Bevel cutting Plasma and oxyfuel Machine

Bevel cutting Plasma and oxyfuel Machine

（machine picture just for reference）

Description：

1, The machine is the six generation model, leading the third generation models of other domestic companies

2, Machine clamping mechanism is changed to magnetic suction structure to avoid collision and cutting center unstable

3, After more than 20 years use of the first CNC plasma bevel cutting machine, the database has been fully constructed to fully meet the diversification and high quality requirements of your company as the first brand of domestic steel structure.

4, Modular design for cross beam adopts heavy loaded structure, rotary cutting torch adopts light loaded structure, and the dynamic of whole machine structure is in high precision, stable and smooth surface cutting.

5, CNC multi-axis motion control, the cutting torch’s compound movement can complete carbon steel bevel cutting.

6, It can be equipped with various plasma cutting machines to achieve high quality cutting.  It can cut carbon steel, stainless steel and other non-ferrous metals.

7, Cutting torch rotary structure adopts combined bearing structure, which performs high precision, small axis rotation swinging and accurate cutting torch rotary positioning in high loaded.  

8, Cutting torch swinging structure uses new materials, which has patented design, lightweight and durable, fast angle adjustment

9, Cutting torch initial positioning adopts contact resistance method; the anti-collision device adopts the sliding structure, which is reliable and stable.

Five, Basic configuration and requirement, and machine description

Our company's plasma rotary bevel cutting machine can realize the automatic control of the cutting process of carbon steel/stainless steel and nickel alloy plate cutting with fast cutting speed, high cutting accuracy, and good cutting quality. With advanced computer remote direct communication technology, the design, manufacture, installation and commissioning of the machine are fully completed under the ISO9001 quality monitoring program.

A.Gantry longitudinal moving station, double pinion and rack driving, Inovance AC servo system (including servo and motor)

B.The cross beam adopts a rectangular square steel structure. The beam has a moving body which installs one plasma bevel cutting torch and one flame cutting torch.

C.Cross beam rails use linear rails; longitudinal rails are machined by surface grinders, guide rails scraping systems;

D.Reducer adopts Shimpo product, Japan.  

E.Longitudinal and transverse movement adopts dragging chain device and longitudinal direction adopts downside dragging chain

F.Transverse gas pipe and cables (Demand side should provide power and air interface near machine)

5.1 Basic configuration

5.1.1 Machine configuration specification

1) Model:                                        5000S Plasma rotary bevel cutting machine

2) Structure type:                         Gantry moving style

3) Dimension(length*width*height)  16000×5850×2000(mm)

4) Machine color                           Gray and white

5) Foundation structure:              Longitudinal steel structure or cement foundation

(per customer’s requirement)

6) Longitudinal structure:            Heavy rail connection assembly

7) Rail configuration:                   U71Mn 43Kg

8) Rail distance (mm)                  5000

9) Rail length (mm)                      16000

5.1.2 Main structure specification

1) Gantry structure                    Heavy Double Rectangular Tube Welding Structure

Longitudinal rail structure: Precision heavy rail single sided double bearing guide

Longitudinal driving style: double sides gear and rack synchronous drive

Longitudinal driving motor: AC servo driving and servo motor

Longitudinal reducer style: High-precision planetary reducer

2) Cutting torch moving station: rotary cutting torch dedicated heavy-duty moving station

a) Transverse guide structure: Imported linear guide four-slide guide

b) Transverse driving style: gear and rack driving

c) Transverse driving motor: AC servo driving and servo motor

d) Transverse reducer style: High-precision planetary reducer

3) Torch lifter: Rotary cutting torch special heavy lifting body

a) Lifting guide structure: Imported linear guide four-slide guide

b) Lifting drive form: Steel Ball Screw + High Silent Timing Belt

c) Lifting counterweight form: Reverse cylinder support

5.1.3 Other specification of the machine

1) Cable Routing: Longitudinal and Transverse Hose Cable Chain System

2) Limit arrangement: X,Y,Z,A,V axis

3) Operation table site: right

5.2 CNC system configuration and specification

EDGE CONNECT TC is the most versatile controller in Hypertherm's product line. It is designed for all mainstream applications and incorporates a large number of tools and technologies。

It is easy to integrate and very flexible. EDGE CONNECT can meet most customers’ application requirements.  

