An innovative new plasma cutting machine for flue pipes has been developed by Techserv Cutting Systems, the specialist manufacturer of CNC profile cutting systems. Advanced interpolated motion of the cutting system is used to dramatically increase production throughput - using an economic real-time machine control module from Baldor.

Capable of cutting aluminium and stainless steel flue pipes at any angle, as well as holes of any shape or size, the plasma tube cutter completely automates this aspect of manufacturing. Until now, for example, elbow pipes have traditionally been produced by first cutting complex shapes from flat metal sheet, which are then rolled and welded before assembly. This multi-stage fabrication process necessarily involves considerable movement of work pieces around the factory and is very time-consuming.

The new cutter dispenses with the need to pre-cut complex shapes. Instead, the flat metal sheet is first rolled into a tube and seam welded, then each tube is successively loaded into the machine. The entire cutting operation is handled autonomously; a simple angled cut takes a matter of seconds. Cutting the angled end pieces for an elbow pipe and then assembling them - a task that previously took about 15 minutes in total ¬- can now be accomplished in around 4 minutes.

The tube being cut is mounted in the machine with its top end held in a rotating pneumatically-driven clutch assembly. The plasma cutting torch is moved up and down as the tube rotates, at a rate which determines the severance angle or the size and shape of the hole being cut. Both the main rotational axis and the plasma torch height axis are powered by Baldor BSM series AC brushless servomotors driven by Baldor MicroFlex digital servo drives, and employ interpolation to secure a constant cutting rate regardless of the profile of the cut or diameter of the tube. The machine can handle a wide range of tube diameters, from 90 to 350 mm, with wall thicknesses up to 1.5 mm.

The tube cutter also uses three Baldor stepper motor driven axes. Two of these control the position of a pair of guide rollers, which support the tube during the cutting process and are driven closer together or further apart depending on the diameter of the tube. They also move aside automatically during the tube reload phase to facilitate operator access. The third stepper-driven axis dynamically varies the distance between the plasma torch head and the wall of the tube during the cutting process, to provide optimum performance.

All five electrical axes are controlled by a Baldor NextMove ESB-2, a compact real-time machine control module which receives commands direct from an on-board PC-based CNC system developed by Techserv specifically for tube profile cutting applications. The CNC system software runs under Windows XP, with all operator information presented on a large touch-sensitive full colour HMI.

Baldor’s NextMove controller is particularly cost-effective for applications such as this. It provides all the control functions for the machine’s five servo and stepper motion control axes, with even the base model capable of accommodating a further two axes if required for future machine variants. The controller also features extensive built-in I/O capabilities, again with expansion options, to provide an economic machine control platform.

According to Techserv’s Technical Director, Mike Cowley, “Baldor’s high-level Mint programming language helps us to develop motion control programs for custom applications like this very quickly. Integrating the NextMove controller with our front-end CNC system was also straightforward because it uses the same API naming conventions as ActiveX commands. As we need to change the scaling and speed of the machine’s servo axes on-the-fly in order to maintain a constant cutting rate, the controller’s fast interpolation capabilities provide an important advantage. And as with many of our plasma cutting machines, we find that Mint’s ‘Hold-To-Analog’ command is especially useful, since it allows us to handle real-time control of the plasma arc entirely within the NextMove controller. We continuously monitor the arc voltage and the software interprets this analog value to automatically adjust the distance between the torch and the tube wall, thereby maintaining the constant plasma characteristics needed to ensure optimum cutting performance.”

The new plasma cutter was developed for Flues & Flashings, a company that specialises in the production of ducting products for the domestic and commercial heating markets. According to Gary Watkins, Works Manager at Flues & Flashings, “The performance of the plasma tube cutter is superb. Changing the process so that we are pre-forming the tubes before cutting them, instead of cutting complex shapes from flat metal sheets, has enabled us to virtually quadruple manufacturing throughput. In fact, we were able to produce six months stock during the first two weeks of machine operation.”

http://www.wordsun.com/release.php?id=1133

ESAB Cutting Systems introduces the COMBIREX™ DX Shape Cutting Machine for plasma and oxy-fuel cutting. The COMBIREX DX is a sturdy gantry with a high-stiffness beam design based on ESAB’s larger gantry machines. It features the same precision linear rail and precision rack & pinion drives as its larger cousins, making it a tremendous value with excellent performance and reliability for small to medium fabrication shops and manufacturers.

The COMBIREX DX is one of ESAB’s new global platforms incorporating modular design principles built from modular assemblies. It is the first of a series of machines that will be built in ESAB’s new Florence, SC modular manufacturing facility. The machine will be built from off-the-shelf pre-assembled modules in a lean assembly line. This reduces the actual assembly and test time for a customized machine to less than one week. Customers will be able to order machines customized to their needs, within a fixed array of configurations, and have those machines built, tested and shipped in a four- to six-week time frame. The COMBIREX DX is an enhanced replacement for ESAB’s popular Shadow DX gantry.

Designed for long service life and low maintenance requirements, the COMBIREX DX features digital AC drives and heavy-duty gearboxes. The rugged gantry can be equipped with up to four stations including one plasma station featuring ESAB’s m3 Precision Plasmarc system that allows the machine to cut and mark with the same plasma torch. The plasma station includes a High-Speed Vertical Lifter with pneumatically balanced tool-tip sensing, encoder height for optimizing hole quality, and magnetic breakaway crash protection.

