Press Operation, Delete.
The marked point is deleted.

Displaying axis positions
1. Press View, Positions. The axis positions are displayed in the

selected displayed coordinate system.
2. Press View, Show none. Displaying the axis positions is
deactivated again.
6.14 Starting a run-in program
Conditions
■ Loading and unloading stacks have not been changed since
the Run in.
■ The setup plan of the TruBend, including the regripping sta-
tion, has not been changed since the run in.
■ The correct gripper is loaded at the BendMaster.
■ The program has been run in.
Opening and starting the 1. Press >Set up >Job:

program 2. Select the job to be executed in the "Selected Order" list.
The selected job is opened and graphically displayed. Now it
can be further processed.
Tip
If the job is clicked on again, it is closed.
3. Press PositionAutomatic:

Fig. 40877
4. Press Start in the "Program" field. The job under the job
name is started.
The active execution of a job is indicated by the green light
of the signal lamp on the safety fencing.
5. Press Stop in the "Program" field if the execution of the job
is to be interrupted immediately.
6. Press Resume in the "Program" field if the interrupted job is
to be further executed.
Advance warning, number of The number of blanks on the loading stack, below which a warn-
blanks below minimum on ing information is issued, can be programmed.
loading stack
7. Enter the corresponding quantity in the "Advance Warning
Sheets Load".
Starting with this number, the text "Advance warning Sheets
Load" will be displayed in red. At the same time, the white
signal lamp on the safety fencing is switched on.
Advance warning, free The number of available free deposit places below which a warn-
deposit places below ing information is issued, can be programmed.
minimum
8. Enter the corresponding quantity in the "Advance Warning
Sheets Deposit" field.
Starting with this number, the text "Advance warning Sheets
Deposit" will be displayed in red. At the same time, the white
signal lamp on the safety fencing is switched on.
Having the axis position 9. Press Position.
displayed 10. Press Stack(see "Defining stacks", pg. 4‐78).
Switching to "Stack
11. Press Messages.
assignment"
Switching to "Diagnostics" 12. Press Source text(see "Program, loading", pg. 4‐92).
Switching to "Run in" 13. Press Empty unloading area.
Emptying an unloading
stack

6.15 Production planning
There are three levels in the production planning of the Bend-

Master:
■ Production lists.
A production list may consist of production packages and
jobs. It may contain a maximum of 10 elements.
If no loading or unloading stack is available, then the execu-
tion of the production plan is continued with the next job, pro-
duction package or production list.
■ Production packages.
A production package may consist of one or more jobs. A
production package may contain a maximum of 10 jobs.
If no loading or unloading stack is available, then the execu-
tion of the job is completely stopped.
A number of repetitions can be programmed for the entire
production package.
■ Jobs.
A job contains one bending part and the quantity as to how
often it is to be produced. In addition, the speed can also be
set.
Creating or modifying a production plan
Conditions
■ It must be possible to use the tool setup plan for TruBend
and the regripping station for all jobs within the production
package.
■ The required grippers are in the gripper deposits.
■ All jobs of the production package have been retracted.
Opening a production plan 1. Select >Position >Production plan:
Tip
Press >> or << to show or hide the tabs on the right-hand
side.
2. Select "Production list" to create or open a production list.
or
Ø Select "Packages" to create or open a production pack-
age.
Create production package 3. Press .
or production list 4. Enter the name of the production list or production package
under "Parameter".
Open production package or 5. Mark the desired production package or production list.
production list

6. Press .
The selected element is opened and displayed in the window
on the left.
Adding elements to the 7. In the window on the right, mark the desired production
production plan packages or jobs.
Fig. 59281
8. Press <. The marked element is added to the production

plan on the left.
Tip
The Update button can be used to update the list of availa-
ble jobs.
9. Press Save to save the production plan.
Remove elements from the 10. Highlight the desired element in the window on the left.
production plan 11. Press >. The marked element is removed from the produc-
tion plan on the left.
Modifying the sequence of 12. Highlight the element to be modified in the production plan.
the elements 13. Press ⇑ to move the element up.
or
Ø Press ⇓ to move the element down.
Deleting an element 14. Highlight the desired element in the window on the right.
completely 15. Press . The marked element is removed from the pro-
duction plan on the left.
Setting the speed and required number
1. Open "Jobs", "Packages" or "Production lists" in the window

on the right.

2. Click on the "Required" field of the desired element in the
production plan on the left.
3. Enter how frequently the element is to be produced.
4. Click on the "Override" field of the desired job in the produc-
tion plan on the left.
5. Enter the speed in [%] at which the job is to be produced.
6. Press Apply. The settings are transferred to the control.
The following statuses can be displayed in the "Status" field:
− : No data available in the control.
− : The data was transferred to the control.
7. Press Save. The elements are saved to the production plan.
Executing the production plan
Both single production packages and complete production lists

can be processed.
1. Mark the production list, production package or job in the

window on the left.
2. Press Save.
3. Press Apply.
4. According to the selected element, press Check job, Check
package or Check job list.
A check is made to determine whether all start requirements
have been fulfilled.
− The loading and unloading stacks are available.
− The required grippers are available.
− The job has been run in.
If all requirements are fulfilled, the status changes to ready.
Possible status messages:
− : Job/package/list ready.
− Job/package/list cannot be run.
5. Press Start production plan. The production plan is executed.
− : Execution of job/package/list in progress.
− Execution of job/package/list has ended.
6. Press Stop production plan. Start production plan is stopped.
− : Job is interrupted.
− : No loading or unloading stack available.

6.16 Connection to storage (option)
The TruBend Cell 5000 can be linked to a storage system.

The stack positions must be booked correctly in the warehouse
management software, (e. g. TruTops Fab). The image recogni-
tion alone is not sufficient.
Parts automatically requested from the storage system by the
BendMaster may be set down on the storage pallet only as indi-
vidual stacks . The stack must not include any parts of a differ-
ent job.
The operator must observe the following:

■ The BendMaster must not collide with neighboring stacks on
the storage pallet when picking up a part.
■ The stack height must not exceed the permissible maximum
value when returning processed parts to storage.
Defining parts data
1. Press >Set up >Job menu.

2. Enter the "parameters", "lot size" etc.
3. Press Parts data.
4. In the drop-down menu, press Unprocessed material, Fin-
ished part or, if available, Intermediate layer part.
The selected parts data is displayed and can be entered
(see "Tab. 4-9", pg. 4‐55), (see "Tab. 4-10", pg. 4‐55), (see
"Tab. 4-9", pg. 4‐55).
■ The material designation must be known to the storage
management.
■ Observe that the entries are case sensitive.
Defining loading and unloading areas of

1. Press >Set up >Areas menu.

2. Define the loading and unloading areas. The control sends
the entries directly to the storage management program:

Area type Description
Load Search exact If programmed, the BendMaster directly performs the fine recognition proc-
ess and picks up the parts.
The BendMaster obtains the information about the position, orientation and
height of the stacks from the storage management software.
Load Search automatic At the beginning of each stack, a coarse and then a fine recognition proc-
ess are automatically performed and then the stack is completely exe-
cuted.
Load Search Manual The operator performs the rough recognition process manually.
Intermediate layer search exact If present, the BendMaster directly picks up an intermediate layer.
The BendMaster obtains the information about the position, orientation and
height of the stacks from the storage management software.
Intermediate layer search automatic If present, a rough recognition process is performed at the beginning of
each intermediate layer stack and the stack is then completely executed.
Intermediate layer search manual The operator performs the rough recognition process manually.
Area types, receiver Tab. 4-28
Moving a storage cart manually
1. Move the BendMaster into the parking position.

2. Open the lift gate at the lift gate control.
3. Move the storage cart manually using the control panel of
the storage control system.
Moving the BendMaster semi-automatically
Conditions
■ The >Set up >Areas menu is open.
Selecting the storage station 1. Press Display, Details.

2. Select a storage station from the drop-down menu.

Fig. 61853
3. Remove the checkmark from "Activate/deactivate automatic

mode".
4. Press the desired sequence.
Requesting material 5. Enter the desired material ID. This entry is case sensitive.
The material ID must be known to the storage management
software.
Sequence
− Request material.
− BendMaster automatically moves into parking position.
− The lift gate opens.
− The storage cart enters with the requested material.
− The lift gate closes.
Requesting a pallet 6. Enter the desired pallet ID. This entry is case sensitive.
The pallet ID must be know to the storage management soft-
ware.
Sequence
− Request a pallet.
− The storage cart enters with the requested pallet.
Requesting an empty pallet 7. Enter the desired pallet ID. This entry is case sensitive.
− The pallet ID must be know to the storage management
software.
− By default, the SPmI pallet type is defined as an empty
pallet in the storage management program.
Sequence
− Request an empty pallet.