5.2.1 CNC System                        Hypertherm EDGE CONNECT TC (Electric control cabinet with cooling air conditioning)

5.2.2 CNC control axis                  six axis

5.2.3 CNC Standard configuration

1)CNC System                            Windows® 10

2)Hardware                                 Solid harddisk 

3)Display screen                          19 inch

4)RAM                                           4GB

5)USB interface                           > USB 2.0 ports

6)Temperature range                Ambient temperature  0°C -- + 40°C

7)Quality certificate                   CE、CSA

8)Operating voltage and frequency 100-240V, 50/60 Hz, DC24V

5.2.4 Control box have the air-conditioner.

5.3 Automatic programming nesting software

Specifically developed for CNC bevel cutting machine; used on the computer; automatic nesting software for drawing, bevel editing, beveling parts with welded bevel parts

5.3.1 Software style: HYPERTHERM PRONEST, USA.

5.4 Height controller

Sensor THC is a torch height control system that integrates perfectly with CNC cutting system EDGE CONNECT/Micro EDGE/Voyager, Full-closed AC servo control.  Precise initial piercing height ensures rapid transfer of the arc to the work piece, reduces wear of consumables, eliminates double arcs between electrodes and nozzles, reduces spatter, and avoids impinging on slag when the torch moves.  It is the first choice for fine plasma power.  

5.4.1 Height controller                              Hypertherm, USA

5.4.2 Controller style                                 Sensor THC

5.4.3 Height control principle                   Arc

5.4.4 Height control work method           Automatic

5.4.5 Arc voltage setting method            Digital input, height setting

5.5 Rotary bevel body specification

5.5.1 Rotary bevel body system             Vistmac

5.5.2 Rotary bevel body style                 Special for XPR460

5.5.3 Matched cutting torch                    XPR460

5.5.4 Action function                                Rotary + AB BEVEL

5.5.5 Rotary structure                             Combined bearing body

5.5.6 Swing structure                              Parallel link body

5.5.7 Protection structure                       Self-reset anti-collision device

5.5.8 Correction function                        Use bevel head calibration tool after self-reset collision avoidance

5.6High precision plasma source HYPERTHERM XPR460 (Auto gas console)

وصف

XPR460 provides excellent carbon steel plasma cutting performance, at the same time it have excellent versatility, also have industry-leading cutting quality when cutting stainless steel

Six, Equipment main technical specifications:

6.1 Main indicators of travelling

6.1.1 Effective cutting width                     3000mm

6.1.2 Effective cutting length                    12000mm

6.1.3 Cutting torch lifting distance           200mm

6.1.4 Linear positioning accuracy            ±0.2 mm/1 m

6.1.5 Linear repeat accuracy                   ±0.2 mm/1 m

6.1.5 Torch lifting control accuracy                    ±0.1 mm

6.2 Main indicators of speed

6.2.1 Free-travelling speed                    25000mm/min

6.2.3 Cutting torch lifting speed            3000mm/min

6.2.4 Plasma cutting speed                    50-8000mm/min (Infinitely variable speed)

6.2.5 Setting speed error                         ≤±5%

6.3 Main cutting indicators:

6.3.1 Plasma cutting thickness (CS piercing)   0^س angle cutting piercing  ≤45mm

                                                                               45^س angel cutting piercing  ≤30mm

6.3.2 Material                                                       Carbon steel, alloy-steel, stainless steel

6.3.3 Working gas                                               Plasma: O₂，Air， Ar，H2，N₂

6.3.4 Slot compensation minimum                   0.1mm Incremental unit

6.3.5 Cutting precision                                       JB/T10045.4-1999 standard IC Level accuracy

6.3.6 Working power supply                             AC380V±5% 50Hz

6.4 Rotary bevel body main indicators

6.4.1 Cutting parts shape                                   I，V，A，Y

6.4.2 CNC limited rotation angel                       Double-swing fit circumferential Angle> 48 degrees

6.4.3 CNC bevel angel range                             ±45 degree

6.4.4 CNC variable bevel setting accuracy      0.1 degree

6.4.5 CNC bevel accuracy and verticality        ≤±3 degree

6.5 Machine standard comprehensive test pattern scribing accuracy

6.5.1 Cross-over point excursion             0.35mm

6.5.2 Linearity                                             0.3mm

6.5.3 Circularity                                          0.35mm

6.5.4 Diagonal deflection                          0.5mm

6.6 Installation accuracy of guide track

6.6.1 Lateral linearity of main guide track              0.4mm/10000mm

6.6.2 Lateral linearity of assistant guide track       1mm/20000mm

6.6.3 Parallel between longitudinal rail-face and level surface of main and assistant guide track: ±0.2mm/1000mm

6.6.4 Rail strength meets machine acceleration: ≥ 0.6m/s

6.7 Standards compliant

6.7.1 Equipment positioning accuracy, repeatability                    JB/T5102-2011 standard

6.7.2 Plasma arc cutting quality and dimensional deviation       JB/T10045.4-1999 standard 

6.7.3 Gas cutting quality and dimensional deviation JB/T10045.3-1999

Seven, Equipment working condition and environment

7.1 Power specification

7.1.1 Machine                            AC380V±5% 50 Hz 10 KW

7.1.1 Plasma                              AC380V±5% 50 Hz 92 KW

7.2.1 Compressed air                       Pressure 1.0Mpa flow, oil-free

7.2.2 Compressed N₂                       Pressure 1.0Mpa flow, oil-free

7.3 Working environment

7.3.1 Temperature                            -10℃~ 45℃

7.3.1 Relative humidity                     90% non-condensing

7.3.1 Surroundings                           Within 5 meters without shock

7.4 Working hours                            8 hours per shift

Eight, Equipment structure and main component functions

8.1 Gantry structure

The machine gantry is composed of beam and two longitudinal driving frames. The main beam uses a special rectangular square tube steel structure, through tempering to stress, increase steel, anti-varying. Specification: 400mm×300mm×10mm×2pc, material : Q235 steel. It adopts the double gantry structure to increase rigidity.

Longitudinal end frame adopts steel plate welding; in the central position of the longitudinal end frame is a longitudinal drive connector, longitudinal drive system installed in the center of the machine to ensure the smooth operation of the machine. The main frame is also equipped with an operating platform to facilitate the operation of the equipment. Longitudinal operation uses large diameter steel rollers, its advantages are good strength, wear resistance, stable operation

Longitudinal guide track adopts high accuracy fine milled guide track, the sliding guide track mended accurately is tightly fixed on the basis of concrete or steel-frame with bearer, and it is equipped with adjusting bolt so that convenient for installation and adjustment.

The gantry type of the cutting machine guarantees the key components of the machine's working accuracy and running stability, so controlling the machining accuracy of the beam and end frame is particularly important. The cross beam is finished by a CNC gantry machining center imported from Taiwan, and the multi-face machining is completed in one clamping, which effectively guarantees the installation accuracy of the transverse rack and guide rails. Longitudinal end frame holes are machined by the floor boring machine, effectively ensuring the parallelism between the end frame roller holes and the verticality of the guide holes.

The 3×8 meter pentahedral large CNC gantry machining center, with six-axis linkage, was introduced from Taiwan and was worth more than 7 million yuan. Only our company has this equipment in the domestic cutting industry.

Its sophisticated technology, advanced testing equipment, international leading technology, one-time clamping and processing have greatly improved the precision of gantry machining. It provides technical support for the manufacture of large machine tools with extremely high processing speeds.  

Processing 8 meters beam can be formed once

8.2 Longitudinal drive device

Longitudinal work accuracy and positioning accuracy requirements are relatively high.  The machine adopts high-precision gears and rack drives. The meshing between the gears and racks is spring-loaded. This can reduce the engagement error on the one hand and also improve the smoothness of the transmission. Mechanical processing accuracy and installation accuracy are necessary conditions for ensuring the accuracy of the host's work. Coupled with high-precision precision planetary gear box and AC servo system, under the control of the CNC system, the speed and position detection, it is easy to control the machine's working accuracy

Both ends of the main end frame are respectively equipped with horizontal guide wheels, The direction of the rack plane is a fixed guide wheel, and the reverse side is an eccentric guide wheel.  Utilizing an eccentric to adjust the straightness of the end frame and guide rail, Keep the gantry stable in a straight line during movement.  Both ends of the main and secondary end frames are also equipped with rail scraping systems.  Sweep the debris on the rail surface at any time while the machine is running to ensure the normal movement of the machine.

8.3 Transverse driving device

The requirements for transverse drive working accuracy and positioning accuracy are the same as for longitudinal drive requirements, transverse driving guidance use linear guides. Clamping uses bearings and eccentrics, high-precision gears, rack drives. The machining precision of the pentahedron machining center and the installation accuracy of senior technicians ensure the accuracy of the host's work. Coupled with high-precision precision planetary gear box and AC servo system, under the control of the CNC system, the speed and position detection, it is easy to control the machine's working accuracy. Both ends of the beam are equipped with transverse limit switches and the machine's transverse reference point.

