Portal cutting machines have been designed for precision plasma-arc cutting, combine high productivity with high accuracy and their advanced process integration ensures high levels of cutting quality.
Esab Automation now has an extended range of Eagle portal cutting machines which have been designed for precision plasma cutting. There are four models in the range which combine high productivity with high accuracy. Advanced process integration ensures consistently high levels of cutting quality.
The four EAGLE machines offer cutting widths from 1500mm, with one torch, up to 3000mm with two torches.
Cutting thickness is up to 30mm with cutting speeds and positioning rates up to 35mm/minute.
The Eagle’s feature automatic switching from cutting to marking.
To promote the highest plasma cutting quality, a number of advanced design features are included.
The voltage related electric arc height regulation ensures optimum cutting quality through the entire cutting process.
The machine’s double side synchronised rack and pinion drive together with an advanced guiding system ensure 100% accuracy over the entire cutting range.
The cutting torch height is exactly pre-set by the Super Rapid Initial Height Sensing System which positions the plasma torch precisely in less than 1.5 seconds, thereby also eliminating unnecessary down time.
Economy, efficiency and flexibility are hallmarks of Esab precision plasma systems they provide exact cutting edges with little slag, minimum material deformation due to a very restricted heat affected zone and no reworking.
By configuring the plasma systems, plate thicknesses up to 30mm can be cut in stainless steel, aluminium or unalloyed steels.
Accompanying the Eagle range are Esab Vision Control Systems.
These provide comprehensive control possibilities with integrated cutting databases and the possibility of implementing fully automated production cycles.
Full details of the entire Eagle range are provided in new literature available from the company - telephone Esab for details.
http://www.cncmachinesinfo.com/articles/
Tuesday, December 18, 2007
Plasma cutters are ideal for accuracy
Plasma cutters are one of the most modern tools for cutting all kinds of metal. A plasma cutter uses electricity to superheat gas to the point where it becomes plasma, which can then be used to cut metal. Because there is no friction between surfaces produced by this process the resulting material will be free of burrs and imperfections. When you combine this technology with CNC (computer numerically controlled) machinery you have a cutting tool that can produce incredibly accurate and detailed patterns even in thick steel and titanium.
Plasma technology
CNC plasma cutting machines use computer programming and precise robotic controls to automate the production of shapes and patterns in metal. With a CNC plasma cutting tool you can produce precisely proportioned metal pieces with a minimum of burrs and imperfections. The accuracy and precision of CNC plasma cutting means that components can often be taken directly from the cutting machine and put into use without further finishing, saving time, effort, and expense.
Principles of operation for a CNC plasma cutter
As mentioned, a CNC plasma cutter uses computer programming to direct the plasma onto the material. This plasma is produced by feeding a gas past an electrode, which superheats this gas (gases used include oxygen, argon, and nitrogen) until it becomes plasma.
Plasma is a fourth state of matter (in addition to solid, liquid, and gas) and this plasma is directed through a restricted opening onto the surface of the metal. Once the plasma contacts the metal the metal is cut using heat. Because the metal is superheated to a molten state there is no messy residue left behind as there is when using friction-based cutting systems (saws).
A CNC plasma table
The best way to direct your plasma cuts is with a CNC plasma table equipped with a gantry that moves the CNC plasma cutter above the work to be cut. Because a CNC plasma cutter is so hot, however, a CNC plasma table does not actually have a table surface. Instead, the metal you are cutting becomes the table surface, and the cut pieces fall through to a holding area beneath the machine. The accuracy and technical sophistication of CNC plasma cutting are the main reasons why many companies that work with metal have switched to plasma cutters.
http://www.insidewoodworking.com/cnc/plasma_cutters.html
Plasma technology
CNC plasma cutting machines use computer programming and precise robotic controls to automate the production of shapes and patterns in metal. With a CNC plasma cutting tool you can produce precisely proportioned metal pieces with a minimum of burrs and imperfections. The accuracy and precision of CNC plasma cutting means that components can often be taken directly from the cutting machine and put into use without further finishing, saving time, effort, and expense.
Principles of operation for a CNC plasma cutter
As mentioned, a CNC plasma cutter uses computer programming to direct the plasma onto the material. This plasma is produced by feeding a gas past an electrode, which superheats this gas (gases used include oxygen, argon, and nitrogen) until it becomes plasma.
Plasma is a fourth state of matter (in addition to solid, liquid, and gas) and this plasma is directed through a restricted opening onto the surface of the metal. Once the plasma contacts the metal the metal is cut using heat. Because the metal is superheated to a molten state there is no messy residue left behind as there is when using friction-based cutting systems (saws).
A CNC plasma table
The best way to direct your plasma cuts is with a CNC plasma table equipped with a gantry that moves the CNC plasma cutter above the work to be cut. Because a CNC plasma cutter is so hot, however, a CNC plasma table does not actually have a table surface. Instead, the metal you are cutting becomes the table surface, and the cut pieces fall through to a holding area beneath the machine. The accuracy and technical sophistication of CNC plasma cutting are the main reasons why many companies that work with metal have switched to plasma cutters.
http://www.insidewoodworking.com/cnc/plasma_cutters.html
HOW A PLASMA CUTTER WORKS
Plasma cutters work by sending an electric arc through a gas that is passing through a constricted opening. The gas can be shop air, nitrogen, argon, oxygen. etc.
This elevates the temperature of the gas to the point that it enters a 4th state of matter. We all are familiar with the first three: i.e., solid, liquid, and gas. Scientists call this additional state plasma. As the metal being cut is part of the circuit, the electrical conductivity of the plasma causes the arc to transfer to the work.
The restricted opening (nozzle) the gas passes through causes it to sqeeze by at a high speed, like air passing through a venturi in a carburetor. This high speed gas cuts through the molten metal. The gas is also directed around the perimeter of the cutting area to shield the cut.
In many of today's better plasma cutters, a pilot arc between the electrode and nozzle is used to ionize the gas and initially generate the plasma prior to the arc transfer.
Other methods that have been used are touching the torch tip to the work to create a spark, and the use of a high-frequency starting circuit (like a spark plug). Neither of these latter two methods is compatible with CNC (automated) cutting.
The photo at right shows consumables from a Hypertherm Powermax 900 plasma cutter. The electrode is at the center, and the nozzle just below it. The orange piece above the electrode is the swirl ring, which causes the plasma to turn rapidly as it passes.
While these parts are all referred to as consumables, it is the electrode and nozzle that wear and require periodic replacement.
http://www.plasma-cutter.com/technical.htm
This elevates the temperature of the gas to the point that it enters a 4th state of matter. We all are familiar with the first three: i.e., solid, liquid, and gas. Scientists call this additional state plasma. As the metal being cut is part of the circuit, the electrical conductivity of the plasma causes the arc to transfer to the work.
The restricted opening (nozzle) the gas passes through causes it to sqeeze by at a high speed, like air passing through a venturi in a carburetor. This high speed gas cuts through the molten metal. The gas is also directed around the perimeter of the cutting area to shield the cut.
In many of today's better plasma cutters, a pilot arc between the electrode and nozzle is used to ionize the gas and initially generate the plasma prior to the arc transfer.
Other methods that have been used are touching the torch tip to the work to create a spark, and the use of a high-frequency starting circuit (like a spark plug). Neither of these latter two methods is compatible with CNC (automated) cutting.
The photo at right shows consumables from a Hypertherm Powermax 900 plasma cutter. The electrode is at the center, and the nozzle just below it. The orange piece above the electrode is the swirl ring, which causes the plasma to turn rapidly as it passes.
While these parts are all referred to as consumables, it is the electrode and nozzle that wear and require periodic replacement.
http://www.plasma-cutter.com/technical.htm
SELECTING A PLASMA CUTTER
So you want to purchase a plasma cutter! It's kind of a bewildering prospect to select a piece of equipment that is new to you with so many manufacturers and models to choose from.
Let 's approach the problem logically. To start with, there are a number of questions that you must answer for yourself, before you can go any further:
How many hours a day do you plan to use your plasma cutter? In other words, what kind of duty cycle must it have?
What kind of electrical service do you have where you intend to use the machine? Is it 50 amp 220 volt single phase, or perhaps 30 amp 110 volt single phase? What other equipment will be running simultaneously on the same circuit?
What kind of portability must your plasma cutter have? Will you be using it exclusively in your shop, or will you need to take it to the job? Do you have a means of supplying the machine with compressed air in remote locations? How will you do that, with a portable compressor or an air bottle? How will you supply electric current at the site?
What kind of material do you plan to cut, and how thick is it likely to be?
Will you be doing manual cutting exclusively, or is there a possibility that you may want to use your plasma cutter with a CNC cutting machine?
What are your budget limitations?
Generally speaking, the higher the amperage output of the plasma cutter, the greater the duty cycle is at lesser amperages. In other words, if you plan to use the machine around the clock, you should consider a larger unit than you would need to cut the material you will be working.
If you will be using your machine frequently, but not continuously, consider a unit that is capable of cutting the thickest material you are likely to work. Most manufacturers provide duty cycle information in their literature.