− The storage cart enters with the requested pallet.
Checking the stock 8. Press Check inventory. All available stocks are displayed.
Returning to storage 9. Press Store back-up. The pallet at the BendMaster storage
station returns to the storage system.
Sequence
− The storage cart departs with the pallet.
Aborting the travel to 10. Press Abort.
storage
All positions are deleted in the control.
11. Re-book all positions by means of a manual travel to stor-
age.
Moving a storage cart in automatic mode
Optionally, single jobs (single order operation) or entire produc-

tion plans with store connection can be executed automatically
(see "Production planning", pg. 4‐102).
If a job or production plan is started, the control checks whether
the required raw material is in the production cell.
The control also checks whether the finished parts are to be
booked to the storage system. An empty pallet is requested from
the storage system if necessary.
Sequence ■ The storage control is notified about the activated travel

order.
■ The BendMaster moves into parking position.
■ The storage pallet is reserved by the storage system.
■ The BendMaster releases the pallet.
■ The storage system disables the pallet and sends the "Open
gate" request.
■ The BendMaster control opens the lift gate. The pallet is
moved into or out of the production cell.
■ The gate is closed.
■ The storage system releases the pallet again.

Conditions
■ The >Set up >Areas menu is open.
Selecting the storage station 1. Press Display, Details.

2. Select a storage station from the drop-down menu.
3. Set the checkmark at "Activate/deactivate automatic mode".
All storage trips are performed automatically as programmed
in TruTops Bend.

7. Working at the press brake without
BendMaster
7.1 Working at the press brake without

BendMaster
Conditions
■ BendMaster and TruBend have been switched on.
■ Working at the press brake without BendMaster
■ All EMERGENCY STOPs are released.
■ 6-axis-sensor fingers fixated.
1. Use the "Robot in parking position" travel function to move

the BendMaster into the parking position in manual or auto-
matic mode (see "Executing travel functions", pg. 4‐48).
2. Switch from BendMaster operating mode to TruBend operat-
ing mode manually.
The covering of the floor lane is not designed for standing

NOTICE on or storing parts on it!
Damage to the floor lane.
Ø Do not step on the covering.
Ø Do not deposit any workpieces on the covering.
3. Close all safety doors if the operator is inside the bending

cell.
4. Activate the catch with the green button on post 1.
5. Operate the TruBend manually (refer to the "TruBend opera-
tor's manual").
6. Deactivate the catch with the red button on post 1 if neces-
sary:
Ø Press the red button on the control panel.
or
Ø Press the EMERGENCY STOP impact button.
Exceptions: The two EMERGENCY STOP impact buttons
on the TruBend control and control panel and the fully
pressed foot switch at the control panel. (In this case the
system stops, but the catch remains active.
4‐110 Working at the press brake without BendMaster 2015-06-01 B579EN

8. Errors and Messages
All errors and messages are stored in the control of the Bend-
Master. They can be called up in the >Diagnostics menu.
8.1 Displaying and acknowledging errors

and messages
Show Both the red LED on the portable manual control unit and the
red signal lamp on the safety fencing will go on if there is an
error at the BendMaster.
1. Press >Diagnostics >Existing messages.
Fig. 39953
2. Press Alarms, Errors/messages to display each message

type individually.
3. Press Alarms, All to display all messages.
Acknowledge 4. Mark the message to be acknowledged.
5. Press Acknowledge.
8.2 Troubleshoot an error
1. Mark the error message to be acknowledged by pressing it

(it is displayed in the footer).
2. Press Cause to display the possible error cause.
B579EN 2015-06-01 Errors and Messages 4‐111

3. Press Effect to display the possible effects of the error.
4. Eliminate the cause of the error or the message.
5. Acknowledging faults.
4‐112 Errors and Messages 2015-06-01 B579EN

9. Error handling
9.1 Jumpering the sensor finger
The sensor finger can be jumpered if the error message "Maxi-

mum correction distance in X direction or Z direction achieved"
appears.
1. Confirm the operation message "Align sheet manually or

teach position" with OK.
2. Press >Diagnostics >Existing messages.
3. Press >Press >Sensors for press:
Fig. 43889
4. PressIn Pos.. The sensor gauge fingers are bypassed. The

error message is acknowledged automatically.
5. Press the green START button on the portable manual con-
trol unit. The execution of the program is resumed.
9.2 Image processing diagnostics
Basics Two CCD cameras (Charge Coupled Device) are used for rough
and fine recognition. This type of camera has a surface with ele-
ments that convert light energy into electrical energy.
The electrical energy is sent as an analog signal to the input of
the image processing card via a cable. An analog-digital con-
verter converts the signal into a machine-readable form. Thus
the image of the part lying under the camera is created in the
memory.
B579EN 2015-06-01 Error handling 4‐113

The gray value of an image point (image point = pixel) can
assume values between 0 and 255:
■ 0: black
■ 255: white
Surfaces that are very bright under the camera have high gray
values and surfaces that are dark have lower gray values:
A Actual light conditions under the camera (=part) B Digital image with gray scale values
Fig. 51547
The cameras can be used within an light wavelength range of

400 - 1000 nm (visible range: 380 nm/blue – -760 nm/red).
Rough position The aim of the approximate position is to define the position of
the individual part stacks. This is done with the coarse position
recognition process and the camera pictures used for this pur-
pose.
The image section of the camera for the approximate position is
about 0.9 m x 0.6 m. In order for the area defined by the opera-
tor to be covered nevertheless, this area is divided into n over-
lapping segments. Individual pictures are taken from all seg-
ments and subsequently joined to form an image of the approxi-
mate position in the PC.
4‐114 Error handling 2015-06-01 B579EN

1 Two individual images 2 Composite image of the approximate position
Fig. 52326
Fine position Four pictures are always taken to record the precise position. A
new image is created by placing the four individual images on
top of each other.
The images are always recorded at a distance of 333 mm (dis-
tance between the sheet surface and upper edge of covering
hood) to ensure the precise position recognition takes effect.
Four flashes, which are activated separately, are used to record
the fine position image. They are arranged at an angle of 90° to
each other and, in this way, allow the parts to be illuminated
from all sides in order to create the shadows required at the
edges of the parts.
The individual images are placed on top of each other (precise
to the pixel) in order to retain the dark shadows and reduce the
light reflexes or eliminate them entirely:

1 Four individual images 2 Overlaid overall image
Fig. 52327
It is essential here that the created image is of good quality, as

the following layer recognition process relies on this. A good
image quality is indicated by the fact that the edges of the parts
are clearly identifiable in the recorded image:
Precise position recording of good quality Fig. 52328

Precise position recording of insufficient quality Fig. 52329
CAD data import CAD data is used to generate the position recognition models.
These CAD data contains both a reference point and the contour
information to be searched for in the recorded image.
The reference point defines two things:
■ The position resulting from the position recognition process.

■ The current position of metal.
Since the model is used for position recognition in the recorded
images, the contour of the CAD data must match the contour of
the parts to be identified as precisely as possible.
Fine position model from CAD data Fig. 51858
Position recognition There is a position recognition program that can be used both
for the rough and fine position processes. This program cannot
only define the X/Y position, but also the rotation and change in
size.

Depending on the recorded image, the program provides a num-
ber of valid results (0-99) which are sorted according to their
quality. The better the contours found in the recorded image cor-
respond to the fine position model from the CAD data, the higher
the quality.
Tip
The quality of the results can be seen in the image of the fine
position model:
■ Green lines indicate that the program has found the contour
of the fine position model at this point in the recorded image.
■ Red lines indicate that the contour has not been found.
■ Yellow lines indicate that the contour has been partially
found.
Fig. 52330
The result of best quality can always be referred to in the

approximate position recognition process.
This does not necessarily have to be the case with fine recogni-
tion. If the fine recognition window is an outer contour, the high-
est part may not necessarily be the best result. That is why in
this case the search results are still sorted according to their
position.

