There are specially designed gantry CNC plasma cutting machines that significantly speed up the time of working with metal.
At the same time, the cutting quality will be at a high level, and the costs will be minimal.
Portal installations are divided into types according to some criteria:
- way to rearrange the portal;
- the nature of management;
- the size of the table under the car;
- number and type of plasma cutters.
Also, metal-cutting manipulators can be equipped with a drive on only one side or on two.
The quality of the gas forming the plasma is chosen:
- pure oxygen;
- oxygen mixed with nitrogen;
- only nitrogen.
Gas is chosen based on the purpose of production, the material of the workpiece, the conditions regarding the quality of cutting and the price tag for gas.
An important component of such equipment is numerical control or CNC.
A CNC-equipped machine works quietly under the control of one employee of the enterprise, and not a whole group of workers.
CNC-enhanced machines produce a building product well in terms of speed and quality.
Description of portal plasma installations cutting metal
The set of installation for cutting metal structures includes a torch, a source, a directing energy flow, a control panel and a motor mechanism.
The element that sets the installation in motion may itself be movable or immovable.
The cutting machine operates with the help of hinges, a console or a portal. Whatever the installation, it performs one task - it evenly cuts a sheet of metal into pieces.
After plasma cutting, there is no need to process the edges of the product, and this is a definite plus of this method of cutting metal plates.
But if a metal object is cut by an ordinary machine with cutters, then its pointed edges will have to be smoothed out. Also, a plasma machine can cut material of any thickness and complexity.
A plasma-powered installation first heats up the point from which the cut will be made. This happens with the help of an electric arc.
As soon as the area is heated, it is exposed to gas under high pressure.
As a result, the edges of the cut part become smooth.
Capabilities of the portal plasma machine:
- high-quality cutting of all metals with any thickness with an accuracy of 0.1 mm;
- production of complex steel, aluminum, iron elements;
- cutting pipes of various circumferences, lengths and thicknesses;
- guaranteed result that does not require additional reheating of the material.
Distinctive moments of work and the design of a portal-type plasma cutter
The gantry CNC plasma cutting machine is designed so that a sheet of metal is placed under the gantry. This is what distinguishes the portal-type unit from other installations.
Also, this cutting machine has a support and photo-electronic control to monitor the evenness of the lines of the drawing given to the device.
Such a device helps to make exactly the same parts.
Gantry CNC plasma cutting manipulators continue to be modernized, they increase the speed of work.
At the same time, manufacturers also improve the quality of cutting. How the mechanism works this machine, shows the video.
The control panel (portal system) has guides in the form of rails and a transmission from the rack to the engine.
The design of the device can be subject to vibration, so it must be protected by a special system that protects the mechanism and increases its life.
The portal system can be called the center of the entire apparatus, sometimes it is supplemented by a compressor.
Any source of plasma is suitable, but its choice depends on what result you want to achieve and what preferences the buyer has.
The automated support that moves the plasma torch can be equipped with a touch mechanism. It measures what will be the height of the manufactured part.
The table on which metal sheets are cut is combined with the portal. In choosing the size of the table, you need to build on how large the sheets will be.
It is worth paying attention to the dimensions of the main mechanism of the apparatus. The table can be portable and stationary.
CNC Plasma Cutter
The portal plasma machine is driven and cuts metal thanks to the CNC stand. You can control the device through the remote control or control board.
But the button that starts and stops the plasma cutter is not available on all devices. Naturally, with a remote control, it is much easier to control the cutting progress.
Advanced cutting machines operate on software. Through the program, the mechanism can be given the task of creating a specific layout and cutting the workpiece according to it.
The CNC control system improves cut quality and increases productivity. The CNC machine realizes any configurations and schemes.
This program is not difficult to run on plasma equipment.
The advantages of a CNC machine can be listed in a whole list:
- on different parts you can repeat the same, even complex contour;
- production of equal-sized pieces of metal according to a difficult drawing;
- you can cut any contour;
- high performance of the device;
- adjustment of the start time and its total duration.
Characteristics of the plasma cutter "PRM-1"
This machine is based on a powerful welded frame. Thanks to this, the installation processes materials that weigh up to 3 tons.
Equipping the device with a water table and draft sheets allows you to cut the material without additional ventilation. The liquid of the table protects the processed metal from deformation.
Plus, the work surface is easily cleaned of waste.
The machine has excellent gantry rigidity thanks to the 3cm linear guides.