Many people make the mistake of thinking that the greater the capacity of the machine, the better it is. In general, fabricators consider oxy-fuel to be superior to plasma for cutting steel when thicknesses exceed about 1/2 inch. This is because of the slight bevel (4 to 6 degrees) in the cut face that plasma produces. It is not noticeable in thinner materials, but becomes more so as thicknesses increase. Also, at thicknesses above 1/2 inch, plasma has no cutting speed advantage over oxy-fuel.
There is little point in buying a plasma cutter that will cut 1 1/2" plate, if you are going to use acetylene for such work anyway. If you are planning to cut non-ferrous metals such as stainless or aluminum, which cannot be cut by oxy-fuel, consider a 50 to 80 amp. 220 volt plasma cutter.
If you plan to use your plasma cutter outside the shop occasionally, you should consider one of the new breed of semi-portable machines. These units are little powerhouses that weigh less than 100 lbs., yet are capable of cutting 3/4" to 1" in a pinch. You will need a bottle of air or a compressor, and a hefty portable generator.
If you believe that you may automate your plasma cutting at some point, you must select a unit that does not use a high-frequency starting circuit. A high-frequency start acts like a spark plug in a car. Rather than using a relatively lower voltage pilot arc to initiate the plasma process, it uses a high voltage spark. This causes electrical interference such as locking up the computer, destroying files, etc. None of Hypertherm's Powermax units use a high frequency starting circuit.
Like most other things in life, you get what you pay for. Imported plasma cutters can be found on the market for $800 or less. However, that is money that could be put toward a modern inverter type unit costing more initially, but less over time when the cost of replacement parts and consumables is factored in. On that note, it should be pointed out that Hypertherm's Powermax line uses a new, patented air flow system and torch design that actually delivers up to 4 times the consumables life of their other models and competing brands.
Make your selection intelligently, based on the above considerations, and your plasma cutter will give you years of reliable performance. Don't make the mistake of purchasing a unit on the basis of cost. An inexpensive machine that doesn't meet your needs is no bargain.
http://www.plasma-cutter.com/selection.htm
Let 's approach the problem logically. To start with, there are a number of questions that you must answer for yourself, before you can go any further:
How many hours a day do you plan to use your plasma cutter? In other words, what kind of duty cycle must it have?
What kind of electrical service do you have where you intend to use the machine? Is it 50 amp 220 volt single phase, or perhaps 30 amp 110 volt single phase? What other equipment will be running simultaneously on the same circuit?
What kind of portability must your plasma cutter have? Will you be using it exclusively in your shop, or will you need to take it to the job? Do you have a means of supplying the machine with compressed air in remote locations? How will you do that, with a portable compressor or an air bottle? How will you supply electric current at the site?
What kind of material do you plan to cut, and how thick is it likely to be?
Will you be doing manual cutting exclusively, or is there a possibility that you may want to use your plasma cutter with a CNC cutting machine?
What are your budget limitations?
Generally speaking, the higher the amperage output of the plasma cutter, the greater the duty cycle is at lesser amperages. In other words, if you plan to use the machine around the clock, you should consider a larger unit than you would need to cut the material you will be working.
If you will be using your machine frequently, but not continuously, consider a unit that is capable of cutting the thickest material you are likely to work. Most manufacturers provide duty cycle information in their literature.
Many people make the mistake of thinking that the greater the capacity of the machine, the better it is. In general, fabricators consider oxy-fuel to be superior to plasma for cutting steel when thicknesses exceed about 1/2 inch. This is because of the slight bevel (4 to 6 degrees) in the cut face that plasma produces. It is not noticeable in thinner materials, but becomes more so as thicknesses increase. Also, at thicknesses above 1/2 inch, plasma has no cutting speed advantage over oxy-fuel.
There is little point in buying a plasma cutter that will cut 1 1/2" plate, if you are going to use acetylene for such work anyway. If you are planning to cut non-ferrous metals such as stainless or aluminum, which cannot be cut by oxy-fuel, consider a 50 to 80 amp. 220 volt plasma cutter.
If you plan to use your plasma cutter outside the shop occasionally, you should consider one of the new breed of semi-portable machines. These units are little powerhouses that weigh less than 100 lbs., yet are capable of cutting 3/4" to 1" in a pinch. You will need a bottle of air or a compressor, and a hefty portable generator.
If you believe that you may automate your plasma cutting at some point, you must select a unit that does not use a high-frequency starting circuit. A high-frequency start acts like a spark plug in a car. Rather than using a relatively lower voltage pilot arc to initiate the plasma process, it uses a high voltage spark. This causes electrical interference such as locking up the computer, destroying files, etc. None of Hypertherm's Powermax units use a high frequency starting circuit.
Like most other things in life, you get what you pay for. Imported plasma cutters can be found on the market for $800 or less. However, that is money that could be put toward a modern inverter type unit costing more initially, but less over time when the cost of replacement parts and consumables is factored in. On that note, it should be pointed out that Hypertherm's Powermax line uses a new, patented air flow system and torch design that actually delivers up to 4 times the consumables life of their other models and competing brands.
Make your selection intelligently, based on the above considerations, and your plasma cutter will give you years of reliable performance. Don't make the mistake of purchasing a unit on the basis of cost. An inexpensive machine that doesn't meet your needs is no bargain.
http://www.plasma-cutter.com/selection.htm
CNC PLASMA CUTTING
CNC (computer numerically controlled) plasma cutters fully automate the shape production process. Early cnc machines used a tape with small holes punched through to provide instructions to a primitive (by today's standards) computer.
Today's CNC units use either expensive limited production computers made specifically for running burning machines, or personal computers adapted to run the machines. While the latter group lack some of the refined features of the $100,000 and up machines, such as automatic shape nesting and automatic tip height control, they provide the same cut quality and production speed.
In CNC cutting, you arrange your shapes on the computer screen and cut them automatically, without having to touch the material.
tm2_action_sm.jpg (11620 bytes)
CNC software lets you program pauses for piercing, scale up or down in seconds, set acceleration and deceleration at corners, and other functions not possible with electric eye units.
The above shapes were created in CorelDraw, and then turned and nested together to minimize scrap material. The group of shapes were then exported as a single DXF file. The file was then imported into our Torchmate driver software, which automatically converts it to G-code for cutting.
The shapes are cut in a sequence that minimizes the distance the torch must travel. While cutting speed here is 80 inches per minute (IPM), rapid traverse between cuts is 300 IPM.
http://www.plasma-cutter.com/cnc.htm
Today's CNC units use either expensive limited production computers made specifically for running burning machines, or personal computers adapted to run the machines. While the latter group lack some of the refined features of the $100,000 and up machines, such as automatic shape nesting and automatic tip height control, they provide the same cut quality and production speed.
In CNC cutting, you arrange your shapes on the computer screen and cut them automatically, without having to touch the material.
tm2_action_sm.jpg (11620 bytes)
CNC software lets you program pauses for piercing, scale up or down in seconds, set acceleration and deceleration at corners, and other functions not possible with electric eye units.
The above shapes were created in CorelDraw, and then turned and nested together to minimize scrap material. The group of shapes were then exported as a single DXF file. The file was then imported into our Torchmate driver software, which automatically converts it to G-code for cutting.
The shapes are cut in a sequence that minimizes the distance the torch must travel. While cutting speed here is 80 inches per minute (IPM), rapid traverse between cuts is 300 IPM.
http://www.plasma-cutter.com/cnc.htm
CNC software targets plasma arc cutting equipment
Designed for HyPerformance(TM) Plasma systems and FASTLaser(TM) processes, Automation CNC v6.0 provides HPR interface with full-screen diagnostics, configurable Watch Windows, and ability to create custom cut chart databases. HPR130 auto gas console features allow users to setup plasma supply operations. Along with facility for determining focal position, software offers Dynamic Pierce Control, auto process control, and laser marking capabilities.
Hanover, NH, USA - Automation CNC v6.0 software from Hypertherm, Inc. is now available for metal fabricators seeking greater productivity from mechanized HyPerformance(TM) Plasma systems and FASTLaser(TM) processes. CNC v6.0 is especially designed for applications of HyPerformance Plasma.
Newly released by Hypertherm Automation, CNC v6.0 is a performance upgrade that will be standard on all future shipments of Hypertherm CNC controllers including all EDGE[R], MicroEDGE(TM), Voyager(TM) and Mariner(TM) models. The company recommends that current CNC users contact their Hypertherm representative for specific information about system compatibility and available software upgrades to CNC v6.0.
The CNC v6.0 HPR (HyPerformance) interface is the most complete ever offered by Hypertherm Automation. It features full-screen diagnostics, configurable HPR Watch Windows, and the ability to create custom cut chart databases. HPR130 auto gas console features allow users to setup plasma supply operations by selecting material type, material thickness, process current and process gases.
The new CNC release also enhances FASTLaser software tools. Using Hypertherm's patent-pending process monitoring, it provides an automatic adjustment feature for determining focal position. The new automated focal position calibration routine simplifies the process of finding the spot where the laser focal position meets the material surface. It can be used whenever a shift in focal position occurs as with lens installation or resonator maintenance. Additional laser enhancements in CNC v6.0 include time saving Dynamic Pierce Control (DPC), auto process control and laser marking.
"Hypertherm is committed to being the supplier of choice for all our customers' thermal cutting needs," wrote Tate Picard of Hypertherm Automation in a recent Field Facts newsletter. "By actively soliciting feedback from our customers about software enhancements they'd like to see, we've been able to dramatically improve CNC v6.0 user interface screens and functionality. Additional requests from our customers promise to make CNC v7.0, already underway, even better."