1 Search results 2 Sorting by position (the innermost blank is selected)
Fine position recognition with open outer contour Fig. 52331
Note
Flaws on the surface, such as scratches or printed films, have a
greater influence when sorting by position than when sorting by
quality.
If the fine recognition window only contains closed inner con-

tours, the best result can always be applied. If parts on the stack
are then displaced, the parts further down are concealed.
Examples for sorting by quality with sheet stacks with inner contours Fig. 52333
Opening the diagnostics tool
Vision Diagnostics can be used for both the rough and fine posi-
tion recognition. The program runs on the visual PC and estab-
lishes an Ethernet connection to the control computer.The results

of the rough and fine position recognition processes are dis-
played and can be edited.

2. Press TRUMPF Logo at the TOS user interface.
3. Press MMI.
4. Press BV diagnostics. The "Vision Diagnostics" tool is
started.
or
Ø If the diagnostics tool is already open, press <Alt>+<Tab>
to switch to "Vision Diagnostics".
5. Press . The recording is made.

Recording with Vision Diagnostics
Fig. 54846
Name Description
Disconnect Terminates the connection to the image processing application or re-establishes the
connection if it was previously interrupted.
"Status" The Vision Diagnostics status is displayed:
■ "Disconnected": no connection to the image processing software. The search
results are not displayed in the diagnostic program.
■ "Edit mode": "Run mode" is not active. Parameters can be changed.
■ "Run mode": "Run mode" is active. The saved parameters are applied for the
position recognition process.
"Zoom" If selected, the Zoom function can be used to zoom into the recorded image.
"Foreground" If checked, Vision Diagnostics always remains in the foreground.

Name Description
"Run mode" Various parameters, which can influence the position recognition results, are saved
for each position recognition model (e.g. "Contrast" or "Acceptance").
■ These parameters cannot be changed if "Run mode" is active.
■ If "Run mode" is deactivated, position recognition is not possible. However, the
parameters can be modified (e.g. "Acceptance" or "Contrast").
Search Starts a manual search with the set parameters on the current image recording.
The results are graphically displayed and the quality and contrast are shown in the
"Position recognition results" field.
Image recording Starts manual image recording with the parameters entered in "Image recording set-
tings".
Create model The search contour programmed in TruTops Bend is displayed in the original state
and in yellow. It can be modified if required:
■ Press Yes to use the contour (is then displayed in green).
■ Press No if you do not want to use the contour (is then displayed in red).
■ Press Cancel to cancel contour processing.
Tip
The omission of CAD data may be a practical option if, for example, bore holes
in the model are of a different size than in the actual part.
Note
No closed contour may be interrupted by omitting elements.
Save settings Saves the user-defined settings for the currently loaded position recognition model.
The saved settings are available again if this model is reloaded for the next position
recognition process.
If the "Use Pattern Settings" is selected, the saved settings are used.
"Position recognition The search results are displayed.
results"
"Quality" Displays the quality of the results of the last position recognition process.
Note
To ensure sufficient process reliability, this result should be on average approx. 10%
above the nominal value set in Acceptance.
"Contrast" Specifies the contrast in percent at which the position recognition process is only
just accepted in order to obtain valid results. 100% contrast: maximum contrast.
Black pixels on white pixels.
■ Typical fine position values: 20 - 50.
■ Typical approximate position values: 10 - 30.
"Results" ■ Shows the number of results found
"Index" If a position recognition process provides several results, all results can be
displayed one after another with "Index". The result with index 0 is used.
+ shows the next result.
- shows the previous result.
Note
The fine recognition results are already sorted by the method set (quality or posi-
tion).
'c:\control\application\ Currently loaded search contour.
TeachTalk\...'
"Position recognition set- Parameters for position recognition can be set.
tings"

Name Description
"Predefined settings" The "Predefined settings" drop-down menu contains four preset parameter blocks
which make it easier to edit parameters and contain the position recognition param-
eters for the corresponding contours.
■ Simple contour: Parameters for a simple contour.
■ Average contour: Parameters for more complex contours.
■ Complex contour: Parameters for highly complex contours.
■ Inner contour: Parameters for closed inner contours.
"Acceptance" Specifies the quality in percent at which position recognition is only just accepted in
order to obtain valid results. 100% quality: the entire model contour was found in
the camera image.
"Accuracy" Specifies to what degree the image data are compressed during the position recog-
nition process. Higher values speed up the position recognition process, lower val-
ues slow it down.
If, for example, low sheet thicknesses with narrow edges are to be identified, a
smaller value must be selected.
"Contrast" Displays the contrast in the last position recognition result.
"Elasticity" Specifies by how many the pixels the actual contour may vary at the most from the
required contour of the model to obtain a valid result.
Deviations which affect the quality can be caused by influences, such as machining
tolerances, burrs on edges, working distances etc.
"Ignore Polarity" During position recognition, it is always assumed that the part in the camera image
is bright and the background is dark (shadows). If that is not the case "Ignore Polar-
ity" must be selected.
Tip
If the polarity of the edges is partially not constant, e. g. in the event of complex
contours or problematic surfaces, "Ignore Polarity" must be activated. This is not
necessary in the case of very simple contours (e.g. angles between two lines).
"Sort by position" If activated, the results are sorted according to their position, not their size, during
the fine position recognition process.
"Rough recognition" Display whether the loaded search contour has rough recognition.
"Fine recognition" Display whether the loaded search contour has a fine recognition.
"Image recording settings" Parameters for image recording can be set.
"Surface" The "Surface" drop-down menu contains four preset parameter blocks that can be
used for image recording in case of blanks with different surface properties.
Note
A change in the parameter block has an effect only if a new image recording has
been made.
■ Opaque: Parameters for an opaque surface.
■ Average: Parameters for a slightly glossy surface.
■ Reflecting: Parameters for reflecting surfaces.
■ Mirroring: Parameters for mirroring surfaces.
"Exposure time" Manual setting of the exposure time for snapshots.
■ 0: Low exposure time.
■ 30: Maximum exposure time.

Name Description
"Amplification" Setting for the amplification of the contrast in the entire image.
■ 0: No amplification.
■ 5: Maximum amplification.
"Minimum" The entire image is generated from the minimum value of the pixels of the four
snapshots.
"Average" The entire image is generated from the average of the pixels of the four snapshots.
Tab. 4-29
Summary of the position recognition parameters according to the

type of contour:
■ ↑: Increase value..
■ ↓: Reduce value.
■ -: Do not change value.
■ 0: Do not activate.
■ X: Activate.
■ 0/X: Both options.
Simple contour Average contour Complex contour Inner contour

Acceptance - - - -
Elasticity - - - -
Polarity, ignoring 0 0/X 0/X X
Sorting according X X X 0
to position
Tab. 4-30
In principle the following applies:
Position recognition Position recognition

more tolerant less tolerant
Acceptance - -
Elasticity - -
Polarity, ignoring X 0
Tab. 4-31
Saving the image recorded last
If an image could not be recorded successfully, the image

recorded last for the selected job can be saved for the TRUMPF
Service department or development department for teleservice.
Note
An image recording can only be saved when a job is loaded.

1. >Diagnostics menu, press "BV diagnostics".
2. Press Save CDB to save the image last recorded of the
selected job.
3. Decide whether the fine or coarse exposure is to be saved.
Restarting the program
1. >Diagnostics menu, press BV diagnostics.

2. Press BV restart. The image processing software is restarted.
9.3 Teleservice

2. Press MMI.
3. Press Teleservice. The following window opens after a short
while:
Fig. 40876
A TRUMPF service engineer can now dial into the BendMas-

ter via teleservice.

10. Solving problems and
troubleshooting
Problems which occur frequently during the fine position recogni-

tion process are described and possible solutions illustrated by
means of examples in the following sections.
First check The following things must always be checked first if problems
occur regarding the fine position recognition:
■ Correct position of the BendMaster when recording the
image.
■ The entire selected search contour is on the recorded image.
■ The distance between the sheet surface and the upper edge
of the BendMaster's covering hood is exactly 333 mm when
recording the image.
■ Good quality of the recorded image; all edges of the part are
easily identifiable.
10.1 Problem: no part recognized
Error description There are no results from the position recognition process:
No position recognition results Fig. 52490
4‐126 Solving problems and troubleshooting 2015-06-01 B579EN

Reason The program could not find any results of sufficient quality, in
other words, there are no results of quality higher than the
threshold value of 80% set in "Accept".
Solution: no part identified
Increase the position recognition tolerance (two options):
1. Set Pre-defined settings to Complex contour.

