Plasma cutting of profile and round pipes. PresCut-t CNC plasma pipe cutter for metal pipes Plasma cutting of rectangular pipe

CNC Plasma Pipe Cutter for metal pipes PresCut-t, produced by our company, is specially designed for shaped processing and cutting of pipes.

The equipment is perfect for making piles, tees, tie-ins. Design features allow you to count on work with a pipe up to 426 mm and a workpiece length up to 6000 mm.

The work process is automated as much as possible thanks to the implemented CNC system, which can be mastered within a few hours. Precise positioning of the torch and workpiece allows you to solve a wide variety of tasks.

This CNC plasma pipe cutter for metal pipes has software, which converts drawings into NC programs that will be recognized - DXF format. Moreover, the drawings are made, they can be in different software packagessuch as SOLIDWORKS.

The PresCut-t pipe cutter is equipped with a freestanding CNC stand. Its advantage is also that, if desired, you can work at a distance of up to ten meters from the workpiece being processed. The 7-inch color monitor shows the progress of the task in real time. The case is dusty and waterproof. The intuitive interface makes it possible for the operator to master the pipe cutter with minimal experience of using a smartphone or personal computer.

To make the process of plasma cutting of a pipe high-quality and safe, a THC cutting height tracking system is installed. Mounting the torch allows it to be angled and chamfered in the pipe being cut.

Accurate positioning of the pipe to be machined is ensured by a stepper motor and planetary gearbox. The workpiece is fixed in a lathe chuck and supported along its entire length on a rotating slide.

The body is all-welded, made of a profile of 100x100 mm, movement along the X-axis is performed by stepper motors with a force of 87 kg / cm. The transmission is provided by a sprocket / toothed rack. The guides are supplied from the renowned manufacturer Hiwin.

Also, it is important to add that the PresCut-t CNC plasma pipe cutter for steel pipes can become an integral part of a gantry plasma cutting machine with any size of the working field, for example, 1500x3000 mm, 2000x6000 mm, etc.

In this case, both the gantry machine and the pipe cutter are controlled by the same CNC system, which is very convenient - no additional operator training is required. Switching between the cutting of a sheet or a pipe takes place from the control panel.

Those. basic configuration characteristics:

Pipe diameter - up to 426 mm
Wall thickness up to 12 mm
Max. part weight for processing up to 800 kg
Pipe length up to 6,000 mm
Accuracy when positioning along the X, Y axes +/- 0.1 mm
Accuracy when positioning the rotary axis +/- 0.5 degrees
Torque transmission from the motor along the X, Y axes toothed rack / pinion
Z-axis torque transmission - ball screw
The transmission of the moment of the rotary axis is a chain transmission through a spur gearbox.
Guides along the X, Y axes - Hiwin
Idle speed up to 15,000 mm / min
Fully compatible with all common CAM systems

In addition, we can recommend various sources of plasma cutting (different power), you can choose any that is most suitable for the thickness of the metal piercing. For example, you can install a budget plasma cutter from the Taiwanese company DOG70 (metal piercing thickness up to 16mm) - the cost is 99,000 rubles.

Also, a CNC plasma cutter for metal pipes can be fitted with a cutter from the range american company Hyperterm. For example, Hyperterm Powermax 45 (pierce thickness up to 12 mm).

A large selection of pipe diameters, the ability to process various alloys, as well as an affordable price, make plasma pipe cutting one of the most demanded technologies.

We also add that from the point of view of quality, the main difference between this technology and the use of pipe cutters operating on autogen is the cleanest seam with minimal burr formation. In addition, plasma cutting of pipes expands the user's capabilities - it allows for metal surface preparation and chamfering.

The production time is 3 weeks. Special assembly will not be needed, since the equipment is supplied to the buyer in assembled form.

The PresCut-t CNC plasma pipe cutter for metal pipes is delivered either by transport companies or by self-pickup. In order to get an answer to all your questions, we recommend that you contact our managers. They will give answers to all your questions and help you understand technical features... With their help, you will be able to get exactly the configuration that best suits your requirements.

Humanity has been processing metals for many centuries. Stamping, forging, and, of course, cutting allow you to get the desired part from the workpiece. At the same time, the level of development of modern technologies makes it possible to move further and further from simple, mechanical cutting of metal (especially large thickness). Laser, waterjet and plasma cutting are increasingly used in industry (and not only). Our steel pipe cutter is also a step forward compared to the manual machine. Let's talk about the plasma method of metal processing in more detail.