Since 1968, Hypertherm has been the industry leader in plasma arc cutting equipment and service. Now, with its entry into the plate-laser cutting market, Hypertherm expands its technology leadership commitment. By continually delivering breakthrough advances in metal-cutting productivity and precision - first in plasma, now also in laser - Hypertherm reaffirms and extends its position as the world's leading supplier of advanced high temperature metal cutting technology. Hypertherm serves a wide range of industrial metal cutting needs from its headquarters in Hanover, New Hampshire, with subsidiaries, sales offices and partner representation worldwide.
Hypertherm, HyPerformance, FASTLaser, EDGE II, MicroEDGE, Voyager and Mariner are registered trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.
http://www.cnc-info.blogspot.com/
Hanover, NH, USA - Automation CNC v6.0 software from Hypertherm, Inc. is now available for metal fabricators seeking greater productivity from mechanized HyPerformance(TM) Plasma systems and FASTLaser(TM) processes. CNC v6.0 is especially designed for applications of HyPerformance Plasma.
Newly released by Hypertherm Automation, CNC v6.0 is a performance upgrade that will be standard on all future shipments of Hypertherm CNC controllers including all EDGE[R], MicroEDGE(TM), Voyager(TM) and Mariner(TM) models. The company recommends that current CNC users contact their Hypertherm representative for specific information about system compatibility and available software upgrades to CNC v6.0.
The CNC v6.0 HPR (HyPerformance) interface is the most complete ever offered by Hypertherm Automation. It features full-screen diagnostics, configurable HPR Watch Windows, and the ability to create custom cut chart databases. HPR130 auto gas console features allow users to setup plasma supply operations by selecting material type, material thickness, process current and process gases.
The new CNC release also enhances FASTLaser software tools. Using Hypertherm's patent-pending process monitoring, it provides an automatic adjustment feature for determining focal position. The new automated focal position calibration routine simplifies the process of finding the spot where the laser focal position meets the material surface. It can be used whenever a shift in focal position occurs as with lens installation or resonator maintenance. Additional laser enhancements in CNC v6.0 include time saving Dynamic Pierce Control (DPC), auto process control and laser marking.
"Hypertherm is committed to being the supplier of choice for all our customers' thermal cutting needs," wrote Tate Picard of Hypertherm Automation in a recent Field Facts newsletter. "By actively soliciting feedback from our customers about software enhancements they'd like to see, we've been able to dramatically improve CNC v6.0 user interface screens and functionality. Additional requests from our customers promise to make CNC v7.0, already underway, even better."
Since 1968, Hypertherm has been the industry leader in plasma arc cutting equipment and service. Now, with its entry into the plate-laser cutting market, Hypertherm expands its technology leadership commitment. By continually delivering breakthrough advances in metal-cutting productivity and precision - first in plasma, now also in laser - Hypertherm reaffirms and extends its position as the world's leading supplier of advanced high temperature metal cutting technology. Hypertherm serves a wide range of industrial metal cutting needs from its headquarters in Hanover, New Hampshire, with subsidiaries, sales offices and partner representation worldwide.
Hypertherm, HyPerformance, FASTLaser, EDGE II, MicroEDGE, Voyager and Mariner are registered trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.
http://www.cnc-info.blogspot.com/
Plasma cutting CNC runs Windows XP Embedded
agreement between JETCAM International and ZUND Systemtechnik will ensure hat current and future ZUND cutting technologies are supported by JETCAM CAD/CAM productsCAD/CAM and Nesting specialists JETCAM International has announced an agreement with ZUND Systemtechnik, based in Switzerland whereby JETCAM Expert will be offered with the ZUND range of flatbed cutting machines. The agreement will ensure that current and future ZUND cutting technologies are supported by JETCAM products, with closer co-operation between sales, marketing, technical and development staff of both companies.
Mike Weber, managing director for JETCAM International said: 'With composite prices only increasing, and machine throughput becoming ever more important, we feel that the combination of ZUND and JETCAM technologies complement each other very well'.
'Customers now have a complete end-to-end solution which provides interaction and automation at every stage of the manufacturing workflow.' Mike Zuend from ZUND Systemtechnik added: 'This partnership cements a relationship that has already proven successful for some time.
Customers appreciate that they can receive a proven solution from a single vendor rather than a fragmented offering.
We can now combine the productivity and versatility of the ZUND cutters with JETCAM's automation and efficiency.' ZUND and JETCAM have already completed several successful installations for tier 1 and 2 companies in the aerospace and motorsport industries including several Formula 1 manufacturers.
JETCAM software is available either from JETCAM International and its worldwide network of distributors, or through selected Zund partners.
* About JETCAM International - JETCAM International has been developing and distributing its JETCAM Expert range of CADCAM software since 1986.
In use in over 70 countries worldwide, JETCAM Expert software supports virtually every CNC punching, laser, plasma, routing, waterjet and flatbed cutting machine available today, allowing users to program any combination of CNC machines with a single CAM system.
* About ZUND Systemtechnik AG - ZUND is recognized worldwide as the leading manufacturer of multifunctional, digital flatbed cutting and printing systems.
For over 20 years, ZUND has been spearheading the development of Swiss flatbed cutting technology, setting standards for precision, quality, and versatility while producing systems and tools for knife-cutting, laser-cutting, creasing, routing, etc.
http://www.manufacturingtalk.com/news/jea/jea165.html
Mike Weber, managing director for JETCAM International said: 'With composite prices only increasing, and machine throughput becoming ever more important, we feel that the combination of ZUND and JETCAM technologies complement each other very well'.
'Customers now have a complete end-to-end solution which provides interaction and automation at every stage of the manufacturing workflow.' Mike Zuend from ZUND Systemtechnik added: 'This partnership cements a relationship that has already proven successful for some time.
Customers appreciate that they can receive a proven solution from a single vendor rather than a fragmented offering.
We can now combine the productivity and versatility of the ZUND cutters with JETCAM's automation and efficiency.' ZUND and JETCAM have already completed several successful installations for tier 1 and 2 companies in the aerospace and motorsport industries including several Formula 1 manufacturers.
JETCAM software is available either from JETCAM International and its worldwide network of distributors, or through selected Zund partners.
* About JETCAM International - JETCAM International has been developing and distributing its JETCAM Expert range of CADCAM software since 1986.
In use in over 70 countries worldwide, JETCAM Expert software supports virtually every CNC punching, laser, plasma, routing, waterjet and flatbed cutting machine available today, allowing users to program any combination of CNC machines with a single CAM system.
* About ZUND Systemtechnik AG - ZUND is recognized worldwide as the leading manufacturer of multifunctional, digital flatbed cutting and printing systems.
For over 20 years, ZUND has been spearheading the development of Swiss flatbed cutting technology, setting standards for precision, quality, and versatility while producing systems and tools for knife-cutting, laser-cutting, creasing, routing, etc.
http://www.manufacturingtalk.com/news/jea/jea165.html
CAD/CAM supports ZUND cutting technologies
agreement between JETCAM International and ZUND Systemtechnik will ensure hat current and future ZUND cutting technologies are supported by JETCAM CAD/CAM productsCAD/CAM and Nesting specialists JETCAM International has announced an agreement with ZUND Systemtechnik, based in Switzerland whereby JETCAM Expert will be offered with the ZUND range of flatbed cutting machines. The agreement will ensure that current and future ZUND cutting technologies are supported by JETCAM products, with closer co-operation between sales, marketing, technical and development staff of both companies.
Mike Weber, managing director for JETCAM International said: 'With composite prices only increasing, and machine throughput becoming ever more important, we feel that the combination of ZUND and JETCAM technologies complement each other very well'.
'Customers now have a complete end-to-end solution which provides interaction and automation at every stage of the manufacturing workflow.' Mike Zuend from ZUND Systemtechnik added: 'This partnership cements a relationship that has already proven successful for some time.
Customers appreciate that they can receive a proven solution from a single vendor rather than a fragmented offering.
We can now combine the productivity and versatility of the ZUND cutters with JETCAM's automation and efficiency.' ZUND and JETCAM have already completed several successful installations for tier 1 and 2 companies in the aerospace and motorsport industries including several Formula 1 manufacturers.
JETCAM software is available either from JETCAM International and its worldwide network of distributors, or through selected Zund partners.
* About JETCAM International - JETCAM International has been developing and distributing its JETCAM Expert range of CADCAM software since 1986.
In use in over 70 countries worldwide, JETCAM Expert software supports virtually every CNC punching, laser, plasma, routing, waterjet and flatbed cutting machine available today, allowing users to program any combination of CNC machines with a single CAM system.
* About ZUND Systemtechnik AG - ZUND is recognized worldwide as the leading manufacturer of multifunctional, digital flatbed cutting and printing systems.
For over 20 years, ZUND has been spearheading the development of Swiss flatbed cutting technology, setting standards for precision, quality, and versatility while producing systems and tools for knife-cutting, laser-cutting, creasing, routing, etc.
http://www.manufacturingtalk.com/news/jea/jea165.html
Mike Weber, managing director for JETCAM International said: 'With composite prices only increasing, and machine throughput becoming ever more important, we feel that the combination of ZUND and JETCAM technologies complement each other very well'.