The "elasticity"is increased and the "acceptance" threshold is
reduced.
The part position is recognized with a "quality" of 89 %:
Position recognition by "complex contour" Fig. 52491
2. Select "Ignore Polarity".
B579EN 2015-06-01 Solving problems and troubleshooting 4‐127

Position recognition by "Ignore Polarity" Fig. 52492
10.2 Problem: Part underneath detected
Error description Not the highest part, but a part below it is identified:

The part below it was identified. Fig. 52493
Reason The program could not find any results of sufficient quality for
the highest part with an "acceptance" of >80 %. The part under-
neath it was found with sufficient quality.
Solution: part underneath detected
Increase the position recognition tolerance:
Ø Increase the "elasticity" to 2.0.

Position recognition by increasing the "Elasticity" to 2.0 Fig. 52494
10.3 Problem: part interference contour

recognized
Error description An existing interference contour on the surface of the part, not
the part itself, is recognized:

Interference contour (scratch) has been recognized Fig. 52495
Reason The interference contour looks like the contour searched for and
is identified with a quality of 92%. Since the results for outer
contours have to be sorted by their position (see "Fig. 52331",
pg. 4‐119), the innermost result, in this case the scratch on the
blank, is always selected.
Solution: interference contour recognized
Reduce the position recognition tolerance.
Ø Set "Predefined settings" to Simple Contour to reduce the

"elasticity" and increase the "acceptance" threshold.

The position of the topmost part is recognized with a quality
of 99%. The scratch is no longer recognized:
The highest part was identified Fig. 52496

Chapter 5
Maintenance (customer)
1 General guidelines 5‐3
2 Maintenance Overview 5‐5
3 Lubrication 5‐6
3.1 Overview 5‐6
BendMaster: Z slide 5‐7
Regripping station (option) 5‐8
4 Mechanical elements 5‐10

Safety fencing 5‐10
Lift gate 5‐10
Transport equipment (option): transport 5‐11
belt
BendMaster: Z axis 5‐11
Regripping station 5‐12
B579EN 2015-06-01 Maintenance (customer) 5‐1

Sheet removal station 5‐13
Press brake: sensor gauge finger 5‐13
Gripper changing console (option) 5‐14
BendMaster: pivoted-jaw gripper (option) 5‐15
5 Electrical components 5‐16

5.1 Overview 5‐16
BendMaster: control cabinet 5‐17
BendMaster: switch cabinet 5‐18
BendMaster: fan in the C arm 5‐20
BendMaster: fan, Z slide 5‐21
6 Optical components 5‐22

6.1 Overview 5‐22
BendMaster: sheet sensor 5‐22
7 Pneumatic components 5‐24

Press brake: compressed air supply 5‐24
5‐2 Maintenance (customer) 2015-06-01 B579EN

1. General guidelines
Correct maintenance is essential for maintaining the quality of

the machine. It prevents operational malfunctions and their con-
sequences.
Risk of fatal injury during maintenance work with the

DANGER machine switched on!
Ø Unless expressly stated otherwise: Shut down the machine
properly, secure the MAIN SWITCH and secure with a pad-
lock.
Ø Strictly observe the safety regulations.
Notes on cleaning ■ Clean the entire machine at regular intervals.

■ Brush off large elements of dirt and dust or remove them
using an industrial vacuum cleaner.
■ Clean polycarbonate panes only with an antistatic plastic
cleaning agent (mat. no. 1672922).
Notes on lubrication Refer to the lubrication chart and maintenance instructions for
the lubrication of the machine. The following points should also
be observed:
■ Use only lint-free cleaning cloths and low-viscosity spindle oil
("scavenge oil") to clean lubricating points. Do not use clean-
ing wool, kerosene or benzene.
■ Do not mix synthetic lubricating oils with mineral oils or syn-
thetic oils from other manufacturers, even if the synthetic oil
in question has equivalent properties.
■ Dispose of waste oil appropriately.
Stiff safety fencing doors due to lubrication of the roller

NOTICE guides.
Lubricating grease attracts dirt.
Ø Do not lubricate the roller guides on the safety fencing
doors.
Ø Readjust the safety fencing doors if the roller guides should
be stiff.
Qualifications of All maintenance work may only be performed by persons who

maintenance personnel have been trained for the maintenance work described and who
have acquired the relevant knowledge.
Certain types of maintenance work (e.g. in the switch cabinet)
require, in addition to the above-mentioned qualifications, com-
plete professional training or advanced training in electrical engi-
neering. Furthermore these specialists require authorization to do
electrical work on this system (Germany: electrician for defined
B579EN 2015-06-01 General guidelines 5‐3

tasks in accordance with DGUV Vorschrift 3, previous number
was: BGV A3).
Furthermore, the regulations of the relevant country are also
applicable.
5‐4 General guidelines 2015-06-01 B579EN

2. Maintenance Overview
Interval/ Maintenance point Maintenance work Page

operating
hours
1000 BendMaster: Z slide Lubricating the linear guides 5‐7
1000 BendMaster: control cabinet Cleaning or changing filter 5‐17
1000 BendMaster: switch cabinet Clean the Peltier cooler 5‐18
1000 BendMaster: fan in the C arm Cleaning the fan 5‐20
Weekly Sheet removal station Checking and cleaning the sheet removal 5‐13
station
Weekly BendMaster: pivoted-jaw gripper (option) Performing a visual inspection 5‐15
Weekly BendMaster: pivoted-jaw gripper (option) Check the opening and closing speed. 5‐15
Every 6 Regripping station (option) Lubricating the linear guides 5‐8
months
Every 6 Regripping station (option) Checking and lubricating the rack 5‐9
months
Every 6 Safety fencing Checking polycarbonate windows for dam- 5‐10
months age
Every 6 Safety fencing Cleaning the polycarbonate panes 5‐10
months
Every 6 Lift gate Checking the lift gate without store inter- 5‐10
months face
Every 6 Lift gate Checking the lift gate with store interface 5‐10
months
Every 6 Transport equipment (option): transport Checking the conveyor belt 5‐11
months belt
Every 6 BendMaster: Z axis Checking the toothed belt 5‐11
months
Every 6 Press brake: sensor gauge finger Performing a visual and functional test 5‐13
months
Every 6 Gripper changing console (option) Performing a visual inspection 5‐14
months
Every 6 Gripper changing console (option) Checking the limit switch 5‐14
months
Annually Press brake: compressed air supply Checking the audible compressed air 5‐24
monitoring
As needed Regripping station Cleaning or replacing the muffler 5‐12
As needed BendMaster: fan, Z slide Function test 5‐21
As needed BendMaster: sheet sensor Clean the glass pane 5‐22
B579EN 2015-06-01 Maintenance Overview 5‐5

3. Lubrication
3.1 Overview
1 Linear bearing on the other regripping station 2 Linear bearing at the Z-slide guide carriage
Fig. 71106
Maintenance interval
Read the maintenance instructions
Lubricate with a grease gun
Tab. 5-1
5‐6 Lubrication 2015-06-01 B579EN

Note
Approved lubrication agents of the same quality from other man-
ufacturers can also be used. However, different types of oil may
not be mixed.
Lubrication point Quantity Recommended lubricants Identifica- Viscosity,

tion consis-
tency
BendMaster: Z slide - Castrol LMX KP2N-30 NLGI 2
Regripping station: linear bearings (Material no. 0817798)
at Z3 and Z4
Arm 1 counterweight
Arm 2 counterweight
Regripping station: rack - INNOTEC Ceramic Grease Spray KP2N-30 NLGI 2
(Material no. 0816642)
Lubricants Tab. 5-2
3.2 Maintenance Instructions
BendMaster: Z slide
(see "Overview", pg. 5‐6)
106420: Maintenance interval: 1000 operating hours

Lubricating the linear guides
1. Move the BendMaster into home position.
Collision with sheet stacks.

