Defining the right heavy-duty plasma cutting table for your plant is an important decision to make. You need information and time to think it through, so the outcome can be a solution and not a problem.
In previous articles we have discussed light-duty and medium-duty plasma cutting tables. In each case we have shown examples of the whole system, including the cutting table, the power source and related equipment and accessories. We are going to follow that trend in this article too.
To get started, let’s first review what is considered heavy duty when it comes to plasma cutting.
What would be a heavy-duty plasma cutting table?
A heavy-duty plasma cutting table is an equipment with more capabilities than average. It is superior in at least 4 areas, which are: 1) thickness that can cut through, 2) cut quality, 3) functions and 4) efficiency. Let’s see each one of these points.
Capabilities of a heavy-duty plasma cutting table
Thickness that can cut through: A heavy-duty plasma cutting table usually can cut through thickness of 2 inches or more. That does not mean that they are used only for these purposes, but they can tackle that kind of thickness.
Cut quality: To operate a heavy-duty plasma cutting table you need a very powerful power source. This equipment can achieve cut qualities far better than a manual cutting power source. So, the right equipment can help you to achieve the right quality.
The cut quality is not coming from the cutting table, but rather, from the power source. Hypertherm’s cutting equipment provides outstanding quality, even in low amperages. Now, in more advanced equipment, such as the ones recommended in this article for heavy duty (XPR170 and XPR300), quality is even better. You can expect your quality to improve, after upgrading your equipment to heavy duty.
Functions: A heavy-duty plasma cutting table allows you to perform other functions more than just cutting, like beveling. This is a valuable function because many parts in the cutting production process are going to be welded. Applying a beveling is essential to produce high quality welds.
Efficiency: When a heavy-duty plasma cutting table is in place, more parts can be cut at the same time. This could be due to having more than one torch, the table being big enough to handle two metal plates at the same time, or the speed the equipment can reach.
Other differences of a heavy-duty plasma cutting table
Seeing heavy-duty plasma cutting equipment from another perspective, we found other set of differences to identify them. They typically have a higher amperage output and a more powerful cutting torch, which allows it to cut through materials like steel, aluminum, and stainless steel with ease. Some common features of a heavy-duty plasma cutting table are:
Amperage output: The higher the power source amperage output, the thicker the material the plasma power source can cut. Usually, the quality of the cut also is better in higher amperage systems.
For example, we are going to mention later the Hypertherm XPR170, of which maximum output current is 170 Amperes. That is why it can cut through up to 40 mm (about 1.5 in) in some materials.
Cutting torch: The torch is the part of the plasma cutting system that gets in contact with the metal and does the cutting. A more powerful cutting torch will be able to cut through thicker materials more easily.
Following the example with the XPR170, the torch required is designed especially for that system. You cannot simply connect the torch you use in the Hypertherm Powermax45.
Cooling system: A heavy-duty plasma cutting table will have a powerful cooling system to help it dissipate heat more quickly. This is important because plasma cutting generates a lot of heat, and if the machine is not properly cooled, it can overheat and damage itself.
Heavy-duty plasma cutters are often used in industrial settings, such as fabrication shops and manufacturing plants, where they are needed to cut through thick materials quickly, with more quality, and efficiently.
So, let’s now review in detail what would be the components of a heavy-duty plasma cutting system.
Components of a heavy-duty plasma cutting system
There are basic components for a plasma cutting system that, logically, can be found in heavy-duty solutions, and we are about to describe them. Nevertheless, the specific equipment and accessories a system might have will vary depending on the manufacturer and model. Later on, we are going to show 1 example of a heavy-duty plasma cutting table along with a couple of ideal power sources for it. So, the components would be:
A power source: It is the equipment that provides the high-voltage current that is needed to create the plasma arc. It needs to be set up with some cutting parameters.
Since there are several options when it comes to high duty power sources, your current and future needs regarding production speeds, material thicknesses, and cut quality is what defines which one you should get.
Keeping up with the same example we mentioned earlier, Hypertherm has 2 options in the XPR product line: XPR170 and XPR300. But there is also the option of the MAXPRO200. So, which one is ideal for you? When you talk to one of our experts about it, they are going to lead you to the right answer.
A plasma cutting torch: Is the part of the system that does the cutting on the metal surface. It is connected to a high-voltage power supply and to a gas flow regulator.
