Plasma cutting machine application

In industrial production, metal thermal cutting generally includes gas cutting, plasma cutting, laser cutting, and the like. Among them, plasma cutting has a wider cutting range and higher efficiency than gas cutting. Fine plasma cutting technology is close to the quality of laser cutting in terms of the quality of the cut surface of the material, but the cost is much lower than laser cutting. Therefore, plasma cutting has developed rapidly since it was successfully developed in the United States in the mid-1950s. With the rapid development of computer and digital control technology, CNC cutting has also flourished and improved processing accuracy. Saving materials and improving labor productivity have shown great advantages. This has led to the development of plasma cutting technology from manual or semi-automatic to numerical control, and has become one of the main directions of the development of CNC cutting technology. CNC plasma cutting technology is a high-tech integrated with numerical control technology, plasma cutting technology and inverter power supply technology. Its development is based on the common progress of computer control, plasma arc characteristics research, power electronics and other disciplines. China's CNC cutting technology started in the 1980s, and CNC plasma cutting technology started later. However, in recent years, some universities, research institutes and manufacturers in China have carried out research on CNC plasma cutting technology, and gradually developed and produced various specifications of CNC plasma cutting equipment, which has narrowed the gap with advanced foreign technology.

1. Status of domestic CNC plasma cutting

Flame cutting and plasma cutting are most commonly used in sheet metal blanking in our factory. The equipment used includes manual cutting, contouring machine cutting, semi-automatic cutting machine cutting and CNC cutting machine cutting. Compared with other cutting methods, the manual cutting is arbitrarily large, flexible and convenient, and does not require special supporting cutting equipment. However, the shortcomings of manual cutting and cutting are also obvious. The quality of the slit is poor, the dimensional error is large, the material waste is large, the workload of the subsequent processing step is large, and the working conditions are bad. Cutting with a profiling machine can greatly improve the quality of the workpiece, but it must be pre-processed with the workpiece, which is not suitable for single piece, small batch and large workpiece. Although the semi-automatic cutting machine reduces the labor intensity of workers, its function is simple and only suitable for cutting of one shape. The above three cutting methods are widely used in small and medium-sized enterprises in China even in some large enterprises because of low equipment cost and simple operation.

With the vigorous development of the domestic economic situation and the acceleration of the trend of welding and casting, the advantages of CNC cutting are gradually becoming recognized. CNC cutting not only greatly improves the utilization rate of the board, improves the product quality, but also improves the workers' The labor environment and labor efficiency are further improved. At present, the CNC cutting machine used in China's metal processing industry is mainly based on flame and ordinary plasma cutting machine, but pure flame cutting can not meet the needs of modern production, and the current market demand for CNC cutting Most of the machines are CNC plasma cutting machines. This type of cutting machine can meet the needs of cutting materials and metal parts of different materials and thicknesses. Therefore, the demand will be larger and larger, but the gap with foreign countries is still extremely high. Obviously, the main performance is: 90% of the metal processing industry in developed countries is CNC cutting machine cutting, only 10% is manual cutting; while China's CNC cutting machine only accounts for 10% of the total amount of blanking, which under CNC plasma cutting The proportion of materials is smaller. The reason, higher equipment cost, complexity and maintenance and operation constrain the numerical control The further popularization of cutting in China. Therefore, the domestic CNC cutting machine manufacturers have introduced foreign control system technology. After secondary development, they have applied to the cutting field and designed a CNC cutting machine suitable for China's national conditions. CNC cutting equipment has technically reached or exceeded similar foreign products.

The annual market demand for CNC cutting machines in China is between 400 and 500 units. The products are mainly CNC plasma cutting machines. In comparison, the profile cutters sell thousands of units a year, and the semi-automatic cutters sell tens of thousands of units a year. It can be seen that the development potential of China's CNC cutting market, especially the CNC plasma cutting market, is huge.

1.1 Introduction to plasma cutting types a. Ordinary plasma arc cutting. According to the main working gas used, it is mainly divided into argon plasma arc cutting and oxygen plasma arc cutting. Oxygen plasma arc cutting and air plasma arc cutting and other types. The cutting current is generally below 100 A and the cutting thickness is less than 30 mm.

b. Re-constrained plasma arc cutting. According to the re-constraint mode of the plasma arc, it is mainly divided into water re-compression plasma arc cutting, magnetic field re-constrained plasma arc cutting and the like. Since the plasma arc is compressed again, the current density and the energy of the cutting arc are further concentrated, thereby improving the cutting speed and the processing quality.

c. Fine plasma arc cutting. The plasma arc current density is very high, usually several times the current plasma arc current density. Due to the introduction of techniques such as rotating magnetic field, the stability of the arc is also improved, so the cutting precision is quite high. The surface quality of fine plasma cutting in foreign countries has reached the lower limit of laser cutting, and its cost is only one-third of that of laser cutting.