The portal moves exactly as a result of:
- the operation of three strong motors along the x and y axes, which have a ø110 mm flange, and the presence of a toothed belt reducer;
- operation of a stepper motor on the z-axis with a flange ø86 mm.
Two motors located on the x-axis eliminate the possibility of the portal warp at high speed and during acceleration.
The unit cuts metal with high quality, because it is supplemented with an automatic THC system that controls the height of the cutter above the material.
The device has a proprietary high-speed system for searching for a reference point on the z-axis. This design is also equipped with special sensors - limit, inductive.
The set of such a machine has everything you need for cutting metal, you will not need to purchase the missing things on purpose.
But sometimes you have to buy only the consumables of the device, such as an electrode and a nozzle.
Plasmorez brand "PRM-1" is characterized by the following dimensions:
- length, width and height of the machine - 400, 230 and 170 cm, respectively;
- length and width of the hone for work - 373 and 168 cm;
- the maximum length and width of the manufactured material is 300 by 150 cm.
The weight of this device is 1300 kg. The X axis can move 330 cm, the Y axis can move 154 cm, and the Z axis can move 20 cm.
The speeds of working movements are directly dependent on the density of the material being harvested and the power of the electric current.
The type of transmission along the x-axis and y-axis is 6 teeth and a rack, along the z-axis - balls and screws.
The drive of the device is a stepper motor with a belt reducer. The power supply of the installation is carried out under voltage of 380V.
This unit consumes 2 kW of power, not taking into account the strength of the plasma source and compressor.
As standard, tables for stacking sheets are not supplied. Tables can be made at the request of the customer.
Mobile, collapsible / collapsible options for installations. Intended for personal use in garages, services, private houses, private workshops. Perfect for traveling mobiles repair teams. They can be equipped with a Helvi Combi PC 502K air-plasma cutting source with a built-in two-piston compressor, which is powered by a stationary network or a 220V generator.
Stationary installations. Designed for personal use in garages, services, private homes, private micro-productions. Great for private workshops.
All-welded structures. Tables are water-filled.
Stationary installations. Designed for use in services, private mini-productions. Ideal for private workshops.
Stationary installations. Designed for use in services and private industries.
Designs (table and portal) - separate. The tables are ventilated, with a labyrinth smoke extraction system. Made according to the modular principle: depending on the dimensions of the working area, they consist of 2, 4, 6 or 12 modules. Each module is divided into sections with valves to reduce the power of the filter-ventilation system and increase the efficiency of gas flow. Sections are equipped with: removable baths, which simplifies the cleaning process; removable nets - to capture small details; removable knives - for stacking sheets.
Stationary installations. Equipped with one support for installing a plasma or gas cutter. Specially designed for machine building companies.
Stationary installations. Equipped with two independent supports for mounting plasma and gas cutters. Are designed for work in the conditions of the increased loading of the machine-building enterprises.
Gantry plasma cutting machine is the best example of device layout. This design eliminates all weak sides handheld and console equipment, such as low cutting accuracy or vibration that occurs unevenly during operation (for consoles). However, the systems are considered as high-performance units for equipping production facilities.
The gantry CNC plasma cutting machine is a convenient piece of equipment in that most of the work processes are automated. The operator only needs to upload the data to the computer system, and the cutting of the sheet material occurs automatically.
Thermal cutting, in which a portal installation is involved, is characterized by minimal vibrations. The rigid frame eliminates them by stabilizing moving components with guides. In this case, the risk of errors and deviations in the dimensions of the parts is minimized, and there is also no need for subsequent machining.
Experts note that the maximum cleanliness of the cut is obtained if, in the process of setting the parameters, the nozzle speed and current indicators are optimally selected. It is selected by trial cuts on the metal, decreasing or raising the value to the required level. If the speed or current is too high, dross will form on the surface.
Plasma cutting for which it is used portal machine, is carried out using gas, and for each type of metal, its composition is selected. For example, when processing aluminum and its derivatives with a thickness of up to 20 mm, nitrogen is used, for 20–100 mm a mixture of nitrogen and hydrogen is already required, and for large dimensions, argon and hydrogen. In such conditions, it is necessary to start the adjustment from 200 A.
Copper is cut according to the increase in thickness:
- up to 15 mm with nitrogen;
- up to 100 - compressed air;
- more - agro-hydrogen compositions.
Brass is dissolved in a similar way, but in this case, you can increase the speed. On average, the figure is raised by a quarter.