NOTICE
Ø When moving the BendMaster in Z direction, pay attention
to the existing sheet stack.
2. Manually move the BendMaster in such a way that the

grease nipples of the Z-slide linear guides can be accessed
through the openings in the cover of the floor lane.
B579EN 2015-06-01 Lubrication 5‐7

1 Grease nipple in the opening
Fig. 71108
3. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
4. Lubricate the grease nipples of all four linear guides with the
grease gun.
Regripping station (option)
106421: Maintenance interval: Every 6 months

Lubricating the linear guides
1. Release gripper.
4. Lubricate the grease nipples of all four linear bearings with
the grease gun.
5‐8 Lubrication 2015-06-01 B579EN

1 Grease nipples
Grease nipple at the regripping station Fig. 71107

Checking and lubricating the
rack
2. Check the rack for damage.
3. In case necessary, lubricate the rack.
B579EN 2015-06-01 Lubrication 5‐9

4. Mechanical elements
Safety fencing

Checking polycarbonate
windows for damage
Ø Check polycarbonate windows for damage. In case neces-
sary: request Technical Service.

Cleaning the polycarbonate
panes
Means, Tools, Materials
■ Anti static plastic cleaner (mat. no. 1672922).
Ø Clean the polycarbonate panes with anti-static plastic cleaner.
Lift gate

Checking the lift gate
without store interface
No maintenance work is required on any of the guide elements
(guide carriage and guide rail; toothed wheel and rack)
1. Check the lift gate for damage.

2. Manually open the lift gate in manual mode.
3. Check the control unit of the lift gate of the upper end posi-
tion. Correct display: ¯.Eo¯.
4. Manually close the lift gate in manual mode.
5. Check the safety bar for proper function. The lift gate has to
open itself again.
7. Check the control unit of the lift gate of the lower end posi-
tion. Correct display: _.Eu_.
8. Carry out steps 1 to 7 on all lift gates.

Checking the lift gate with
store interface
No maintenance work is required on any of the guide elements
(guide carriage and guide rail; toothed wheel and rack)
5‐10 Mechanical elements 2015-06-01 B579EN

1. Check the lift gate for damage.
2. Manually open the lift gate in manual mode.
3. Check the control unit of the lift gate of the upper end posi-
tion. Correct display: ¯.Eo¯.
5. Check the safety bar for proper function. The lift gate has to
open itself again.
7. Check the control unit of the lift gate of the lower end posi-
tion. Correct display: _.Eu_.
8. Place the system on automatic mode and lock the protection
doors.
The control unit must remain without any power; the system
is deactivated.
9. Carry out steps 1 to 8 on all lift gates.
Transport equipment (option): transport

belt

Checking the conveyor belt
Condition
1. Manually move the transport belt, checking the belt for dam-
age while doing this.
2. Carry out checks on all transport belts.
BendMaster: Z axis

Checking the toothed belt
2. Check the toothed belt for damage and wear.
Position change of the Z axis by altered pitch.

NOTICE
Existing programs are no longer correctly processed.
Ø Do not re-tension the toothed belt.
B579EN 2015-06-01 Mechanical elements 5‐11

3. In case necessary: request Technical Service.
Regripping station
106622: Maintenance interval: As needed

Cleaning or replacing the
muffler
■ If necessary: muffler (material no. 0137657)
The muffler must be cleaned when the suction power of the vac-
uum ejector is reduced. If the suction power is still not correct
after cleaning, the muffler must be replaced.
1 Silencer
Regripping station suction cup Fig. 71049

2. Screw out the muffler.
3. Blow out the muffler with compressed air.
or
Ø Replace the muffler if it is severely soiled.
4. Switch on the system again in manual mode.
5. Check vacuum function at the regripping station.

Sheet removal station
106623: Maintenance interval: Weekly

Checking and cleaning the
sheet removal station
Sheet removal station pallet Fig. 71050

2. Check the sheet removal station for damage.
3. Clean and conserve the pallet.
Press brake: sensor gauge finger

Performing a visual and
functional test
Condition
1. Check the sensor gauge finger for damage.

2. At the HMI user interface, open >Press >Press sensor sys-
tem.
The "ON/OFF" checkbox must be activated.
3. Enter 20% in both fields "Backstop resistor", "Left" and
"Right".
4. Check the sensor gauge finger for ease of movement.
5. Enter 80% in both fields "Backstop resistor", "Left" and
"Right".
6. Check the sensor gauge finger for ease of movement com-
pared to the previous setting.

7. In case necessary: request Technical Service.
Gripper changing console (option)

Performing a visual
inspection
Ø Check all gripper changing consoles for damage.

Checking the limit switch
Condition
1. Open the >Robot >Gripper deposit station menu.

The following statuses are possible:
Symbol Description
Deposit station not taught.
Deposit station occupied; gripper unknown.
Deposit station occupied; gripper known.
Deposit station free.
Status of gripper changing console deposit station Tab. 5-3
2. Manually remove all grippers from all gripper changing con-

soles.
All symbols must change to the "Deposit station free" status.
3. Manually place the gripper in the deposit station 1 of gripper
changing console 1.
The symbol from deposit station 1 must change to "deposit
station occupied, gripper unknown".
4. Carry out the procedure on all available deposit stations.
5. Perform one automatic gripper pick-up and one automatic
gripper deposit on each of the deposit stations.
6. If the grippers are not properly held or deposited, the
"deposit station not taught" symbol is displayed:
Request Technical Service.

BendMaster: pivoted-jaw gripper (option)

Performing a visual
inspection
WARNING (option)
Risk of crushing.
Ø Check the pivoted-jaw gripper for damage.

Check the opening and
closing speed.
WARNING (option)
Risk of crushing.
Operating mode Manual control mode Automatic

Gripper open slow fast
Gripper closed fast fast
Traveling speed, gripper Tab. 5-4
1. Check all four speeds in the two operating modes.

The closing speed must be at least 4 mm/s in manual mode.
2. If this closing speed is not met, Request Technical Service..

5. Electrical components
5.1 Overview
1 Fan at rear side of the BendMaster control cabinet

Fig. 51884
5‐16 Electrical components 2015-06-01 B579EN

1 BendMaster switch cabinet
Fig. 71565
BendMaster: control cabinet

Cleaning or changing filter
Depending of the machine configuration, the fans are arranged
differently.

■ 4x filter mat 120x120 (mat. no. 1779951).
B579EN 2015-06-01 Electrical components 5‐17

1 Filter, control cabinet
Fig. 71110

2. Pull out the fan cover:
3. Clean and blow out the filters and fans with compressed air.
4. Replace all four filters if they are very dirty.
5. Reinstall the cover.
7. Check whether airflows can be felt.
BendMaster: switch cabinet

Clean the Peltier cooler


1 Peltier cooler
Fig. 71109
2. Pull off the lamella grid on the front side of the device.
3. Blow out the air inflow and air outflow openings with com-
pressed air.
5. Check whether the inner and outer airflows can be felt.

BendMaster: fan in the C arm

Cleaning the fan
Fan in C arm Fig.

3. Remove the four screws from the fan mounting device.
4. Pull out the fan mounting device:
5. Blow out the fan with compressed air.
6. Refit the fan mounting device.
8. Check whether airflows can be felt.

BendMaster: fan, Z slide

Function test
Depending on the series, there are three different Peltier cooling
units:
■ Peltier cooling unit 1: manufacturer, TRUMPF
■ Peltier cooling unit 2: manufacturer, Rübsamen & Herr
■ Peltier cooling unit 3: manufacturer, Rittal
In countries where there are higher ambient temperatures, an
optional second Peltier cooling unit is available.
Fig. 71112
1. Check whether an airflow can be felt on the rear side of the

switch cabinet on the Z slide.
2. Only for Peltier cooling units 1 and 2:
− Clean the Peltier cooling unit with compressed air.
3. In case the message "cooling element ventilation: station X
failure" is shown, Request Technical Service.