8.4 Cutting torch lifter:

Lifting device adopts linear guide, ball screw to drive the lifting of cutting torch. Among the key parts that affect the cutting accuracy of the machine, the guide bar uses a four-slide design of a linear guide to ensure long-term operation reliability.

Lifting shaft installed in heat-resistant dust cover to improve the service life under high temperature environment; equipped with upper and lower limit safety devices to ensure smooth and reliable operation in the up and down direction. In order to ensure high-speed lifting performance under heavy load, a cylinder-type weight loading system is adopted so that the working load of the motor is prevented from the influence of gravity.

8.5 Power cabinet.

Modular design, simple layout, strong and weak electricity separation safe and reliable; each line is numbered for easy checking. All electrical components use international famous brands, stable and reliable. Due to the high frequency interference caused by plasma during arc ignition and cutting, we installed an isolation voltage divider on the equipment. Good isolation to remove the electromagnetic effect of plasma high voltage, high frequency and high current effectively. Logical control using PLC programmable controller: CNC cabinet with temperature-controlled air conditioning device

The program uses a programmable controller manufactured by Japan’s Mitsubishi as an interface for plasma power supplies, numerical control systems, and height controllers. It saves a large number of electrical components and wiring, making the interface intelligent, which greatly improves the safety and reliability in the operation of the equipment.

Main feature

-Small size, easy installation

-Rich programming instructions and powerful programming function

-Scalable I/O points

-Runnable writer

-Long service life and high reliability

8.6.4 Bevel control function

The part program only needs to specify the bevel angle, the system calculates the linkage position and speed of each axis automatically.  The other program format is exactly the same as the plane program

Deflection axis manual control, automatic zero return.  Stroke soft limit/hard limit, automatic program angle control.

Rotary axis manual control, automatic zero return, stroke soft limit/hard limit, system automatic normal control

(2) The A-axis rotary shaft is designed with a lightweight, high-speed, and high-rigidity integrated combination rotary bearing, ensuring high control accuracy and dynamic tracking accuracy of the cutting path. It operates smoothly, and there is no notch phenomenon caused by excessive burning at the turning path. During cutting, it can track the normal direction of the cutting path in real time. It can handle complex small-segment paths without the possibility of bevel head stall, and the circular fitting angle is greater than 48 degrees.

(3) The bevel angle control adopts the AB-axis fitting method, allowing for programmable real-time bevel angle changes during cutting. High-tech new materials, ultra-quiet transmission mechanisms, combined with ingenious structural design, minimize volume, weight, and noise.

(4) The torch positioning uses a light-touch adjustment method, equipped with a torch protection device, innovative initial height positioning technology, and a unique floating height adjustment of the torch, making the expensive cutting head safer to use and longer-lasting.

8.7.2 Plasma bevel cutting head main parts:

(1) Bevel head A-axis swing structure

(2) Bevel head B-axis swing structure,

(3) Bevel head torch holder standard XT-300 torch holder

(4) New magnetic anti-collision system for the torch

(5) Bevel head calibration tool.

8.8 Sensor THC high precision arc height controller

Sensor THC is a torch height control system that integrates perfectly with CNC cutting system EDGE/MicroEDGE/Voyager, full closed loop AC servo control.  Precise initial piercing height ensures rapid transfer of the arc to the work piece, reduce wear of consumables, eliminate double arcs between electrodes and nozzles, reduce spatter, and avoid impinging on slag when the torch moves. It’s first choice for precision plasma source.  The feature:

1)Programmable process parameter control

2)Used as a axis of the controller, servo motor control accuracy is accurate

3)1-10 voltage gain adjustment adjusts sensitivity

4)Unique initial positioning function for initial positioning using contact signals and motor torque

5)Independent setting of parameters of proportional gain, differential gain and feed forward gain ensures stable operation of lifting mechanism

6)Accurate adjustment accuracy, tracking voltage accuracy between ± 0.25V

7)Unique retraction distance setting to reduce cutting time

8)Initial perforation height positioning allows pre-flow gas at the same time, shortening the cutting cycle

9)Overvoltage protection eliminates torch undershoot caused by automatic removal of arc voltage fluctuations, such as crossing the slot or cutting to the board edge

10)Any choice of manual/automatic mode

11)RS232 communication interface can communicate with Hypertherm XPR170/XPR460/HPR400 series

12)Automatic arc voltage adjustment

13)Non-contact inductive upper and lower limit switches

14)Standard arc voltage tracking accuracy ±0.25V

15)Plate inclination angle no more than 30^س, arc pressure tracking accuracy up to ±1.0V