Depending on the class of steel sheet, rolled products are processed by various methods. High-alloy grades generally burn through only up to 100 mm thickness. Stainless steel is processed with nitrogen up to a sheet thickness of 20 mm and air or nitrogen-oxygen composition for sheets up to 50 mm. Buying an installation is also relevant for carbon alloys, with which it is allowed to work with an air, oxygen or nitrogen-oxygen mixture.
It is important to consider that the support table and the coordinate machine that the equipment is equipped with are independent elements. If the workpiece is dropped, the computerized system will not be damaged. Otherwise, the repair cost will be significant. Thus, the installations of our production are beneficial in many respects.
Kirill Sysoev
Calloused hands do not know boredom!
Content
Very often used to work with metal sheets specialized machines, through which the process of division is carried out. One of the popular devices is considered to be a portal plasma cutting machine, it has its own positive sides, which allow you to perform work quickly, efficiently and at minimal cost. In the article we will consider all the nuances of this mechanism, the rules for its operation and give advice on buying.
Features of Gantry Plasma Cutting Machines
Plasma cutting of metal is performed both manually and mechanized. The general set of equipment for dividing metal in this way, when plasma is used, includes: a plasma torch, an energy source, a cutting stroke control system and a mechanism that moves the installation. In this case, the latter can be both mobile and immovable, articulated, portal-console or portal. Control for such installations is allowed photoelectronic type, magnetic and numerical.
Whatever the device, it has one task - to cut the metal evenly from the sheet according to the specified scheme. Main positive characteristic when using plasma cutting - this is the absence of the need for subsequent processing of the edges of the resulting product. For example, if a cutting machine with metal cutters is used, then the edge of the part will need to be smoothed, and if plasma is used, this work should not be done. The second positive characteristic of plasma cutting is the ability to work with different thicknesses of material and cut the most difficult parts.
purpose
It should be understood that cutting a sheet of metal using plasma begins with heating the first point with an electric arc, which is created by a potential difference between the electrode and the workpiece (when current passes through the nozzle). When the place has already warmed up, a jet of oxygen or other gas under strong pressure displaces it and a smooth and even edge of the part is obtained. This process supports the thermal oxidation of the metal, which occurs along the cut line. The main tasks of a portal-type plasma cutter can be listed as follows:
- cutting any type of metal of different thickness with an accuracy of 0.1 mm;
- production of parts of any complexity from sheet aluminum, iron, steel, etc.;
- cutting pipes of different diameters, thicknesses and lengths;
- high-precision result without the possibility of profile overheating.
Features and principle of operation
The portal-type plasma cutting machine is characterized by the fact that the sheet of metal is placed under the portal. This is the main difference, since in a cantilever device this part is placed under the console, and in hinged mechanisms - under the hinge frame. In addition to the portal, the device under consideration will necessarily contain a support, a copying mechanism and a plasma torch. A photoelectronic control is also possible, which performs the task of tracking the correctness of the contour of the drawing that was sent to the device (a special photocell is used here).
If the plasma cutter is supplemented program management, then this will allow you to make many identical parts without slightest difference. Such a device is very often used in mass production. In the current conditions, portal-type plasma cutting machines are constantly being improved and increase the speed of their work, the quality of the parts obtained, while reducing operating costs. It is worth watching a video that clearly demonstrates the operation of such a mechanism:
Design
A standard plasma cutting machine should include a number of components that together perform a quality job. Each of these parts can be replaced during the operation of the devices with an adjacent or the same mechanism (only working). Let's look at each part:
- Gantry system with rail-type guides and transmission from rack to stepper motor. A system of dynamic protection against possible vibrations should also be present here, it increases the period of high-quality uninterrupted service of the entire apparatus. The gantry system is the main part of the entire installation, it additionally allows the use of a compressor.
- Plasma source. It is allowed to choose any, depending on preferences and the desired result.
- An automated support that moves the plasma torch itself vertically. If an automatic control system is used, then a touch mechanism may additionally be present, which determines the height of the future workpiece.
- The cutting table must be aligned with the portal. The choice of such a part should depend on the maximum dimensions of the sheets to be cut, as well as on the dimensions of the main part of the plasma cutter. It will be stationary or portable, it is at the request of the customer.
- CNC rack or other software that will submit tasks to the main device.
- Remote control or control board. It does not exist in all devices, but if these parts are included, it is much easier to control the metal cutting process, stop and start the device (this will require one button).
- Software. Present in advanced mechanisms and allows the operator to create layouts and transfer them to the installation.