'Customers now have a complete end-to-end solution which provides interaction and automation at every stage of the manufacturing workflow.' Mike Zuend from ZUND Systemtechnik added: 'This partnership cements a relationship that has already proven successful for some time.
Customers appreciate that they can receive a proven solution from a single vendor rather than a fragmented offering.
We can now combine the productivity and versatility of the ZUND cutters with JETCAM's automation and efficiency.' ZUND and JETCAM have already completed several successful installations for tier 1 and 2 companies in the aerospace and motorsport industries including several Formula 1 manufacturers.
JETCAM software is available either from JETCAM International and its worldwide network of distributors, or through selected Zund partners.
* About JETCAM International - JETCAM International has been developing and distributing its JETCAM Expert range of CADCAM software since 1986.
In use in over 70 countries worldwide, JETCAM Expert software supports virtually every CNC punching, laser, plasma, routing, waterjet and flatbed cutting machine available today, allowing users to program any combination of CNC machines with a single CAM system.
* About ZUND Systemtechnik AG - ZUND is recognized worldwide as the leading manufacturer of multifunctional, digital flatbed cutting and printing systems.
For over 20 years, ZUND has been spearheading the development of Swiss flatbed cutting technology, setting standards for precision, quality, and versatility while producing systems and tools for knife-cutting, laser-cutting, creasing, routing, etc.
http://www.manufacturingtalk.com/news/jea/jea165.html
Hypertherm simplified plasma cutting system
Hypertherm has simplified mechanized plasma cutting system integration with the introduction of Hypertherm PowermaxEDGE. The 'bundled' solution integrates a patented Powermax G3 Series plasma system with either a standalone Sensor PHC, Plasma Height Control, or the EDGE Ti CNC with integrated torch height control.
Metal fabricators can configure the PowermaxEDGE for their specific requirements starting with one of three Powermax G3 plasma systems - the Powermax1000, Powermax1250 or Powermax1650 - depending on cutting requirements. Each model features patented Coaxial-assist technology as well as advanced torch and power supply designs to cut thicker plates, at faster speeds, with better overall cut quality and consumable life. The PowermaxEDGE with a Powermax1650 cuts up to 88" per minute on ½" thick plate.
Sensor PHC is an easy-to-use automatic plasma height control that maximizes cut quality. Designed for easy integration to CNC tables, it features simple operational controls and fault indicators. The PowermaxEDGE provides easy integration for small- to mid-range table applications, including original equipment manufacturers building light to medium gantry cutting tables, light duty cycle needs such as HVAC or custom fabricators, and for retrofit of existing oxy-fuel or plasma tables.
http://home.nestor.minsk.by/build/news/2007/04/2408.html
Metal fabricators can configure the PowermaxEDGE for their specific requirements starting with one of three Powermax G3 plasma systems - the Powermax1000, Powermax1250 or Powermax1650 - depending on cutting requirements. Each model features patented Coaxial-assist technology as well as advanced torch and power supply designs to cut thicker plates, at faster speeds, with better overall cut quality and consumable life. The PowermaxEDGE with a Powermax1650 cuts up to 88" per minute on ½" thick plate.
Sensor PHC is an easy-to-use automatic plasma height control that maximizes cut quality. Designed for easy integration to CNC tables, it features simple operational controls and fault indicators. The PowermaxEDGE provides easy integration for small- to mid-range table applications, including original equipment manufacturers building light to medium gantry cutting tables, light duty cycle needs such as HVAC or custom fabricators, and for retrofit of existing oxy-fuel or plasma tables.
http://home.nestor.minsk.by/build/news/2007/04/2408.html
Software for cutting machines - Systems and Software
Columbus software, an integrated package designed specifically for cutting machines, is said to offer simple setup and full process control for every cutting machine in a shop, plus part programming, true shape nesting, common line cutting, plate and inventory management, parts management, and machine-specific estimating in a single integrated package. Modules can run on a desktop workstation, or the basic package (Vision Plus-CNC) can run directly on the company’s Vision PC or NT control. In addition, the software will support other cutting systems.
The software supports straight or bevel cutting with oxyfuel, plasma, waterjet and laser, plus all current marking devices, in numerous combinations.
An estimating module tracks specific information, such as the machine’s cutting speeds, rapid speeds, lift speeds and pierce times for accurate job costing. This information can be exported to Excel or other databases for customized reporting and costing.
http://www.findarticles.com
The software supports straight or bevel cutting with oxyfuel, plasma, waterjet and laser, plus all current marking devices, in numerous combinations.
An estimating module tracks specific information, such as the machine’s cutting speeds, rapid speeds, lift speeds and pierce times for accurate job costing. This information can be exported to Excel or other databases for customized reporting and costing.
http://www.findarticles.com
CNC plasma cutters available from machineryequipment website
The new and bright way to buy and sell CNC plasma cutters online is the machineryequipment website.
CNC plasma cutters
Whether it is a new CNC plasma cutter or a second hand plasma machine that a company has out grown; machineryequipment is the website to see, it has all the top brands and the new Plasma cutting technology. The website does not sell the products direct; it advertises all the good deals around Australia.
The beauty of the machineryequipment website is that the user is in control of advertising the product, the negation of purchasing is as simple as finding the product that one wants and contacting the supplier.
http://www.ferret.com.au/articles/z1/view.asp?id=2813
CNC plasma cutters
Whether it is a new CNC plasma cutter or a second hand plasma machine that a company has out grown; machineryequipment is the website to see, it has all the top brands and the new Plasma cutting technology. The website does not sell the products direct; it advertises all the good deals around Australia.
The beauty of the machineryequipment website is that the user is in control of advertising the product, the negation of purchasing is as simple as finding the product that one wants and contacting the supplier.
http://www.ferret.com.au/articles/z1/view.asp?id=2813
Plasma cutting system
HYPERTHERM, represented in Australia by Westgate Hi-Tech Machinery, will exhibit the HyPerformance HPR260 plasma cutting system at the 2005 Schweissen & Schneiden Welding and Engineering Show in Essen, Germany.
By enhancing HyDefinition technology, HyPerformance boosts performance, productivity and profitability with consistent cut quality across a full range of plate thicknesses. It is suitable for cutting fine feature parts, a capability that will be demonstrated at the stand.
Powermax live cutting will take place at Stand 322, including both handheld and mechanised demonstrations. Hypertherm’s laser-plate cutting technologies will also be featured with a focus on the LH1575 FASTLaser cutting head. All mechanised demos will incorporate Hypertherm Automation’s EDGE II fast, accurate CNC controller.
Hypertherm consumables will be on display, highlighting performance-enhancing SilverPlus, FineCut and HySpeed technologies, as well as Hypertherm’s RT60 and RT80 retrofit torches, which deliver performance similar to newer Powermax G3 systems when retrofitted to older models. Centricut consumables will also be represented.
http://www.ferret.com.au/articles/cf/0c0318cf.asp
By enhancing HyDefinition technology, HyPerformance boosts performance, productivity and profitability with consistent cut quality across a full range of plate thicknesses. It is suitable for cutting fine feature parts, a capability that will be demonstrated at the stand.
Powermax live cutting will take place at Stand 322, including both handheld and mechanised demonstrations. Hypertherm’s laser-plate cutting technologies will also be featured with a focus on the LH1575 FASTLaser cutting head. All mechanised demos will incorporate Hypertherm Automation’s EDGE II fast, accurate CNC controller.
Hypertherm consumables will be on display, highlighting performance-enhancing SilverPlus, FineCut and HySpeed technologies, as well as Hypertherm’s RT60 and RT80 retrofit torches, which deliver performance similar to newer Powermax G3 systems when retrofitted to older models. Centricut consumables will also be represented.
http://www.ferret.com.au/articles/cf/0c0318cf.asp
CNC profile plasma tables
ADVANCED Robotic Technology (ART) CNC profile plasma tables, including the SVP series 4400, will be demonstrated at Austech 2004 during National Manufacturing Week in Sydney from June 1-4.
ART has developed a machine which keeps in total control either by using the touch-screen and/or pendant control.
This makes it easy to learn, providing on-the-fly operational information, while the interactive touch-screen provides a quick and simple means of entering machine instructions.
Profile Master, the software which achieves absolute productivity with Windows-based integral CAD/CAM profiling, packed with real-world features, and Powermax G3 series from Hypertherm, the performance standard for air plasma cutting technology, will also be displayed at the Austech 2004 show.
The smart plasma range is also able to handle the highs and lows by maximising consumable life, performance, as well as integrated tool control systems - the intelligent torch height controller, the initial height sensor and the break-away torch protection mechanism, which are standard on all machines.
All SVP plasma machines include a weaved deck and downdraft extraction trough which travels along with the gantry to reduce emissions into the work area, which ultimately keeps scrap collection and cleaning to a minimum.
Manufacturers don't have to go overseas for a quality plasma cutter, ART has everything right here -- industrial strength, outstanding quality, exceptional value, and innovative software.
ART also manufactures the most advanced range of CNC routing tables from three metres through to 14 metres.
http://www.ferret.com.au/articles/1e/0c01f01e.asp
ART has developed a machine which keeps in total control either by using the touch-screen and/or pendant control.
This makes it easy to learn, providing on-the-fly operational information, while the interactive touch-screen provides a quick and simple means of entering machine instructions.
