Machine tool manufacturer Trumpf and metrology solution leader Automated Precision Inc. (API) met at a trade show, and the rest is history.

For Trumpf, it was love at first sight: API’s XD Laser could measure the three degrees of freedom (DoF) needed for production of the TruMatic 7000 punch laser machine in a single process. But a subsequent demo at Trumpf’s factory in Ditzingen, Germany, revealed that this friendship would have even more benefits. The XD’s interferometer and small size offered easily repeatable measurement processes, fewer steps for alignment of the crossbeam and increased accuracy.

As for the TruMatic 7000, Trumpf refers to it as a “marvel of modern manufacturing” thanks to its ability to seamlessly process steel plates weighing nearly 400 kg (about 882 lb). But it has a weakness: A single incorrect position in the punching sequence turns the entire plate into scrap. The only remedy was a complicated and time-consuming process for maintaining accuracy — not surprising, given the fact that the crossbeam extends more than 6 m while the measurement tolerances required are less than .01 mm. This meant using a combination of different instruments and multiple setups, which increased downtime and introduced more room for error.

Then the XD Laser and its interferometer came along. It eliminated the need for beam splitters, making it possible to cover the full length of the cross beam. Trumpf programmed the laser to take two measurements, analyze and graphically display the results; this allowed the crossbeam measurement process to be automated.

The API device has also been used at customer locations for on-site calibration. Trumpf’s Michael Theurer has noted that “even when on-site with a customer, the new measurement process provides detailed statements about the structure, the alignment and the straightness in the Y and Z axes after only two hours, and we can provide all the data in a detailed report.”

Dramatically reduced inspection and alignment times, improved accuracy and reduced potential for error: These are Trumpf’s takeaways from that fateful trade show meeting. Here’s hoping that the two technologies will live happily ever.