A bit of theory

Since the school physics course, everyone knows that any substance has three states - solid, liquid and gaseous. A piece of ice was brought from the street - it melted and turned into water, but if you heat it on the stove, it turns into steam - everything is easy and simple. However, there is also a fourth state of matter - plasma. As applied to metal cutting technology, the word "plasma" means a working fluid (gas), which, under the influence of high temperatures, ionizes and becomes a conductor. Yes, this is not a "classical" stellar plasma, which is essentially a crumb of elementary particles. But the high temperature (the count goes to thousands and tens of thousands of degrees) makes it possible to use such a plasma for cutting metal. Let's look at the implementation of this method directly in the hardware.

Physical implementation

A pipe cutter for steel pipes using plasma cutting of metal is in principle uncomplicated. Initially, an electric arc is ignited between the material to be cut and the electrode of the device. An alternative solution is to create an arc in the apparatus, between the electrode and the nozzle itself. Ultimately we need a result - an electric arc, and we got it. Then, a working fluid, most often gas, begins to enter this arc under high pressure. Under the influence of the high temperature of the latter, it turns into plasma, the flow of which cuts the material.

As a gas, you can use both ordinary air and other substances - for example, nitrogen, argon, hydrogen, and even water vapor. The applicability of this or that working fluid depends on the type of material being processed. For cutting ferrous metals, active gases (air or pure oxygen) are used, for cutting non-ferrous metals - inactive gases (all the same nitrogen, argon and hydrogen).

In terms of design, a classical plasma system consists of several main components. The first is the power supply. It can operate both from a regular network with a voltage of 220V, and from an industrial three-phase. A transformation takes place in it alternating current in constant, also the power source allows you to adjust the current required for work - depending on the type of metal being processed and its thickness. Traditional systems plasma cutting allows you to get a current of about 12-20 thousand amperes per square inch (most of the equipment of this type is foreign, so the metric systems are appropriate).

The steel pipe cutter features higher precision and better surface finish. The value of the current strength during its operation can also reach quite large values. The second most important component of the system is the arc ignition device. A small AC circuit with a voltage of about 5 kV forms a spark that ignites the working fluid of the system, its other name is a pilot arc. The third component is the plasmatron itself. Its purpose is leveling and cooling (in some cases - liquid) supplies... These include the electrode, nozzle and swirler of the working fluid. The last important part is the compressor, which injects gas into the apparatus.

Industrial plasma cutting systems are usually equipped with drives that allow more accurate positioning of the flow of the working fluid relative to the work surface. There are both manual and CNC systems.

Advantages and Disadvantages of Plasma Cutting

Plasma cutting has several advantages over other metal cutting methods. First of all - high processing speed, especially when working with sheets of small and medium thickness. In this case, the maximum sheet thickness can reach 200 mm. The second advantage is the ability to work with any metals, because the temperature of the working fluid is measured in tens of thousands of degrees. The third advantage is practically complete absence thermal deformation of the processed material. And, of course, we recall that a pipe cutter for steel pipes provides excellent cutting quality and the ability to obtain parts of any shape. In addition, plasma cutting is characterized by a safe process - since it does not use pressurized cylinders or flammable gases.

There are also disadvantages - the design of the system is rather complicated, which affects both the cost of one cutting operation and regular maintenance... The flow of the working fluid flies out at a speed close to sound - the noise level is appropriate. Also, when using nitrogen as a working fluid, you should take care of the removal of harmful substances that are formed during the operation of the system. However, the above disadvantages are not critical, so equipment for plasma cutting of metal is becoming more widespread.

The method of cutting round and shaped pipes by plasma is one of the most productive and efficient. This technology is actively used for cutting pipes of various diameters and cross-sections, corners, sheet metal, channel bars, profiles. Plasma cutting of metal provides a high speed of the process, while the thickness of the cut material can be up to several centimeters. This technology was invented even before World War II, but its massive use in industry with the release of the necessary machine tools was established only in the middle of the last century.

Our company provides services for cutting round and shaped pipes using plasma cutting. The modern equipment used for the operation allows making holes, removing saddles, cutting in length for products up to 30 cm in diameter.

How does plasma cutting of metal structures work?

The main tool for cutting various materials by this method is a plasma jet, preheated to 20-40 thousand degrees. The technology allows to process steel of a large number of grades, including alloyed compositions, while the processing speed is 25 mm per second. Plasma cutting is allowed for non-ferrous alloys and aluminum blanks.
The procedure for cutting a pipe on a plasma cutting machine consists of a number of sequential operations:

The pipe to be processed is laid on a rotary table, while it is provided with freedom of rotation along the longitudinal axis.
The second end of the workpiece is clamped by turning machines.
The turntable and cutter start to work.
Cutting of the workpiece is possible in both planes (horizontal and vertical) due to the possibility of its rotation and movement horizontally.
As soon as the work is done, the machine shuts down.
The pipe section is removed with a special tool.