1.2 Plasma cutting power supply

The high-leakage transformer-resistant and secondary-side rectifying cutter power supply that was originally applied in China has been gradually replaced by an inverter-type plasma cutting power supply. The principle is shown in Figure 1. Domestic plasma power supplies are mostly used for manual cutting and matching on trolley cutting machines. In recent years, due to improved performance, they have also been gradually used in CNC cutting machines, but they still need to be further improved.

1.3 Current Status and Development of Numerical Control Technology

The rapid development of computer technology has promoted the upgrading of numerical control technology, and this has increasingly perfected the high-precision, high-speed and high-efficiency functions of numerical control plasma cutting. The new generation CNC system developed by the CNC system manufacturers in Europe, the United States and Japan, which represent the world's advanced level, utilizes the rich software and hardware resources of the industrial computer to have an open architecture, that is, the development of the numerical control system can be on the unified operating platform, facing the final The user, by changing, adding or cutting structural objects (numerical control functions), forms a series, and can easily integrate the user's special application and technology into the control system to quickly realize the development of different varieties and different grades of products.

The open architecture makes the CNC system have better versatility, flexibility, adaptability and scalability, and it is developing in the direction of intelligence and networking.

At present, the open system has two basic structures:

a. CNC + IPC motherboard. The main board of the industrial computer is inserted into the traditional CNC machine. The industrial control board is mainly used for real-time control. The CNC is mainly used for real-time control based on coordinate axis motion.

b. Industrial computer + motion control board. The motion control board is inserted into the standard slot of the industrial computer for real-time control, while the industrial computer is mainly used for non-real-time control.

The numerical control system of CNC plasma cutting machine produced in China is developed on the basis of the introduction of foreign numerical control technology, and gradually forms a numerical control system that can better adapt to domestic users. Generally speaking, in the numerical control system, it has the basic functions of similar foreign systems. However, compared with foreign advanced numerical control systems, there is still a big gap in error recording, networked production, and fully automatic production.

1.4 Anti-jamming measures of CNC plasma cutting system

The cutting power supply has strong electromagnetic interference, which requires the computer control system to have high anti-interference ability, which can resist the high frequency interference during plasma arc ignition, and also resist the interference of high current plasma arc during operation, and can resist Other sources of interference at the job site. The anti-interference design improves the reliability of the CNC plasma cutting system and reduces the failure rate.

2. Status and development trend of CNC plasma cutting at home and abroad

The manufacturers of foreign CNC cutting machines are mainly concentrated in Germany, the United States and Japan. From the perspective of mechanical structure, its development has experienced three stages: cross type (light type), door type (small size) and gantry type (large size), and the corresponding models are various. The manufacturers that can represent the highest level of CNC plasma cutting technology are mainly concentrated in Europe and America. For example, the cutting precision of the fine plasma cutting machine of the US hypertherm company has reached the lower limit of laser cutting. At present, foreign manufacturers have installed a special cutting robot on the gantry cutting machine. Developed a gantry-type cutting tool for a five-axis control system that cuts various trajectories in space and uses a special tracking probe to control the cutting trajectory during the cutting process. In contrast, although the cross type, door type and gantry type are produced in China, the breadth is not enough, the manufacturer's product model is relatively simple, and there is no gantry type special profile cutting machine product.

In recent years, due to the increasing requirements for cutting quality and labor environment, advanced plasma cutting methods such as large-scale underwater plasma cutting and fine plasma cutting have been developed rapidly, and the corresponding products in China have been in market demand. The amount has also increased year by year. In China's plasma cutting equipment production industry, due to the lack of mechanism for the transformation of plasma cutting theory research and production practice, the new technology is not widely used, and the speed of new product development is not fast, which restricts the further development and application of plasma cutting technology.

It can be foreseen that the market demand for CNC cutting machines in China will still be dominated by CNC plasma cutting machines. At the same time, the demand for advanced cutting equipment such as large-scale underwater plasma cutting and fine plasma cutting, which has been widely used abroad, is increasing year by year in China.

From the trend of the development of foreign CNC plasma cutting industry, intelligent precision cutting will become the future development direction of the cutting industry.

3. Conclusion

China's steel output has already reached 100 million tons, coupled with the booming manufacturing industry, this will certainly promote the sound development of domestic CNC plasma cutting technology. In general, China's CNC plasma cutting has reached the level of similar foreign products in terms of basic functions, but there is still a long way to go to fully meet or exceed foreign standards. All domestic enterprises and scientific research units should increase scientific research efforts, attach importance to horizontal cooperation among enterprises, form complementary advantages, and strive to further improve in the following aspects:

a. The relevant conversion of plasma theory research and production should be strengthened;

b. Plasma power supply should further improve stability;

c. Actively develop CNC plasma cutting equipment suitable for China's national conditions and economic reliability;

d. The man-machine dialogue interface is friendly and suitable for cutting and cutting workers;

e. Network interconnection function.

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