6. Optical components
6.1 Overview
1 Sheet sensor
Fig. 71114
BendMaster: sheet sensor

Clean the glass pane
■ Glass cleaner 1000 ml (mat. no. 1637606).
■ Spray bottle, 1000 ml, with atomizer (mat. no. 1733721).
■ Cloth for cleaning glass, (mat. no. 0351897).
5‐22 Optical components 2015-06-01 B579EN

1 Glass pane
Sheet sensor Fig. 71113
1. Move the BendMaster into the manual gripper change posi-

tion.
2. Rotate the C axis in such a way that the sheet sensor can
be cleaned.
4. Clean the sheet sensor's glass pane.
B579EN 2015-06-01 Optical components 5‐23

7. Pneumatic components
Press brake: compressed air supply
106523: Maintenance interval: Annually

Checking the audible
compressed air monitoring
From version S08.00.
The horn for the audible air pressure monitoring is located in the
switch cabinet for options. The test the horn is done by closing
the air supply to the TruBend.
Note
Turning off the compressed air in the switch cabinet for
options does not lead to a warning signal.
1. Close the compressed air shut-off valve under the press
brake's switch cabinet. An audible warning signal must
sound.
1 Stopcock
Compressed air unit under the press brake switch cabi- Fig. 71115
net
2. If required: contact Technical Service.
5‐24 Pneumatic components 2015-06-01 B579EN

Chapter 6
Maintenance (Technical
Service)
1 Maintenance overview 6‐2
B579EN 2015-06-01 Maintenance (Technical Service) 6‐1

1. Maintenance overview
The following maintenance work may only be done by TRUMPF

Technical Service since special expert knowledge is required.
Customers without a valid service agreement must request tech-
nical service in good time.
Neglected maintenance work can result in serious damage to the
system.
Operating Maintenance point Maintenance work Category

hours inter-
val
Before enter- BendMaster: brakes Check the brakes for proper function (visual 1, 2, 3
ing the safety inspection). The BendMaster must not drop
cabin
Every year Air conditioning unit Check the function of the air conditioning unit 1
and clean it
Every year BendMaster: Z axis Check the hardware limit switch 1
Every year BendMaster: Z axis Check the pass overs of the path segments 1
Every year BendMaster Check the vacuum ejector 1
Every year BendMaster: Z slide Clean the fan 1
If required Entire system Perform safety equipment test 1
Tab. 6-1
6‐2 Maintenance overview 2015-06-01 B579EN

Index
4-axis sensor gauge finger ..................... 3‐12
6-axis sensor gauge finger ..................... 3‐13
B
A B axis ............................................... 3‐5, 4‐25
Backgauge and Y movement ................. 4‐91
A axis ............................................... 3‐5, 4‐25 Backgauge before Y movement ............. 4‐91
A stack active ................................ 4‐79, 4‐81 Backgauge sensor system ......................4‐90
A stack blocked .......................................4‐80 Backgauge sensors .................................4‐90
A stack full ...............................................4‐80 Backlighting table ................. 3‐25, 4‐60, 4‐71
A stack ready .................................4‐79, 4‐81 Backstop resistor ........................... 4‐36, 4‐92
A stack ready .......................................... 4‐80 Before and after approximate search .....4‐61
Acceptance ............................................ 4‐123 Before approximate search .....................4‐61
Accessories ............................................. 1‐22 BEND_SHEET .........................................4‐94
Accuracy ................................................ 4‐123 Blow-off time ............................................4‐85
Acknowledge .......................................... 4‐111 Blowing clean time .................................. 4‐85
Activate/deactivate ...................................4‐81 Box ...........................................................4‐83
Activate/deactivate Breakpoint ................ 4‐94 Button
Active Areas ............................................ 4‐64 Bending cell illumination ..................... 4‐10
Additional height measurement .............. 4‐60 Move coordinate system .....................4‐23
Advance warning from ............................ 4‐71 Button, GREEN ....................................... 4‐20
Advance warning quantity .......................4‐54
Advance Warning Sheets Deposit ........4‐101
Advance Warning Sheets Load ............ 4‐101
After approximate search ........................4‐61 C
Alarms .................................................... 4‐111
Align and clamp left ................................ 4‐91 C axis ...............................................3‐5, 4‐25
Align and clamp right .............................. 4‐91 CART ....................................................... 4‐25
Alignment left ...........................................4‐91 Cause ..................................................... 4‐111
Alignment left and right ...........................4‐91 CE marking ................................................1‐3
Alignment right ........................................ 4‐91 Ceiling plate ...............................................2‐9
All ........................................................... 4‐111 Change Height ........................................ 4‐81
All stacks ................................................. 4‐80 Changing user settings ........................... 4‐13
Always approach ..................................... 4‐61 Check inventory .....................................4‐108
Ambient conditions .................................. 2‐11 Check job .............................................. 4‐104
Amplification .......................................... 4‐124 Check job list .........................................4‐104
Apply areas ....................................4‐77, 4‐78 Check package ......................................4‐104
Approach laser position .................4‐68, 4‐69 CHECK_PRESSTOOL ............................ 4‐93
Approach strategy ................................... 4‐91 CHECK_ROBTOOL .................................4‐93
Arm ............................................................ 3‐7 Clamp left ................................................ 4‐91
As with job setting .........................4‐70, 4‐71 Clamp right .............................................. 4‐91
Automatic gripper change ....................... 4‐28 Cleaning .....................................................5‐3
Automatic mode ...................................... 4‐18 Combined separation .............................. 4‐86
AUX ...................................... 4‐26, 4‐32, 4‐33 Complex contour ................................... 4‐123
Auxiliary tools .......................................... 2‐18 Compressed air
Average ......................................4‐123, 4‐124 Properties ............................................ 2‐13
Average contour .................................... 4‐123 Supply lines ......................................... 2‐13
Axes ................................................. 3‐5, 4‐25 Compressed air supply ........................... 2‐13
Connected loads ................................. 2‐13
Cont ......................................................... 4‐94
Contrast ......................................4‐122, 4‐123
B579EN 2015-06-01 Index 7‐1

Control panel ..................................... 3‐9, 4‐9 Empty all unloading areas ...................... 4‐82
Coordinate system Empty unloading area ................. 4‐82, 4‐101
Coordinate system displayed ..............4‐24 Enable key .................................................4‐8
Move coordinate system .....................4‐24 Enabling conditions
Create model .........................................4‐122 Automatic mode .................................. 4‐18
Creating a job ..........................................4‐53 Manual mode .......................................4‐17
Current number of sheets ............. 4‐82, 4‐83 Manual press .......................................4‐20
Cycles ...................................................... 4‐86 Entire search area ...................................4‐74
Error strategy/recognition .............. 4‐60, 4‐70
Error: part interference contour recognized
................................................................ 4‐130
D Error: Part underneath detected ........... 4‐128
Errors/messages .................................... 4‐111
D axis ....................................... 3‐5, 3‐9, 4‐25 Existing messages ......................4‐111, 4‐113
Danger signs .................................. 1‐16–1‐18 Expansion joints ........................................ 2‐8
Danger zone Exposure time ....................................... 4‐123
Safeguarding device ........................... 1‐13 EXTERN_VISION_SHEET ...................... 4‐93
Danger zone, teach mode ...................... 1‐14
Deactivate vacuum intermediate layer ... 4‐72
Decrement Sheet .................................... 4‐82
Default setting ......................................... 4‐61
Default user ............................................. 4‐15
F
Defined search area ................................4‐75 File away ........................................ 4‐56–4‐58
Defining stacks ........................................ 4‐78 Filing away a job .....................................4‐56
Delay time ............................................... 4‐86 Filter .........................................................4‐80
Delete .............................................4‐68, 4‐99 Find stack .............................4‐74, 4‐76, 4‐77
Delete all areas ....................................... 4‐68 Fine recognition ........................... 4‐60, 4‐123
Delete all stacks ......................................4‐80 Description .............................................3‐9
Delete area ..............................................4‐68 Fine recognition after separation ............ 4‐87
Delete stack .............................................4‐80 Fine recognition at the backlighting table ....
Deleting a job ................................ 4‐55, 4‐57 4‐60
Deposit rejects .........................................4‐66 Fine recognition at the stack, periodic ... 4‐60
Deselecting a job .................................... 4‐55 Fine recognition on the stack, once .......4‐60
Details ............................................ 4‐69, 4‐82 Finished part ............................................4‐54
Diagnostics .............................................4‐111 Floor lane .........................................3‐7, 3‐15
Disable .....................................................4‐13 Floor quality ...............................................2‐8
Disconnect ............................................. 4‐121 Floor requirements .................................... 2‐6
Disconnected ......................................... 4‐121 For all bendings ...................................... 4‐90
Display ............................................4‐11, 4‐80 Foreground ............................................ 4‐121
Done ........................................................ 4‐53 Free span base plate ................................2‐9
Double sheet recognition
Integrated double sheet recognition ... 3‐23
Pallet scale .......................................... 3‐23
Double sheet separation ......................... 3‐24 G
Go to breakpoint ..................................... 4‐94
Gripper ........................................... 3‐15, 4‐84
E Gripper and travel motion ....................... 4‐87
Gripper change ........................................4‐28
EC Declaration of Conformity ................... 1‐3 Gripper changing console ............... 3‐25, 5‐5
Edit mode .............................................. 4‐121 Gripper construction kit ........................... 3‐18
Effect ...................................................... 4‐112 Gripper deposit station ........ 4‐29, 4‐31, 4‐86
Elastically cushioned base plate .............. 2‐8 Gripper servicing ..................................... 4‐27
Elasticity .................................................4‐123 Gripper weight ......................................... 4‐61
Electrical power supply ........................... 2‐14 Gripper, then travel motion ..................... 4‐86
Electrics ................................................... 2‐14
7‐2 Index 2015-06-01 B579EN