A gas source and regulator: Some gas, which is typically argon or nitrogen, is needed for the cutting process. The gas regulator controls the flow of the cutting gas.
A cutting table: It is the surface on which the material to be cut is placed. It is typically made of steel or aluminum and has a grid pattern that helps to guide the plasma cutting torch.
A fumes extraction system: Every plasma cutting table requires a fumes extraction system in place, to protect the health of the personnel and extend the life of the equipment. Nevertheless, in a heavy-duty plasma cutting table the fumes extraction system is not only a need, but it is essential, because the production, speed and usage of the equipment increases, and the fumes generated increases too.
A water table: It is a cutting table that is filled with water. The water helps to cool the cutting torch and to prevent the material from warping.
A CNC controller: It is a computer-numerical-control (CNC) system that can be used to automate the plasma cutting process. It can be used to input the dimensions of the cut, the type of material to be cut, and the desired cutting speed.
This can be useful for cutting complex shapes or for cutting multiple pieces of material at the same time. A computer connected to the system is needed to run the CNC software.
The CNC software available for heavy-duty plasma cutting systems
There are several different CNC software programs available for heavy duty plasma cutting. Some of the most popular programs are:
Hypertherm ProNest: It is a powerful CNC nesting software program that is used by many industrial fabricators and manufacturers. It can be used to create cutting files for a variety of CNC machines.
MasterCAM: It is another popular CNC software program that is used for a variety of applications, including plasma cutting. It is known for its powerful features.
Autodesk Inventor CAM: It is a CAD/CAM software program that can be used to create cutting files for a variety of CNC machines. It is known for its ease of use.
Mach3: It is a low-cost, open-source CNC software program that is popular among hobbyists and small businesses. It is known for its ability to be customized to meet the needs of the user.
The specific CNC software program that is right for you will depend on your needs and your budget. If you are a professional fabricator or manufacturer, then you will likely want to use a powerful, feature-rich program like Hypertherm ProNest or MasterCAM.
No matter which CNC software program you choose, it is important to make sure that it is compatible with your heavy-duty plasma cutting power source. You should also make sure that you are familiar with the basics of CNC programming before you start using the software.
What is Hypertherm ProNest?
Hypertherm ProNest is a powerful CAD/CAM nesting software program that is used by many industrial fabricators and manufacturers. It can be used to create cutting files for a variety of CNC machines.
ProNest is known for its powerful features and its ability to create complex cutting files. It also has several features and benefits that make it ideal for plasma cutting, such as:
Automatic part nesting: It can automatically nest parts on a sheet of material, which can save time and material.
SureCut™ technologies: It includes a few SureCut™ technologies that can help to improve the quality of your cuts, such as True Hole™, Rapid Part™, and PlateSaver™.
Powerful 3D CAD tools: It includes a powerful 3D CAD toolset that can be used to create and edit 3D models.
User-friendly interface: It has a user-friendly interface that makes it easy to learn and use.
Here are some of the benefits of using Hypertherm ProNest:
Increased productivity: It can help you to increase your productivity by automating the nesting process and by providing powerful features that can help you to create high-quality cutting files quickly and easily.
Improved quality: ProNest’s SureCut™ technologies can help you to improve the quality of your cuts by reducing dross and by ensuring that your cuts are accurate.
Reduced costs: It can help you to reduce your costs by saving you time and material.
Whats is FastCAM?
FastCAM is a CAD/CAM software program that is used to create cutting files for a variety of CNC machines. It is known for its ease of use and its ability to create high-quality cutting files. It has a few features that make it ideal for plasma cutting, such as:
Automatic part nesting: It can automatically nest parts on a sheet of material, which can save time and material.
Powerful 2D CAD tools: It includes a powerful 2D CAD toolset that can be used to create and edit 2D drawings.
User-friendly interface: It has a user-friendly interface that makes it easy to learn and use.
FastCAM is a comprehensive and powerful CAD/CAM software program that is used by many hobbyists and small businesses to create high-quality cutting files.
Plasma Cutting Table ProArc Master
The ProArc Master is a high precision CNC cutting machine designed to meet the heavy-duty needs of the industry. The rigid structure with heat treatment and I-rail with precision grinding performs stable movement even in high-speed cutting.
It is a reliable and cost-effective machine for high performance cutting requirements. It comes equipped with an advanced CNC controller, stable servo drive system, and double linear way, to ensure accuracy.