CNC control system in metal cutting machines
If the device has numerical control, then the quality of the resulting cut increases markedly and at the same time increases productivity. Any configuration or circuit can easily be implemented with a CNC, which is not so difficult to connect to any machine (both plasma and laser). The advantages of such control on portal machines for plasma cutting of metal include:
- the ability to repeat any contours on different parts;
- creation of identical metal parts according to the most complex patterns;
- the possibility of cutting any contour;
- increased productivity of the plant;
- the ability to control the start time, duration of work.
Prices for gantry air plasma cutting machines
The cost of such mechanisms varies widely, depending on what parameters the plasma cutter will have and what its power is. Hypertherm's most popular MAX 200 model can cost up to 500,000 rubles. There are small tables with portal systems that can be used in small industries, then their price will be lower. If it's about large enterprises for production, the cost of machine tools can reach several tens of thousands of dollars, it is very important to obtain a passport for the goods. The average price range is framed by:
- compact portal plasma cutters (from 40,000 rubles);
- CNC machines (from 150,000 rubles);
- plasma torches (from 37,000 rubles);
- large plasma cutting installations (from 400,000 rubles).
Where to buy a machine for cutting pipes and other works?
It is easy to buy a portal plasma cutting machine from both large manufacturers and dealers. In the first case, the buyer will choose a device at low prices, but the conditions for the purchase may be the order of several devices. In the second case, the cost may be much higher, but the acquisition parameters will be more acceptable (fast and free shipping, the possibility of obtaining one machine, maintenance of the master, setting up mechanisms, additional components, maintenance). List of major manufacturers of gantry installations in Russia:
- Asterkat (St. Petersburg, Kurchatova st., 9).
- Multiplaz (Moscow, Leningradskoe shosse, 34, building 1).
- Siberia-Technology-Service ( Altai region, Barnaul, Kalinin Avenue 24-B).
- Chelyabinsk manufacturer of machine tools (Chelyabinsk, Komsomolsky pr., 14).
- Kotodama (Republic of Tatarstan, Kazan, Kutuya st., 159).
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Of great importance is the fact that the quality of the cut always remains consistently high, and it does not depend on the thickness of the processed metal sheets.
Types of plasma cutting machines for metal
Plasma cutting machines are available in two versions: mobile (compact) and stationary. Each of them has its own advantages and is used in a wide variety of industries. You can get acquainted with the mobile type, which can be used when processing relatively small-sized workpieces, in the article “Plasma cutting machine “SVAROG CUT” 70 (R33)”.
When a large amount of work is to be done on cutting wide-format thick metal, it is economically feasible to use portal-type installations. This type of arrangement of movable structural elements can significantly improve the accuracy of processing. Equipping equipment with numerical control (hereinafter referred to as CNC) greatly facilitates the setup and operation of the machine and increases labor productivity.
If there is no need to constantly process large workpieces, then portal portable metal plasma cutting plants are used. The working tables of such machines, in case of the need to cut large workpieces, can be extended using modules to the required length.
The role of CNC in the operation of a portal plasma cutter
The role of the CNC in the operation of the gantry plasma cutting machine is as follows. There is a library of CNC programs to perform the most common metalworking operations. They are called "standard operations programs" (hereinafter referred to as SOPs). When preparing technological documentation for the manufacture of a specific part, they take the closest PSO in terms of configuration, modify it accordingly (to the desired shape and size) and record it on a standard media compatible with the CNC of the plasma cutting machine. Further, in the process of setting up the machine for processing a particular part, you only need to load this program.
Thanks to the CNC, all operations are carried out without delay, since plasma cutting is carried out according to a pre-set program. The operator of the machine can only control the progress of the technological process.
Advantages and features of portal CNC plasma cutters
If it is necessary to perform a large amount of work on cutting thick metal, it is economically feasible to use CNC gantry plasma cutting machines for the following reasons:
- the use of such equipment is economically feasible;
- processing thick metal on such equipment allows you to get a cut High Quality, which, in most cases, will not require further machining;
- the presence of CNC can significantly increase labor productivity and facilitate the work of the operator of the portal plasma cutter;
- The plasma method of metal cutting under CNC control allows you to get very high precision parts manufacturing. In addition, the equipment allows you to cut any contour, up to an angle (bevel) of 45 degrees (this option is used for chamfering). In the future, after such cutting, only minor mechanical refinement (for example, chamfering) may be required;
- equipment is highly reliable. To increase the service life, a smooth start of the mechanism is provided on the CNC portal plasma cutting unit. This makes the operation of the machine durable, and the process safe;
- The high power of the torch and plasma source, combined with the right software, enables high productivity over a wide range of workpiece thicknesses and sizes.