H L
Handling equipment ................................ 3‐27 L coordinate OK ...................................... 4‐79
Height compensation ...............................4‐60 L height OK ................................... 4‐79, 4‐81
Height measurement in case of error strat- L stack active .................................4‐79, 4‐81
egy ........................................................... 4‐61 L stack blocked ....................................... 4‐79
Height measurement mode .....................4‐71 L stack empty ..........................................4‐79
Height tolerance ...................................... 4‐70 L coordinate OK ...................................... 4‐80
High ......................................................... 4‐90 L no coordinate ....................................... 4‐80
Holder location ........................................ 4‐85 Language .................................................4‐14
Lay down gripper .................................... 4‐31
Liability disclaimer ................................... 1‐22
Lift gate ......................................................5‐5
I Load Search A ........................................ 4‐66
Load Search automatic ......................... 4‐106
Ignore Polarity ....................................... 4‐123 Load Search exact ...................... 4‐66, 4‐106
Image recording .................................... 4‐122 Load Search M ........................................4‐66
Image recording settings .......................4‐123 Load Search Manual .............................4‐106
Images of approximate search ..... 4‐72, 4‐76 LOAD_LAYER ..........................................4‐93
Increment Sheet ...................................... 4‐82 LOAD_SHEET ......................................... 4‐93
Index ...................................................... 4‐122 Loading a job .......................................... 4‐55
Indicator light on safety fencing ............. 4‐12 Loading stack .......................................... 4‐83
Inner contour ......................................... 4‐123 Lock/unlock stack .......................... 4‐80, 4‐81
Integrated system ....................................4‐88 Lot size .................................................... 4‐53
Intended use ..............................................1‐5 Low .......................................................... 4‐90
Intermediate layer part ............................ 4‐54 Low-pass filter ......................................... 4‐90
Intermediate layer search automatic .... 4‐106 Lubrication ..........................................5‐3, 5‐6
Intermediate layer search exact ..4‐66, 4‐106 Lubrication schematic ................................5‐6
Intermediate layer search manual ........ 4‐106
Interpolation points .................................. 4‐95
Interpolation type .....................................4‐97
Isolating transformer
Regulated ............................................ 2‐14
M
Unregulated ......................................... 2‐16 Maintenance
IT network ................................................2‐17 Audible compressed air supply monitoring,
check ..................................................... 5‐5
C fan, BendMaster ................................5‐5
Control cabinet, BendMaster ................ 5‐5
J Fan, Z slide, BendMaster ..................... 5‐5
Gripper changing console .....................5‐5
Job ......................................................... 4‐102 Lift gate ..................................................5‐5
Job details ............................................... 4‐59 Pivoted-jaw gripper ................................5‐5
JOINTS .................................................... 4‐25 Regripping station ................................. 5‐5
Jumpering the sensor finger ................. 4‐113 Sensor gauge finger ............................. 5‐5
Sheet removal station ........................... 5‐5
Sheet sensor ......................................... 5‐5
Switch cabinet, BendMaster ................. 5‐5
K Z axis, BendMaster ...............................5‐5
Key switch for operation mode selection 4‐17 Z slide ....................................................5‐5
Manual mode ...........................................4‐17
Manual press ...........................................4‐20
Material ID ............................................. 4‐107
Material ID (store) ................................... 4‐55
B579EN 2015-06-01 Index 7‐3

Max. sheets ............................................. 4‐83 Handling equipment ............................ 3‐27
Medium .................................................... 4‐90 Integrated double sheet recognition ... 3‐23
Message ................................................ 4‐101 Mobile fanning magnet ....................... 3‐27
Minimum ................................................ 4‐124 Multi-gripper .........................................3‐17
Mirroring .................................................4‐123 Multiple-circuit suction cups ................3‐17
MIXED ..................................................... 4‐26 Pivoted-jaw gripper ..............................3‐20
Mobile fanning magnet ............................3‐27 Productivity package ........................... 3‐26
Moving manually Regripping station ............................... 3‐24
in automatic mode .............................. 4‐22 Screen ................................................. 3‐10
in manual mode .................................. 4‐22 TruTops°Bend ...................................... 3‐29
Moving the regripping station into the park- Vacuum gripper ................................... 3‐15
ing position .............................................. 4‐33 Order, restoring ....................................... 4‐56
Multi-gripper .............................................3‐17 Overlay .................................................... 4‐95
Multiple-circuit suction cups .................... 3‐17 Overlay point ........................................... 4‐95
Overlay size .............................................4‐98
Overlay type ............................................ 4‐98
Override ................................................. 4‐104
N Overview ........................................ 4‐72, 4‐83
Network
IT ..........................................................2‐17
Network link .............................................2‐17
New rough recognition .................. 4‐60, 4‐70
P
No error processing .......................4‐60, 4‐70 Packages ............................................... 4‐102
No filter .................................................... 4‐90 Pallet height .............................................4‐65
No fine recognition .................................. 4‐60 Pallet ID .................................................4‐107
No height measurement ...... 4‐60, 4‐61, 4‐71 Pallet scale .............................................. 4‐88
No position .............................................. 4‐86 Parts data ...........................4‐54, 4‐84, 4‐105
No recognition ......................................... 4‐88 Peeling all points .....................................4‐86
No separation .......................................... 4‐86 Peeling at close range ............................ 4‐86
Normal-active ...........................................4‐37 Peeling from a distance .......................... 4‐86
Number of layers ........................... 4‐82, 4‐83 Peeling switched off ................................ 4‐86
Period ...................................................... 4‐60
Periodic height measurement ................. 4‐60
Pick up gripper ........................................ 4‐30
O Pick up job gripper ..................................4‐30
Pickup ...................................................... 4‐98
Offset fine recognition 1 ..........................4‐82 Pivoted-jaw gripper .......................... 3‐20, 5‐5
Offset fine recognition 2 ..........................4‐82 Planning aid ...............................................2‐4
Offset in X ............................................... 4‐71 Portable manual control unit .....................3‐9
Only after fine recognition ...................... 4‐61 Position ...............................4‐23, 4‐26, 4‐101
Opaque .................................................. 4‐123 Position monitoring active ....................... 4‐61
Operating elements Position recognition results ................... 4‐122
Portable manual control unit .................4‐6 Position recognition settings ..... 4‐122, 4‐123
Operating modes .....................................4‐16 Position regripping station .......................4‐98
Operation ................................................. 4‐99 Position robot .......................................... 4‐98
Operating modes .................................4‐16 Positions ................................................ 4‐100
Operation: moving axes manually .......... 4‐22 Power supply ...........................................2‐15
Options Outer conductor grounded ..................2‐16
at the TruBend .................................... 3‐30 Pre production in case of full storage ....4‐61
Backlighting table ................................ 3‐25 Problem
Double sheet separation .....................3‐24 No part recognized ........................... 4‐126
Extendable floor lane .......................... 3‐15 Production list ........................................4‐102
Gripper .................................................3‐15 Production package ...............................4‐102
Gripper changing console ...................3‐25 Production plan ..................................... 4‐102
Gripper construction kit .......................3‐18
7‐4 Index 2015-06-01 B579EN