Profile Master, the software which achieves absolute productivity with Windows-based integral CAD/CAM profiling, packed with real-world features, and Powermax G3 series from Hypertherm, the performance standard for air plasma cutting technology, will also be displayed at the Austech 2004 show.
The smart plasma range is also able to handle the highs and lows by maximising consumable life, performance, as well as integrated tool control systems - the intelligent torch height controller, the initial height sensor and the break-away torch protection mechanism, which are standard on all machines.
All SVP plasma machines include a weaved deck and downdraft extraction trough which travels along with the gantry to reduce emissions into the work area, which ultimately keeps scrap collection and cleaning to a minimum.
Manufacturers don't have to go overseas for a quality plasma cutter, ART has everything right here -- industrial strength, outstanding quality, exceptional value, and innovative software.
ART also manufactures the most advanced range of CNC routing tables from three metres through to 14 metres.
http://www.ferret.com.au/articles/1e/0c01f01e.asp
Budget profile plasma cutter
ADVANCED Robotic Technology (ART) will display its new CNC SMART profile plasma cutter on Stand 1100 during the 2006 Queensland Manufacturing Technology Exhibition (QMan), at the Brisbane Convention & Exhibition Centre, from October 17-19.
SMART standard features include:
* Touch-screen control.
* Profile shop SMART software.
* Automatic pierce height control.
* Mechanical torch height control.
* Smooth motion control.
* Servo motor drive.
* Traverse speed of 24+ m/min.
* Linear bearings.
* Powder coated chassis and gantry.
Also displayed will be ART's range of CNC profile plasma and routing machinery, Hypertherm plasma units, Keenedge tooling, Colombo spindles, and profiling/optimising software such as ProfileMaster and EnRoute.
ART machines are all designed and manufactured in Australia for supply to aluminium and plastic engineers, boat builders, cabinet makers, metal fabricators, and other industries.
SMART standard features include:
* Touch-screen control.
* Profile shop SMART software.
* Automatic pierce height control.
* Mechanical torch height control.
* Smooth motion control.
* Servo motor drive.
* Traverse speed of 24+ m/min.
* Linear bearings.
* Powder coated chassis and gantry.
Also displayed will be ART's range of CNC profile plasma and routing machinery, Hypertherm plasma units, Keenedge tooling, Colombo spindles, and profiling/optimising software such as ProfileMaster and EnRoute.
ART machines are all designed and manufactured in Australia for supply to aluminium and plastic engineers, boat builders, cabinet makers, metal fabricators, and other industries.
CNC plasma-arc profilers raise capacity
Three CNC cutting and profiling systems, using advanced plasma-arc cutting and precision guidance systems, produce ultra-precise blanks, usable without time-consuming manual reworking
Three CNC plasma-arc cutting machines from ESAB Cutting Systems have increased production capacity at a major manufacturer of aluminium and steel dumper truck bodies. Every month the company processes, an average of 420 tonnes of steel sheet and plate, with thicknesses ranging from 3 to 25mm as well as 30 tonnes of aluminium up to a thickness of 30mm.
The plasma-arc cutting process is used for cutting steel and aluminium.
The first ESAB Suprarex plasma-arc cutting machine has a working range of 12m x 3m.
The latest one has even a larger working range, of 24m x 3m.
Each machine features two high-precision plasma-arc torches and a fume extraction table with a highly efficient fine dust filtering system.
The cutting machines are fully integrated in the production process.
In view of the large number- some 4500 - and complexity of the different parts, manual production is impossible.
Cutting is the first step of the production process and all cutting operations on the Suprarex machines are controlled automatically at a central station.
The cutting parameters are set up using ESAB's COLUMBUS programming software.
The cutting data for each individual part is stored and can immediately be transmitted to the corresponding machine via the network.
The automatic nesting facility is particularly efficient and time-saving - individual cutting paths are designed so that material loss is kept to a minimum.
After cutting, the cut blanks are formed in four tandem bending presses and then robotically assembled and painted.
The advanced plasma-arc technology, in combination with ESAB's precision guiding machines, allows ultra-precise parts to be produced without time-consuming manual reworking.
The costs of investment in the plasma-arc plant is also much lower when compared with laser cutting system prices, said ESAB.
The Suprarex cutting systems significantly contribute to making the whole production process more effective and efficient.
Automatic creation of the nesting schedules reduces the work preparation requirements and set-up times are very short when it comes to cutting a different part.
http://www.manufacturingtalk.com/news/eab/eab145.html
Three CNC plasma-arc cutting machines from ESAB Cutting Systems have increased production capacity at a major manufacturer of aluminium and steel dumper truck bodies. Every month the company processes, an average of 420 tonnes of steel sheet and plate, with thicknesses ranging from 3 to 25mm as well as 30 tonnes of aluminium up to a thickness of 30mm.
The plasma-arc cutting process is used for cutting steel and aluminium.
The first ESAB Suprarex plasma-arc cutting machine has a working range of 12m x 3m.
The latest one has even a larger working range, of 24m x 3m.
Each machine features two high-precision plasma-arc torches and a fume extraction table with a highly efficient fine dust filtering system.
The cutting machines are fully integrated in the production process.
In view of the large number- some 4500 - and complexity of the different parts, manual production is impossible.
Cutting is the first step of the production process and all cutting operations on the Suprarex machines are controlled automatically at a central station.
The cutting parameters are set up using ESAB's COLUMBUS programming software.
The cutting data for each individual part is stored and can immediately be transmitted to the corresponding machine via the network.
The automatic nesting facility is particularly efficient and time-saving - individual cutting paths are designed so that material loss is kept to a minimum.
After cutting, the cut blanks are formed in four tandem bending presses and then robotically assembled and painted.
The advanced plasma-arc technology, in combination with ESAB's precision guiding machines, allows ultra-precise parts to be produced without time-consuming manual reworking.
The costs of investment in the plasma-arc plant is also much lower when compared with laser cutting system prices, said ESAB.
The Suprarex cutting systems significantly contribute to making the whole production process more effective and efficient.
Automatic creation of the nesting schedules reduces the work preparation requirements and set-up times are very short when it comes to cutting a different part.
http://www.manufacturingtalk.com/news/eab/eab145.html
Plasma Cutting Boosts Armor Production
O'Gara-Hess & Eisenhardt (OHE; Cincinnati, OH) first made a name for itself in 1948, when it engineered a bullet-resistant limousine for US President Harry S. Truman. Since then, more than 60 international heads of state and a long list of diplomats have been customers. Part of the Mobile Security Division of Armor Holdings Inc., the company today is the world's largest provider of wheeled vehicle armor.
The armor plate OHE installs ranges from 1/4 to 3/4'' (6.4-19-mm) thick. Because the company retrofits armor to existing vehicles, pieces must sometimes be cut to fit into very tight places with tolerances in the range of ±0.015'' (0.38mm).
Keith Kilpatrick, director of manufacturing engineering at OHE's Fairfield, OH, plant, needed to boost cutting capacity to support the company's increasing business. He had his eye on a plasma cutting system he had seen in a sister plant in Germany, and contacted a representative of ESAB Cutting Systems (Florence, SC).
Developed by a team of US and German engineers, ESAB's Acer 2 plasma cutting system featured highspeed dual side drives, a precision linear rail cross axis guidance system, the company's Precision Plasmarc plasma system, and a Windows-based CNC. It can provide good cut quality on carbon steel, aluminum, and stainless steel
Precision Plasmarc is a proprietary arc constriction technology that results in very low cut edge bevel angle and minimal dross, and requires little or no clean-up. It allows cutting and plasma marking with the same torch when used with an optional integrated flow control and PC. This eliminates the need for a dedicated marking station, improves accuracy by eliminating the need for tool offsets, and speeds cycles by cutting out machine motion between offsets.
The Fairfield facility has grown into two separate production buildings, both using a cellular assembly line process to produce military and commercial vehicles. In both cases, the vehicles are first disassembled and gutted, then the armor package is applied and the vehicles are reassembled.
Armor packages include ballisticgrade steels welded throughout the passenger compartment, transparent armor consisting of multi-layered ballistic glass, battery protection to ensure continued power supply, and Runflat wheels to help the vehicle reach safety in the event of an attack. Suspension upgrades are also included if required.
The machine's integrated flow control uses CNC-controlled proportional valves to control cut, start, and shield gases. Process parameters are selected and stored in the control, but can be manually adjusted and saved for future use, giving the operator flexibility.
Installed in November 2003, the initial Acer machine was so successful a second unit was added in June 2004. The machines have been instrumental in meeting OHE's demanding production schedules, including 350 Up-Armored Humvees per month for the US Army.
http://findarticles.com/p/articles/mi_qa3618/is_200505/ai_n13637771
The armor plate OHE installs ranges from 1/4 to 3/4'' (6.4-19-mm) thick. Because the company retrofits armor to existing vehicles, pieces must sometimes be cut to fit into very tight places with tolerances in the range of ±0.015'' (0.38mm).
Keith Kilpatrick, director of manufacturing engineering at OHE's Fairfield, OH, plant, needed to boost cutting capacity to support the company's increasing business. He had his eye on a plasma cutting system he had seen in a sister plant in Germany, and contacted a representative of ESAB Cutting Systems (Florence, SC).
