Automated Plasma Cutting

Inexpensive manufacturing and integrators have significantly influenced technological advances within the automated plasma cutting industry. In case you’re unfamiliar with the art, plasma cutting is the process of cutting metals with a plasma torch. The actual torch is a combination of gas, electrical arcs, and high pressure air which when blown through a nozzle, turns gas into plasma and a flame hot enough to cut through the hardest metals. Such an automated plasma cutting system can reach up to 50,000 Fahrenheit temperatures and thus qualifies it as either a precision (high-definition) or conventional tool. Its proper classification depends on the characteristics of the tool’s flame.

Automated plasma cutting systems cut faster than conventional plasma cutting systems cut, and they produce more cohesive tolerances and create less bevel and kerf as well. But they also cost more than conventional plasma cutting systems – making a proper ‘cutting system to machine shape’ match extremely important.

Until a manufacturer can precisely identify requirements, get adequate OEM access to a power source and line of machines, and fully understand the entire industry, errors are bound to occur. Fortunately a manufacturer who lacks the proper expertise can be identified by its low price and its obsession with the advantages of an automated plasma cutting system. A more qualified manufacturer is aware of and acknowledges both the advantages and disadvantages of a plasma cutting system.

What kind of machines work well with plasma cutting systems? Gantry or bridge style machines made from extruded aluminum or fabricated steel are the most common. Machines made with extruded aluminum are most appropriate for hobby-type cutting projects. Fabricated steel machines on the other hand, are more appropriate for continuous cutting processes such as factory work.

Cutting machines can use a single-motor, dual-side drive, single-side drive, or two-motor dual-side drive systems. But conventional plasma cutters work best in a single-side drive system or a single-motor dual-side system. And because of specific limitations, the advantages of a two-motor dual-side drive system in a conventional plasma application go unnoticed.

This is of course because a two-motor dual-side drive system is designed for precision performance – the type of performance that only an automated plasma cutting system can exploit.

CNC control completes the functionality of a plasma source and its machine. Hypertherm or Burny are two classes of such controls. Both employ user friendly interaction and can withstand harsh environments. Industrial controls – less prone to incur errors -- are most appropriate for industry-specific demands.

Another important aspect is sizing gear boxes. A gear box must be appropriately sized in relation to a machine’s mass. An undersized motor cannot effectively change the direction of machine’s mass at high transverse and cut speeds. It would only create un-uniform cutting and washed out corners.

Equally important is a railing system’s construction – in particular its thickness, the bulkiness of its rails, and of course, protective, auxiliary heat shields. These components are necessary since automated plasma cutting is often used in abrasive surrounings. Hard material construction, self-cleaning wheels, and a regular cleaning preventive maintenance routine deserve attention as well.