The rugged three-axis precision gantry features all-steel construction with machined mating surfaces and rides on triple-machined T-rails mounted to H-beam rail supports for a sturdy foundation and easy installation on any concrete floor. The machine reaches speeds up to 1,000 ipm (25,000 mm/min) and is available in cutting widths from 5′ to 10′ (1.5 m to 3 m) and working lengths up to 59′ (18 m).

Standard equipment on the COMBIREX DX includes ESAB’s Vision CNC. This control is easy to learn, easy to use, and features a built-in process database that simplifies plasma and oxy-fuel torch setup by automatically setting all parameters based on selection of material type and thickness. This integrates perfectly with ESAB’s m3 plasma system, which automatically selects and mixes the optimal start, cut and shield gas combination. The operator sees a picture and part number for the torch parts that are needed for both plasma and oxy-fuel torches. The Vision CNC also provides network connectivity and USB support.

The COMBIREX DX is available with a choice of 200, 360 or 450 Amp m3 plasma systems. Each of these rugged power supplies is capable of 100% duty cycle and features CNC- controlled output current for improved starting and extended consumable life. Depending on the configuration, the system can cut carbon steel up to 2.5” thick or stainless steel and aluminum up to 1.75” thick.

The m3 system allows both cutting and marking on a wide range of materials and thicknesses. Only ESAB offers fully integrated process control with the plasma system, oxy-fuel gas control, laser pointer and any other process options all operated through the Vision CNC. As the technology leader in machine and process automation and the only total system supplier, ESAB is uniquely qualified to integrate the entire cutting process.By integrating machine motion control, cutting station control and complete plasma process control into the CNC, ESAB leads the way to higher productivity and lowest overall cost-per-part.

ESAB Welding & Cutting Products is one of the world’s largest and most experienced manufacturers of welding and cutting equipment and welding filler metals. Recognized as the technological leader in the industry, ESAB is committed to providing cost effective solutions for its customers. For more information on the COMBIREX DX, visit http://www.esabna.com, http://www.esabcutting.com or call 1-800-ESAB-123.

http://www.prweb.com/releases/2011/4/prweb8266314.htm

New Hyde Park, NY, July 03, 2010 — Techno, Inc. proudly introduces the New HPLC CNC Plasma Cutter Series, a low cost, operator-friendly machine, designed for small to mid-sized shops that wish to bring their manual plasma cutting process to a whole new level. For over 24 years Techno has provided high-quality CNC equipment to various industries and is excited to expand into cnc metal cutting.

“This new expansion just makes sense. We manufacture high-speed CNC router equipment for the wood, plastic, and signage market, so building a plasma cnc cutter was easy,” says Roy Valentine, CNC Sales Manager. “Since we have been designing and programming our own CNC Controls for over 20 years, attaching a high-quality plasma torch to the system and developing the electronic circuitry needed for automated torch functions for a cnc plasma machine was trivial. This in-house know-how has made us an industry leader in the CNC Router market, something we intend to repeat in the plasma cutting market.”

The new CNC Plasma’s unique design has drawn compliments from Hypertherm and Thermal Dynamics CNC Plasma experts, who were impressed with the HPLC’s ease of operation, built-in automatic system functionality, and overall system flexibility. Every HPLC is built from the same heavy-duty welded steel and precision drive system as our CNC Routers. The fully automated CNC Plasma Interface has advanced, yet with user-friendly features that will guide users with ease.

For a limited time, Techno is offering a $1,000 “Metal Cutter” discount on the HPLC series. To qualify for the discount, visit http://www.Plasma-CNC-Router.com, where you can submit your contact information to qualify for the discount and see a video of the HPLC Series in action. Alternatively, new customers can call (888) 599-6631

Contact:
Roy Valentine
Plasma-CNC-Router
2101 Jericho Turnpike Box 5416
New Hyde Park, NY, 11042-5416
(888) 599-6631
jmarketing7@gmail.com
http://www.Plasma-CNC-Router.com

http://bignews.biz/?id=888212&keys=dynamics-CNC-circuitry-hypertherm

ESAB Cutting Systems has a new stock of fully refurbished oxy-fuel or plasma-arc profile cutting machines that have been taken in part exchange.

Refurbished stock currently available includes high-definition plasma and marking machines, cantilever gas cutting machines and combined oxy-fuel/plasma machines.

ESAB Cutting Systems has expanded its stock of refurbished oxy-fuel or plasma-arc profile cutting machines, including Suprarex, Ultrarex and entry level Falcon series.

These include examples from the ESAB Suprarex, Ultrarex and entry-level Falcon series.

In the current economic climate, many companies will see refurbished machines as a cost-effective alternative to new investments.

Critical components are renewed to improve machine performance, safety and accuracy.

Mechanical bearings, control panels, coordinate drive mechanisms, cutters, posts and gas hoses are replaced and optical tracing systems are also often changed.

A new modern CNC control system features a number of inbuilt programming advantages.

http://www.manufacturingtalk.com/news/eab/eab167.html