Developed by a team of US and German engineers, ESAB's Acer 2 plasma cutting system featured highspeed dual side drives, a precision linear rail cross axis guidance system, the company's Precision Plasmarc plasma system, and a Windows-based CNC. It can provide good cut quality on carbon steel, aluminum, and stainless steel
Precision Plasmarc is a proprietary arc constriction technology that results in very low cut edge bevel angle and minimal dross, and requires little or no clean-up. It allows cutting and plasma marking with the same torch when used with an optional integrated flow control and PC. This eliminates the need for a dedicated marking station, improves accuracy by eliminating the need for tool offsets, and speeds cycles by cutting out machine motion between offsets.
The Fairfield facility has grown into two separate production buildings, both using a cellular assembly line process to produce military and commercial vehicles. In both cases, the vehicles are first disassembled and gutted, then the armor package is applied and the vehicles are reassembled.
Armor packages include ballisticgrade steels welded throughout the passenger compartment, transparent armor consisting of multi-layered ballistic glass, battery protection to ensure continued power supply, and Runflat wheels to help the vehicle reach safety in the event of an attack. Suspension upgrades are also included if required.
The machine's integrated flow control uses CNC-controlled proportional valves to control cut, start, and shield gases. Process parameters are selected and stored in the control, but can be manually adjusted and saved for future use, giving the operator flexibility.
Installed in November 2003, the initial Acer machine was so successful a second unit was added in June 2004. The machines have been instrumental in meeting OHE's demanding production schedules, including 350 Up-Armored Humvees per month for the US Army.
http://findarticles.com/p/articles/mi_qa3618/is_200505/ai_n13637771
Affordable CNC Plasma Cutting Machine
The plasma cutting process uses high velocity as well as high temperature ionized gas along with an arc, to cut different types of materials.
Plasma cutting process
The plasma cutter torch has a high velocity ionized gas that conducts electricity, which is used to heat the work piece and eventually melts the material. While the purpose of the arc is to melt the material with its high heat, the function of the gas is to blow the molten material away from the piece and cut the material. Due to the force of the plasma, you get a clean cut with very little or no slag at all. The plasma arc roughly has a speed of up to 20,000 feet per second (that’s more than 13,000 miles per hour!) while the temperature is as high as 30,000º F.
Different types of Plasma cutting machines
Plasma cutting machines are available in a variety of types such as plasma torches, plasma torches, and plasma cutters. Compressed air or nitrogen is used as a cutting gas in plasma cutting torches. The torches have a narrow-width kerf along with a water-cooled electrode. Plasma torches use a high temperature gas steam, which is produced by passing the gas through an electric arc discharge. The plasma torch has two electrodes that are metallic and tubular in nature. The electrical arc flows between the negative or positive electrodes. Plasma cutters are specially used for cutting steel and materials that conduct electricity.
Advantages of Plasma cutting machines
* They provide high quality cuts and fast travel speeds.
* It is a low cost process for short runs as no physical tooling is required.
* A cost effective option for thick metal sheets.
* As compared to laser cutting can cut thicker sheets.
* It can be used to cut a wide variety of geometric shapes along with 2D shapes that do not require too much precision.
Specifications
The process can be used on ferrous and non-ferrous metals and requires only software tooling. It helps to reduce cost by reducing total cut length. At times, some warping may occur on complex parts. The cut edge is somewhat roughened and may show the presence of an oxide layer. Further, the plasma cut surface may not be precisely perpendicular to the surface of sheet material.
http://www.emachineshop.com/articles/affordable-CNC-plasma-cutting-machine.htm
Plasma cutting process
The plasma cutter torch has a high velocity ionized gas that conducts electricity, which is used to heat the work piece and eventually melts the material. While the purpose of the arc is to melt the material with its high heat, the function of the gas is to blow the molten material away from the piece and cut the material. Due to the force of the plasma, you get a clean cut with very little or no slag at all. The plasma arc roughly has a speed of up to 20,000 feet per second (that’s more than 13,000 miles per hour!) while the temperature is as high as 30,000º F.
Different types of Plasma cutting machines
Plasma cutting machines are available in a variety of types such as plasma torches, plasma torches, and plasma cutters. Compressed air or nitrogen is used as a cutting gas in plasma cutting torches. The torches have a narrow-width kerf along with a water-cooled electrode. Plasma torches use a high temperature gas steam, which is produced by passing the gas through an electric arc discharge. The plasma torch has two electrodes that are metallic and tubular in nature. The electrical arc flows between the negative or positive electrodes. Plasma cutters are specially used for cutting steel and materials that conduct electricity.
Advantages of Plasma cutting machines
* They provide high quality cuts and fast travel speeds.
* It is a low cost process for short runs as no physical tooling is required.
* A cost effective option for thick metal sheets.
* As compared to laser cutting can cut thicker sheets.
* It can be used to cut a wide variety of geometric shapes along with 2D shapes that do not require too much precision.
Specifications
The process can be used on ferrous and non-ferrous metals and requires only software tooling. It helps to reduce cost by reducing total cut length. At times, some warping may occur on complex parts. The cut edge is somewhat roughened and may show the presence of an oxide layer. Further, the plasma cut surface may not be precisely perpendicular to the surface of sheet material.
http://www.emachineshop.com/articles/affordable-CNC-plasma-cutting-machine.htm
Plasma Cutting Machine has rigid, space-conscious design
Offered with multiple plasma torch options, EdgeMax features unitizedPlasma Cutting Machine has rigid, space-conscious design. steel table/frame, full capture bearing assemblies, and low-mass aluminum beam driven by dual brushless ac motors. Global S CNC control with Windows® OS, also included, facilitates machine operation for any level of operator. The basic models available are H, for HVAC, blowpipe, and OEM shops; G, for general fabrication shops; and P, for precision plasma cutting.
http://news.thomasnet.com/fullstory/535807
http://news.thomasnet.com/fullstory/535807
Everything you need to know before you purchase a CNC plasma cutting machine
CNC plasma cutting machines are more affordable and easier to operate than ever before. By knowing the right kind of hardware and software makes sense, a fabricator can choose the equipment that makes the most sense for his operation.
The process of choosing a CNC plasma cutting system is much more difficult today than it was 10 years ago, when systems were fewer but more expensive. By 2000 several progressive manufacturers had developed low-cost CNC plasma cutting systems that could run off of a PC.
Hardware and software developers made huge contributions with new, affordable, easy-to-use products. By 2004 it was becoming a chore for the first-time buyer to sort out the increasingly wide range of prices and new models on the market. Knowing about the different CNC plasma cutters available to you and what they are suited for will help you make the best investment for your capabilities.
First, you have to organize the market choices into three categories. One of these categories will have the right CNC plasma cutter for you. These categories, which are organized by price, do not necessarily indicate the level of quality and performance each provides. The price for each group is based on systems with a 5- by 10-foot or smaller cutting surface.
The first group comprises CNC plasma cutting systems that cost $25,000 or less, which have contributed greatly to the profitability of the small shops. They are available as complete plug-and-play systems or as kits. When you get a system from this category, it is important to use it for its intended purpose, which generally is light-duty industrial and artisan applications.
The second category of plasma cutting machines includes units that are priced at $60,000 or less. Some would argue that this group of machines includes the best of both worlds. Like the machines in the first group, they can give a lot of bang for the buck. They are engineered to perform well in demanding applications, up to and including the midindustrial market.
The best systems in this group are built to work hard; even the small tables can weigh up to a ton. They are capable of running one to two full shifts per day continuously with little maintenance. Some come with excellent industrial-grade software, hardware, and drives. Small shops with up to about 20 employees are the largest consumers of the machines from this category, which can handle anything from HVAC-gauge material to thick plate. Machines in this group usually are backed by good customer support, including live, on-screen assistance. This category is a good place for the growing business to start.
The third category includes large, feature-rich, multihead systems with price tags of between $60,000 and $200,000 or higher. These units, which have plenty of features and are smooth, accurate, and easy to operate, are at home in high-production shops. They also come with excellent customer support options. While the biggest and best are in this group, there are some pitfalls as well. Even in these high-end machines, some of their technology is outdated.
Every CNC plasma cutting machine is made up of three independent systems. Let's explore them further.
Mechanical Systems
The mechanical system on a plasma cutting machine includes the drive, the gantry with a torch height mechanism, and the cutting table. These components are not easily upgraded, so it is important to choose them wisely.
Rack-and-pinion gear drives are the most common. The rack gear runs the full length of each axis and the spur gear travels along it. Both are subject to high wear from metallic plasma dust. High-quality machines have a spring-loaded pinion gear to keep it running tight against the rack gear, otherwise the drives will develop play and backlash through use.
Some designers in the industry are advocates of using geared-timing belt drives because they cost less than rack-and-pinion gear drives, have zero backlash, and have long life. Because no force develops between the tool (torch) and the material, and the plasma cutting environment is so dirty, industrial geared-timing belts may be a good choice.
Sometimes a gear-reduction transmission can develop a bit of backlash. A little play in the transmission is not a deal breaker. It may transmit less than 0.001 inch of play at the torch. Also, most controllers can be set to compensate for a little backlash.
The drives should be enclosed or protected in some way. They should not be too exposed to the plasma dust and debris. Also, the drives shouldn't be vulnerable to getting hit by a falling piece of plate or an errant forklift. Basically, you are looking for maintenance-free operation.