Nine, Key parts used in machine

9.1CNC system: Hypertherm EDGE CONNECT TC, 6-axis

9.2 Dragging chain: KODUCT, Korea

9.3 Reducer: Shimpo, Japan

9.4 Plasma: HYPERTHERM XPR460 PLASMA (CORE, AUTO GAS CONSOLE)

9.5 Height controller: Hypertherm SENSOR THC

9.6 Auto nesting software: HYPERTHERM PRONEST, USA.

Ten, Cutting sample：

Eight, Equipment installation, commissioning and training

1)The supplier is responsible for：①providing the complete machine foundation installation drawing to the customer within 7 days after receiving the advance payment; ②working time: about 10 days: on-site free installation, debugging, training and unpredictable days

2)The demand side is responsible for：①The iron and steel foundation of this equipment (such as water bed structure cutting table, H-beam bearing beam, longitudinal dragging chain slot), cement foundation, electric, gas line and the related facilities produced by demand side according to the drawings provided by the supplier. ②The demand side cooperates with and provides the necessary support for cranes, electric welding, electric drills and manpower, and installs the electric , gas, and piping in advance. ③After signing the contract, the demand side assign the staff (1-2 staff)to get the free training in the supplier’s company, including operation, programming, maintenance and repair, and our company will guide the user to familiarize with and initially grasp the performance of the equipment so that they can achieve the level of independent operation.

Nine, Inspection and acceptance methods

1)Acceptance according to JB/T5102-2011 industry standard（equal to the contractual standards and technical documents of both parties, also equal to the international standard ISO9013-2002, and IS8206-1991)

2)After the products are completed, the supplier informs the demand side to pre-acceptance machine at the supplier’s company.

3)After the equipment arrives at the demand-side factory, the supplier shall send the technician responsible for all the installation and commissioning work according to the date of the demand-side notice, and the demand side will assist the work. After both parties of supply and demand have passed the acceptance of "Technical Agreement" and "Industry Standard", the two parties will sign a final acceptance report.

Ten, Quality assurance and after-sales service commitment

1)The warranty period of the product shall be calculated within 12 months from the date when the contracted equipment is installed, commissioned and accepted by the buyer's factory, or the machine is shipped but has not been installed and debugged within 2 months shall be calculated as 15 months, except for man-made damage.

2)After the end of the warranty period, the supplier shall implement a lifetime maintenance service for its products, supply parts at a preferential price, and provide free technical consultation.

3)  Our company has established more than 50 agents in the country and even in the world. We are engaged in product sales and after-sales service all the year round. If a malfunction occurs in the equipment operation, we will give a telephone reply within 2 hours after the user issues a maintenance notice confirmation. (In Jiangsu Province) Within 24 hours, we arrived at the on-site service and we arrived at the scene within 48 hours (outside the province).

Eleven, Commercial terms

Delivery Period: 50 working days delivery of advance payment.

Equipment transportation: The supplier bears the entire transportation cost of the machine, and BODA uses vehicle to deliver it to the customer site.

Payment method：40% TT of total contract price should be paid after the contract was signed in due form; after the equipment is manufactured, it will be paid at 100% of the total contract amount after the supplier's acceptance, and the supplier will deliver the equipment.

Annex: The other cost burdened by the demand side (The cost of installation and maintain personnel abroad)

1. The costs of air travel back and forth, accommodation, visas, meals, the transportation costs and other costs after abroad.

2.The daily subsidy of the personnel abroad, the standard 100 dollars per person per day (2 people), 20-25 dayspaid by demand side first before installation, then calculating according to the actual days after the demand-side finish installation and debugging

（calculating based on the natural days from arrival to departure day at customer country）

3. Working content and time of the personnel abroad

A、Working content: Installation, technical training for operators

B、Working time: about 10 days for Installation，testing，training and unpredictable days

C、The demand side in the contract must provide with export marks.

D、The supply-side appoint one or two professional engineers to install, shakedown test and train at the local.

Attachment: Vistmac series cutting fume purification device

In the course of operation, the CNC plasma cutting machine generates a lot of dust, which seriously pollutes the environment and impairs the health of the operating staff. Therefore, it is necessary to adopt local ventilation and control measures to purify the dust etc, so that the production environment meets the relevant national standards. The  series cutting dust purifier produced by our company integrates advanced technology at home and abroad, with good dust removal effect and high cost performance.

Proposal design 

Customer cutting machine specifications: the length of guide rail 16m, width 6m, with one plasma cutting head (I=300A) cutting dust relatively large

Customer site picture