Technical Specifications
- Rigid structure
- Advanced CNC Controller
- Flip down chair design suitable for production and maximize operation space
- Accuracy: -±0.1mm
- Precision linear way with copper cover for durable lifetime
- Torch Station Maximum: 1 Plasma + 6 Oxyfuel torch
- Rail 37kg/m precision grinding I-rail (3 mt per section)
- Gas control system for oxyfuel cutting (High pressure copper pipes)
- Sealed cable chain for better protection
Technical Specifications
| Feature | Parameter |
|---|---|
| Power input | AC 220V, 50 / 60Hz, 3 phase |
| Travel drive method | Rack & Pinion |
| Longitudinal rail | Grinding l-rail |
| Transverse rail | Double linear way |
| Overall width (A) | 4,000 mm |
| Overall height (B) | 1,950 mm |
| Overall depth (C) | 1,500 mm |
| Cutting width (D) | 2,600 mm |
| Rail gauge (E) | 3,000 mm |
| Parking space | 1,500 mm |
| Cutting speed | 8/12/16 m/min |
| Traveling speed | 12/16/24 m/min |
| Min. distance between 2 torches | 100 mm |
Several different power sources could be used for the ProArc Master cutting system, but in many cases, we have used Hypertherm’s XRP170 or XPR300. Let’s look at this equipment in detail.
Hypertherm XPR170
The XPR170® is the latest system in the XPR® plasma product line so far. Delivering next generation X-Definition® processes from very thin up to mid-range thicknesses, the XPR170 expands plasma capabilities and opportunities in ways never before possible.
With unmatched X-Definition cut quality on mild steel, stainless steel and aluminum, XPR170 increases cut speed, dramatically improves productivity and slashes operating costs. New ease-of-use features and engineered system optimization make XPR easier to run with minimal operator intervention, while also ensuring optimal performance and unmatched reliability.
Technical Specifications
| Feature | Parameter |
|---|---|
| Maximum open-circuit voltage (U0) | 360 VDC |
| Maximum output current | 170 A |
| Maximum output power | 35.7 kW |
| Output voltage | 50 VDC–210 VDC |
| 100% duty arc voltage | 210 V |
| Duty cycle rating | 100% at 35.7 kW, 40° C (104° F) |
| Operational ambient temperature range | -10° C–40° C (14° F–104° F) |
| Power factor | 0.98 at 35.7 kW |
| Cooling | Forced air (Class F) |
| Insulation | Class H |
| EMC emissions classification (CE models only) | Class A |
| Lift points | Top lift eye weight rating 454 kg (1,000 lb.) Bottom lift truck slots |
Hypertherm XPR300
The XPR300® represents the most significant advance in mechanized plasma cutting technology, ever. This next generation system redefines what plasma can do by expanding its capabilities and opportunities in ways never before possible.
With unmatched X-Definition® cut quality on mild steel, stainless steel and aluminum, the XPR300 increases cut speed, dramatically improves productivity and slashes operating costs. New ease-of-use features and engineered system optimization make the XPR300 easier to run with minimal operator intervention, while also ensuring optimal performance and unmatched reliability.
Technical Specifications
| Feature | Parameter |
|---|---|
| Maximum open-circuit voltage (U0) | 360 VDC |
| Maximum output current | 300 A |
| Maximum output power | 66.5 kW |
| Output voltage | 50 VDC–210 VDC |
| 100% duty arc voltage | 210 V |
| Duty cycle rating | 100% at 66.5 kW, 40° C (104° F) |
| Operational ambient temperature range | -10° C–40° C (14° F–104° F) |
| Power factor | 0.98 at 66.5 kW |
| Cooling | Forced air (Class F) |
| Insulation | Class H |
| EMC emissions classification (CE models only) | Class A |
| Lift points | Top lift eye weight rating 680 kg (1,500 lb.) |
Getting a heavy-duty plasma cutting table
A heavy-duty plasma cutting table is a big investment that is meant to last for many years. You need to consider all the options to make the best decision.
If a heavy-duty plasma cutting table is needed in your facilities it is most likely because you already have some cutting operations in place and you are now aware of the need to increase it or improve it. That is the best-case scenario, because that means you understand clearly your needs.
Any of our experts is available to help you find the best solution, customized to your needs. We have more than 40 years of experience helping companies of all sizes to set up cutting systems in place. Feel free to contact us anytime.