Plasma cutting is all about time and accuracy, and the two most significant factors in saving time are material handling and software. You might think that cutting speed is a major factor. Yes, you can save seconds and minutes by tweaking your feed rate, but you can save hours in a week with good software and good material handling procedures.
For good material handling practices, the table should be easy to load and off-load. The gantry should be parked off of the cutting surface, so that a forklift can come straight in when loading heavy plate. The table should be able to handle a full sheet with no built-in obstructions. Also, most operators want the grates to be flush or a bit higher than the frame, which makes it easier to off-load heavy parts.
The cutting table must be able to handle a lot of weight, even if you are not planning to cut heavy plate. If you need to cut plate that is too thick for your plasma power supply, you can slide the plasma torch out of the housing and slide in an oxyfuel torch (they are all interchangeable). Now you are able to cut 2- to 4-in. material, and if you bought the right system, the controller will interface with on/off solenoids on the oxyfuel torch.
Check for play and flex by wiggling the gantry and automatic torch height control mechanism in several places while the machine is stationary. Look to see that the linear rails are secured along their full length. Be sure to run the machine through a few tests at different speeds with the plasma cutter turned off. Watch and listen. Everything should be snug and run smoothly and quietly. Stepper motors, as opposed to servomotors, make a buzzing sound that has nothing to do with the mechanical elements of the system.
Automatic torch height controls (ATHC) can be problematic. A good-quality control can be expensive, so it is important to give it a good workout, especially if you are looking at a lower-priced machine. An adjustable pierce height will significantly increase the consumable life and enable you to pierce and cut much thicker material. Also, make sure the ATHC does not have any sensors or wires sticking out that can get damaged.
The linear guide wheels on each axis are keys to ensuring smooth and accurate motion control. V-groove wheels with sealed bearings are desirable, and they should be spaced widely for increased stability. Cam followers are rightly used sometimes in group 1, but not often in groups 2 or 3.
CNC plasma cutting creates smoke that contains unhealthy black metallic dust as well as ozone. Smoke extraction systems usually come with the machines in group 2 and 3, in the form of a waterbed or a plenum/fan setup. Waterbeds have the added benefit of cooling the material during cutting. Both systems will extract smoke if they are set up correctly.
Hardware
Hardware comprised of the electronic system that controls the transmission (belt or gears) that moves the torch. Of course, this system must operate without a glitch and be maintenance-free. The computer and controller, cables, motor, and any remote control device work together to make the plasma torch do exactly what you have specified in the software program.
Overall, a closed-loop servo system is better than an open-looped stepper. Like the mechanical components, the hardware is not easily upgraded.
Some controllers cannot be upgraded with the latest CAD/CAM software. CNC software is improving in performance and price, and you will want to be able to upgrade as your business grows. Don't get stuck with a machine that can't be upgraded.
Software
There are actually three different software programs in your plasma cutting system: CAD, CAM, and controller.
CAD software is used to draw the parts. If you are a heavyweight with computers, you may be accustomed to AutoCAD®. Other programs available include AutoSketch® and CorelDRAW®. If you don't have any CAD experience, don't worry about it. It is getting easier and easier to learn. And that's what customer support is for. You can be drawing simple parts in an hour.
Sometimes your customer will e-mail you a nice drawing saved in a DXF file format, but sometimes a customer will shuffle into your shop, butt out his smoke, and make a sketch on your floor with a piece of soapstone. You will really be able to dazzle the old boy when you step up to your monitor and redraw his floor art in the form of a perfect CAD drawing. Remember to save your masterpiece as a DXF file.
CAM software is used to make the CAD drawing ready for cutting. It is important to make sure that the CAM software that comes with your system is easy to operate and has enough features. With a few clicks of the mouse, you should be able to:
* Create lead-ins and lead-outs so that the torch starts and stops cutting on the waste side of the profile.
* Set the tool offset so that the torch cuts on the edge of the line.
* Perform autonesting.
* Set the cutting and transverse speeds, pierce and cutting height, and cutting order.
Controller software uses the CAM file that you created to direct the controller to cut your part. It also enables you to manually override the operation with commands like e-stop, back up, and go.
http://www.thefabricator.com/PlasmaCutting/PlasmaCutting_Article.cfm?ID=1642
The process of choosing a CNC plasma cutting system is much more difficult today than it was 10 years ago, when systems were fewer but more expensive. By 2000 several progressive manufacturers had developed low-cost CNC plasma cutting systems that could run off of a PC.
Hardware and software developers made huge contributions with new, affordable, easy-to-use products. By 2004 it was becoming a chore for the first-time buyer to sort out the increasingly wide range of prices and new models on the market. Knowing about the different CNC plasma cutters available to you and what they are suited for will help you make the best investment for your capabilities.
First, you have to organize the market choices into three categories. One of these categories will have the right CNC plasma cutter for you. These categories, which are organized by price, do not necessarily indicate the level of quality and performance each provides. The price for each group is based on systems with a 5- by 10-foot or smaller cutting surface.
The first group comprises CNC plasma cutting systems that cost $25,000 or less, which have contributed greatly to the profitability of the small shops. They are available as complete plug-and-play systems or as kits. When you get a system from this category, it is important to use it for its intended purpose, which generally is light-duty industrial and artisan applications.
The second category of plasma cutting machines includes units that are priced at $60,000 or less. Some would argue that this group of machines includes the best of both worlds. Like the machines in the first group, they can give a lot of bang for the buck. They are engineered to perform well in demanding applications, up to and including the midindustrial market.
The best systems in this group are built to work hard; even the small tables can weigh up to a ton. They are capable of running one to two full shifts per day continuously with little maintenance. Some come with excellent industrial-grade software, hardware, and drives. Small shops with up to about 20 employees are the largest consumers of the machines from this category, which can handle anything from HVAC-gauge material to thick plate. Machines in this group usually are backed by good customer support, including live, on-screen assistance. This category is a good place for the growing business to start.
The third category includes large, feature-rich, multihead systems with price tags of between $60,000 and $200,000 or higher. These units, which have plenty of features and are smooth, accurate, and easy to operate, are at home in high-production shops. They also come with excellent customer support options. While the biggest and best are in this group, there are some pitfalls as well. Even in these high-end machines, some of their technology is outdated.
Every CNC plasma cutting machine is made up of three independent systems. Let's explore them further.
Mechanical Systems
The mechanical system on a plasma cutting machine includes the drive, the gantry with a torch height mechanism, and the cutting table. These components are not easily upgraded, so it is important to choose them wisely.
Rack-and-pinion gear drives are the most common. The rack gear runs the full length of each axis and the spur gear travels along it. Both are subject to high wear from metallic plasma dust. High-quality machines have a spring-loaded pinion gear to keep it running tight against the rack gear, otherwise the drives will develop play and backlash through use.
Some designers in the industry are advocates of using geared-timing belt drives because they cost less than rack-and-pinion gear drives, have zero backlash, and have long life. Because no force develops between the tool (torch) and the material, and the plasma cutting environment is so dirty, industrial geared-timing belts may be a good choice.
Sometimes a gear-reduction transmission can develop a bit of backlash. A little play in the transmission is not a deal breaker. It may transmit less than 0.001 inch of play at the torch. Also, most controllers can be set to compensate for a little backlash.
The drives should be enclosed or protected in some way. They should not be too exposed to the plasma dust and debris. Also, the drives shouldn't be vulnerable to getting hit by a falling piece of plate or an errant forklift. Basically, you are looking for maintenance-free operation.
Plasma cutting is all about time and accuracy, and the two most significant factors in saving time are material handling and software. You might think that cutting speed is a major factor. Yes, you can save seconds and minutes by tweaking your feed rate, but you can save hours in a week with good software and good material handling procedures.
For good material handling practices, the table should be easy to load and off-load. The gantry should be parked off of the cutting surface, so that a forklift can come straight in when loading heavy plate. The table should be able to handle a full sheet with no built-in obstructions. Also, most operators want the grates to be flush or a bit higher than the frame, which makes it easier to off-load heavy parts.
The cutting table must be able to handle a lot of weight, even if you are not planning to cut heavy plate. If you need to cut plate that is too thick for your plasma power supply, you can slide the plasma torch out of the housing and slide in an oxyfuel torch (they are all interchangeable). Now you are able to cut 2- to 4-in. material, and if you bought the right system, the controller will interface with on/off solenoids on the oxyfuel torch.
Check for play and flex by wiggling the gantry and automatic torch height control mechanism in several places while the machine is stationary. Look to see that the linear rails are secured along their full length. Be sure to run the machine through a few tests at different speeds with the plasma cutter turned off. Watch and listen. Everything should be snug and run smoothly and quietly. Stepper motors, as opposed to servomotors, make a buzzing sound that has nothing to do with the mechanical elements of the system.
Automatic torch height controls (ATHC) can be problematic. A good-quality control can be expensive, so it is important to give it a good workout, especially if you are looking at a lower-priced machine. An adjustable pierce height will significantly increase the consumable life and enable you to pierce and cut much thicker material. Also, make sure the ATHC does not have any sensors or wires sticking out that can get damaged.
The linear guide wheels on each axis are keys to ensuring smooth and accurate motion control. V-groove wheels with sealed bearings are desirable, and they should be spaced widely for increased stability. Cam followers are rightly used sometimes in group 1, but not often in groups 2 or 3.