Productivity package ......................3‐26, 4‐50 Search within area .........................4‐72, 4‐77
Project stacks .......................................... 4‐80 SELECT TrumpfRobot .............................4‐93
Selected Order ........................................ 4‐53
Selection .................................................. 4‐75
Sensor gauge finger ..................................5‐5
Q Sensor gauge fingers .............................. 3‐11
Sensors for press ....................................4‐36
Quantity intermediate layers ..........4‐82, 4‐83 Separate before measuring .................... 4‐87
Separating time ....................................... 4‐86
Separation at the gripper ........................ 4‐86
Separation by travel motion ....................4‐86
R Separation method ........................ 4‐85, 4‐86
Recognition ..............................................4‐87 Set Breakpoint .........................................4‐94
Recognition selection .............................. 4‐88 Set PC ........................................... 4‐94, 4‐99
RED button ..............................................4‐20 Set up .................................................... 4‐105
Reference ................................................ 4‐39 Settings from V7.0 and higher ............... 4‐50
Referencing ............................................. 4‐42 Sheet removal station ......................3‐21, 5‐5
Referencing the BendMaster .................. 4‐39 Sheet rotation .......................................... 4‐71
Referencing TruBend .............................. 4‐42 Sheet sensor ............................................. 3‐8
Reflecting ...............................................4‐123 Show none ............................................ 4‐100
Regripping station ................ 3‐24, 4‐32, 4‐33 Simple contour ...................................... 4‐123
Move manually .................................... 4‐32 Small parts .............................................. 3‐13
Remove ............................................... 4‐35 Software ...................................................1‐22
Set up .................................................. 4‐33 Software versions ....................................4‐13
Release write permission ........................4‐14 Sort by position ..................................... 4‐123
Remove all breakpoints .......................... 4‐94 Source text ............................................ 4‐101
Required ................................................ 4‐104 Spare parts ..............................................1‐22
Requirements, space ................................ 2‐6 Speed ...................................................... 4‐97
Residual risks .......................................... 1‐24 Automatic mode .................................. 4‐24
Results ...................................................4‐122 Manual mode .......................................4‐24
Resume ................................................. 4‐101 Stack ............................................ 4‐79, 4‐101
Rotate stack 90° ..................................... 4‐81 Stack empty code ..........................4‐61, 4‐71
Rotate stack by x .................................... 4‐81 Stack execution mode .............................4‐70
Rotation position, approaching ............... 4‐61 Stack layout .............................................4‐78
Rotation to Geo .......................................4‐55 Stack mode ............................................. 4‐79
Rotational position tolerance ...................4‐60 Stack use ....................................... 4‐82, 4‐83
Rotational transformer ...............................3‐9 Stacked ....................................................4‐83
Rough position .......................................4‐114 Start ....................................................... 4‐101
Rough recognition ........................4‐72, 4‐123 Start press ............................................... 4‐43
Description .............................................3‐8 Start production plan .............................4‐104
Rough recognition and backlighting table .... START_ORDER ...................................... 4‐93
4‐60, 4‐71 Starting a program ................................ 4‐100
Run mode .................................. 4‐121, 4‐122 Status ........................................... 4‐54, 4‐121
Running project stacks ............................4‐80 Stepping ...................................................4‐94
Stop ....................................................... 4‐101
Stop production plan ............................. 4‐104
Storage station ...........................4‐106, 4‐109
S Stress due to vibration ............................ 2‐11
Suction cups Off ......................................4‐32
Safety ....................................................... 4‐11 Suction cups On ......................................4‐32
Safety fence ............................................ 1‐14 Surface .................................................. 4‐123
Safety fencing .................................... 3‐9, 5‐5 Switch cabinet ........................................... 3‐7
Screen ..................................................... 3‐10 Switching off ............................................ 4‐46
Search ................................................... 4‐122 Switching off the BendMaster .................4‐46
Search area .............................................4‐75 Switching on ............................................ 4‐38
B579EN 2015-06-01 Index 7‐5

Switching on the BendMaster .................4‐38
Symbols ................................................... 4‐11
W
T Water protection ...................................... 1‐21
Weight load ............................................. 2‐10
Teaching .................................................. 4‐96 When moving .......................................... 4‐92
Technical data ........................................... 3‐4 When stopping ........................................ 4‐92
Teleservice .............................................4‐125 Withdrawal active .................................... 4‐37
through fine recognition .......................... 4‐61 Without backgauge ..................................4‐91
through height measurement .................. 4‐61 Writing BIO .............................................. 4‐15
through quantity .......................................4‐61
Timeout suction ....................................... 4‐85
Tolerance position ................................... 4‐60
TOOL ....................................................... 4‐26 Y
Tool-change height .................................. 4‐86
Tool holder ...............................................4‐59 Y movement before backgauge ............. 4‐91
TOOL MIXED .......................................... 4‐26
Tooling plan ....................................4‐84, 4‐85
Transport ..................................................2‐18
Auxiliary tools ...................................... 2‐18
Z
Transport dimensions .............................. 2‐18 Z axis ............................................... 3‐5, 4‐25
Travel functions ....................................... 4‐48 Z position search A .................................4‐66
Travel motion, then gripper .....................4‐86 Z slide, lubricate ........................................5‐5
Travel point ..............................................4‐97 Zoom ............................................ 4‐73, 4‐121
Troubleshooting ..................................... 4‐126
TruTops°Bend .......................................... 3‐29
U
Unload Precise ........................................ 4‐66
UNLOAD_SHEET ....................................4‐94
Unloading stack .......................................4‐83
Unprocessed material ............................. 4‐54
Update ..................................................... 4‐54
Use Pattern Settings ............................. 4‐122
User configuration ................................... 4‐15
User group ...............................................4‐16
Users ....................................................... 4‐14
V
V- ............................................................. 4‐24
V+ ............................................................ 4‐24
V7.0 ......................................................... 4‐50
Vacuum gripper ....................................... 3‐15
Vacuum monitoring ..................................4‐72
Vibration damping ................................... 2‐10
7‐6 Index 2015-06-01 B579EN

Bendmaster 60

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Operator's manual

Original operator's manual

TRUMPF Maschinen Austria GmbH + Co. KG

For "partly completed machinery" in accordance with the EC

© TRUMPF Maschinen Austria GmbH + Co. KG

The machine documentation includes:

B579EN 2015-06-01 Before you proceed ... I

1 For your safety 1‐3

2 Operational safety 1‐5

4 Measures to be taken by the manufacturer 1‐13

5 Organizational measures to be taken by 1‐20

B579EN 2015-06-01 Table of contents 0‐1

7 Disassembly and disposal 1‐26

Chapter 2 BendMaster installation conditions

Who does what? 2‐3

1 Planning aid 2‐4

2 Installation site 2‐6

3 Compressed air supply 2‐13

0‐2 Table of contents 2015-06-01 B579EN

1 Machine concept 3‐3

2 Technical data 3‐4

3 The most important assemblies 3‐6

B579EN 2015-06-01 Table of contents 0‐3

5 Options at the TruBend 3‐30

1 Description of the operating elements 4‐6

2 Operating the BendMaster 4‐11

0‐4 Table of contents 2015-06-01 B579EN

3 Switching on and referencing the Bend- 4‐38

4 Switching off the BendMaster 4‐46

5 Travel functions 4‐48

6 Running in a TruTops program 4‐50

B579EN 2015-06-01 Table of contents 0‐5

0‐6 Table of contents 2015-06-01 B579EN

7 Working at the press brake without Bend- 4‐110

8 Errors and Messages 4‐111

9 Error handling 4‐113

10 Solving problems and troubleshooting 4‐126

B579EN 2015-06-01 Table of contents 0‐7

1 General guidelines 5‐3

2 Maintenance Overview 5‐5

4 Mechanical elements 5‐10

5 Electrical components 5‐16

6 Optical components 5‐22

0‐8 Table of contents 2015-06-01 B579EN

Chapter 6 Maintenance (Technical Service)

1 Maintenance overview 6‐2

B579EN 2015-06-01 Table of contents 0‐9

1 For your safety 1‐3

2 Operational safety 1‐5

B579EN 2015-06-01 Safety 1‐1

5 Organizational measures to be taken by 1‐20

6 Overview of residual risks 1‐24

7 Disassembly and disposal 1‐26

1‐2 Safety 2015-06-01 B579EN

A warning contains signaling words that have been explained in

Signaling word Description

B579EN 2015-06-01 For your safety 1‐3

1‐4 For your safety 2015-06-01 B579EN

The machine can become a source of danger if it is used inap-