CNC plasma cutting creates smoke that contains unhealthy black metallic dust as well as ozone. Smoke extraction systems usually come with the machines in group 2 and 3, in the form of a waterbed or a plenum/fan setup. Waterbeds have the added benefit of cooling the material during cutting. Both systems will extract smoke if they are set up correctly.
Hardware
Hardware comprised of the electronic system that controls the transmission (belt or gears) that moves the torch. Of course, this system must operate without a glitch and be maintenance-free. The computer and controller, cables, motor, and any remote control device work together to make the plasma torch do exactly what you have specified in the software program.
Overall, a closed-loop servo system is better than an open-looped stepper. Like the mechanical components, the hardware is not easily upgraded.
Some controllers cannot be upgraded with the latest CAD/CAM software. CNC software is improving in performance and price, and you will want to be able to upgrade as your business grows. Don't get stuck with a machine that can't be upgraded.
Software
There are actually three different software programs in your plasma cutting system: CAD, CAM, and controller.
CAD software is used to draw the parts. If you are a heavyweight with computers, you may be accustomed to AutoCAD®. Other programs available include AutoSketch® and CorelDRAW®. If you don't have any CAD experience, don't worry about it. It is getting easier and easier to learn. And that's what customer support is for. You can be drawing simple parts in an hour.
Sometimes your customer will e-mail you a nice drawing saved in a DXF file format, but sometimes a customer will shuffle into your shop, butt out his smoke, and make a sketch on your floor with a piece of soapstone. You will really be able to dazzle the old boy when you step up to your monitor and redraw his floor art in the form of a perfect CAD drawing. Remember to save your masterpiece as a DXF file.
CAM software is used to make the CAD drawing ready for cutting. It is important to make sure that the CAM software that comes with your system is easy to operate and has enough features. With a few clicks of the mouse, you should be able to:
* Create lead-ins and lead-outs so that the torch starts and stops cutting on the waste side of the profile.
* Set the tool offset so that the torch cuts on the edge of the line.
* Perform autonesting.
* Set the cutting and transverse speeds, pierce and cutting height, and cutting order.
Controller software uses the CAM file that you created to direct the controller to cut your part. It also enables you to manually override the operation with commands like e-stop, back up, and go.
http://www.thefabricator.com/PlasmaCutting/PlasmaCutting_Article.cfm?ID=1642
CNC cutter/profiler uses fuel gas and plasma-arc
High performance, competitively priced oxy-fuel gas and plasma machine can be fitted with up to four tool carriages, of which one can be dedicated to precision 200A plasma cutting torch
New from ESAB Automation is the Combirex CXL-P CNC cutting machine. It is a high performance, competitively priced oxy-fuel gas and plasma machine that can be fitted with a maximum of four tool carriages, of which one can be dedicated to precision plasma cutting up to a maximum of 200A. The introduction of the Combirex CXL-P underlines ESAB Automation's commitment to providing highly versatile cutting systems that allow customers to maximise the potential of different cutting technologies.
The Combirex CXL-P is supplied with ESAB's Vision LE CNC controller.
This high performance PC based control is designed for fast and easy use.
Along with the graphics, it shows the outside dimensions of the part and gives the operator control for the required area needed to cut the shape.
http://www.manufacturingtalk.com/news/eab/eab109.html
New from ESAB Automation is the Combirex CXL-P CNC cutting machine. It is a high performance, competitively priced oxy-fuel gas and plasma machine that can be fitted with a maximum of four tool carriages, of which one can be dedicated to precision plasma cutting up to a maximum of 200A. The introduction of the Combirex CXL-P underlines ESAB Automation's commitment to providing highly versatile cutting systems that allow customers to maximise the potential of different cutting technologies.
The Combirex CXL-P is supplied with ESAB's Vision LE CNC controller.
This high performance PC based control is designed for fast and easy use.
Along with the graphics, it shows the outside dimensions of the part and gives the operator control for the required area needed to cut the shape.
http://www.manufacturingtalk.com/news/eab/eab109.html
Improvements in Plasma Cutting
Developments in technology of plasma cutting to better suit consumer needs have helped increase market demand. Improvements in cutting tables linking the CNC and plasma system have helped reduce operating costs.
* Manufacturers of mechanized plasma cutting systems are focused on developing new technologies to meet three key market needs:
o Improved cut quality and consistency
o Increased cutting speeds and material thickness capabilities
o Increased consumable life.
* Together, these three focus areas, along with improvements in cutting tables and automation technology linking the CNC and plasma system, have helped drive reductions in operating costs of modern cutting installations.
* To extend the consumable life of a plasma system equipped with oxygen cutting capability, proper ramping down of gas pressures and power levels needs to occur at the end of the cut. This can happen only when the cut ends on the plate.
* Problems with the gas supply are probably the most common causes of excessive consumable wear. One of the first things a service engineer does when responding to a call about poor consumable life is to run a system gas leak test.
* Gas restrictions causing low flow rates can lead to catastrophic, almost immediate nozzle destruction. Because the initial plasma gas flow is low, the pilot arc attaches to the inside of the nozzle orifice and stays there long enough to cut the nozzle before being forced out of the orifice and transferring to the workpiece.
* In a properly functioning mechanized system, arc transfer occurs within 100 milliseconds. Poor electrical connection from the workpiece to the power supply can delay that to 1� second or more, risking not only increased consumable wear, but also misfiring.
* In most mechanized plasma systems, the connection between the workpiece and the plasma system is through the slats to the table ground, which is where the work cable from the plasma power supply usually is connected.
http://www.used-robots.com/articles.php?tag=1656
* Manufacturers of mechanized plasma cutting systems are focused on developing new technologies to meet three key market needs:
o Improved cut quality and consistency
o Increased cutting speeds and material thickness capabilities
o Increased consumable life.
* Together, these three focus areas, along with improvements in cutting tables and automation technology linking the CNC and plasma system, have helped drive reductions in operating costs of modern cutting installations.
* To extend the consumable life of a plasma system equipped with oxygen cutting capability, proper ramping down of gas pressures and power levels needs to occur at the end of the cut. This can happen only when the cut ends on the plate.
* Problems with the gas supply are probably the most common causes of excessive consumable wear. One of the first things a service engineer does when responding to a call about poor consumable life is to run a system gas leak test.
* Gas restrictions causing low flow rates can lead to catastrophic, almost immediate nozzle destruction. Because the initial plasma gas flow is low, the pilot arc attaches to the inside of the nozzle orifice and stays there long enough to cut the nozzle before being forced out of the orifice and transferring to the workpiece.
* In a properly functioning mechanized system, arc transfer occurs within 100 milliseconds. Poor electrical connection from the workpiece to the power supply can delay that to 1� second or more, risking not only increased consumable wear, but also misfiring.
* In most mechanized plasma systems, the connection between the workpiece and the plasma system is through the slats to the table ground, which is where the work cable from the plasma power supply usually is connected.
http://www.used-robots.com/articles.php?tag=1656
Plasma profiler agency for Press & Shear
Press & Shear has been appointed sole UK agent for Turkish machine tool manufacturer Baykal's range of CNC plasma cutting systems.
The plasma cutting machines have table sizes from 1.5 m by 3 m up to 3 m by 12 m. Other specifications for the plasma cutting machines includes ± 0.1 mm accuracy, 30 m/min axis positioning, ballscrew torch height positioning with patented crash detection, and Windows-based control with automatic nesting capability.
"Most sheet metal sub-contractors and OEMs know us as the UK source for turret punch presses, laser profilers and combination machines from Finn-Power. More recently we have taken on the agency for Italian-built Technojet water jet cutting machines," says Mark Britton, Press & Shear's managing director.
"Baykal's plasma cutting systems neatly complete our portfolio of sheet metal and plate profiling machines, and as they are from one of our existing principals, adoption of the products into our range will be seamless. Our applications and service engineers are currently undergoing training at the factory in Bursa, northwest Turkey."
In 2003, Press & Shear signed a similar agency agreement, which is ongoing, to sell and service Baykal's CNC press brakes.
http://www.machinery.co.uk/article/8932/Plasma-profiler-agency-for-Press--Shear.aspx
The plasma cutting machines have table sizes from 1.5 m by 3 m up to 3 m by 12 m. Other specifications for the plasma cutting machines includes ± 0.1 mm accuracy, 30 m/min axis positioning, ballscrew torch height positioning with patented crash detection, and Windows-based control with automatic nesting capability.
"Most sheet metal sub-contractors and OEMs know us as the UK source for turret punch presses, laser profilers and combination machines from Finn-Power. More recently we have taken on the agency for Italian-built Technojet water jet cutting machines," says Mark Britton, Press & Shear's managing director.
"Baykal's plasma cutting systems neatly complete our portfolio of sheet metal and plate profiling machines, and as they are from one of our existing principals, adoption of the products into our range will be seamless. Our applications and service engineers are currently undergoing training at the factory in Bursa, northwest Turkey."
In 2003, Press & Shear signed a similar agency agreement, which is ongoing, to sell and service Baykal's CNC press brakes.
http://www.machinery.co.uk/article/8932/Plasma-profiler-agency-for-Press--Shear.aspx
Subscribe to:
Posts (Atom)
Posts