The highest level of automation and technical equipment of production allows using only equipment (machine) and the work of a qualified specialist to perform the operation.

Pros of plasma cutting of rolled metal

Plasma cutting services offered by our company allow customers to obtain a number of advantages:

The ability to perform operations with materials from any alloy: refractory, non-ferrous and ferrous metals.
During processing, the material is not deformed, no sagging and scale is formed.
Acceptable cost of plasma cutting services compared to gas cutting.
High cutting accuracy and speed of operations.
Work safety, minimum level of emissions of substances harmful to humans.

Among the existing options for cutting steel pipes, plasma cutting is one of the safest, highest quality, cost-effective, and accurate. The operation requires only the participation of the operator and the use of appropriate equipment.

What gas is used for plasma cutting?

Various types of gases can be used for cutting with plasma. Their choice is made depending on the end goal and the type of material being processed.

The use of air as a plasma-forming gas is an economical method. Almost all metals are cut with the help of air: black steel, copper, stainless steel, brass. The quality of the processed workpiece is average.

If necessary, achieve best quality oxygen is used. With it, the amount of slag on the underside of the workpiece is minimal.

Cutting with shielding gases is typical for advanced and expensive equipment. For cutting on such machines, nitrogen, oxygen, argon and air are used. Thanks to shielding gases, plasma cutting of thick workpieces (up to 5 cm) is close to laser cutting in quality.

Types of plasma cutting machines

The modern equipment used by our company to perform the operation is equipped with electronic control. Thanks to CNC machines, plasma cutting is carried out with high precision practically without human intervention.

Unlike classical equipment for cutting pipes based on autogen, a plasma installation allows you to process a metal surface with special precision. Due to their functionality, such machines are capable of performing auxiliary operations in the form of preliminary surface preparation, bevelling, chamfering and seam cleaning. Precise drives provide the ability to move the unit along the pipe.

The specialists of our company provide a wide range of services for the processing of metal products using high-tech plasma equipment. We offer our clients favorable prices and high quality work.

We present to your attention the latest from the New Technologies company. This complex is based on the concept of "All in one", which made it possible to significantly expand the range of capabilities of a conventional plasma cutting machine, allowing you to combine technological processes manufacture of products from sheet metal and profiles of various sections in the form of round, rectangular and square pipes, as well as with the use of specialized equipment to process other types of profiles. The combination of two types of processing equipment allows us to economically use the production space of our customers. When developing our products, the full potential of modern 3D mechanical engineering is used, which allows us to design our products with the most accurate.

Processing complex for air plasma cutting of metal with CNC PRM-3T intended for production sites engaged in the construction, drilling industry, bridge building, shipbuilding, production of masts and poles, oil platforms, as well as in the field of mechanical engineering equipment, etc.

Processing complex for air plasma cutting of metal with CNC PRM-3T is a 4-axis gantry type CNC machine. The X axis moves the portal along the desktop. The y-axis moves the plasma cutter module across the desktop. The Z axis alternates the plasma cutter perpendicular to the work table. The A axis is rotary about the X axis. The rail guides along which the linear movement support modules move are used as guides. The transmission along the X and Y axes is performed on a gear rack, the transmission of the Z axis of the ball screw, the transmission of the rotation of the A axis is made through a belt drive.

The equipment is equipped with a water bath for installing blanks of sheet metal on it, and it is also possible to process prefabricated structures on the table that do not exceed the span between the portal and the table. For pipe processing, the equipment is equipped with supporting devices for correct positioning of the workpiece relative to the pivot axis and self-centering chuck. For processing square and rectangular profiles, special devices are used for basing.

To move to the zone of processing pipes or sheets, it is necessary to move the working body to one or another area in automatic mode.

The machine is equipped with a THC cutting height tracking system for a high quality and safe cutting process.

The machine uses modern system multi-axis positioning of the cutter and workpiece under the control of CNC "MACH 3". The machine features improved structure and design, high automation, simplicity and ease of operation, and fully meets the needs of the user. That allows you to perform the most difficult work with the required quality.

Equipment set

IN the set of the processing complex for air-plasma cutting of metal with CNC PRM-3T includes:

1	Gantry cut table (bed, bath, portal)	1 PC.
2	Tube processing module bed	1 PC.
3	Swivel block 4 axes.	1 PC.
4	Supporting device (pipe rest)	2 pcs.
5	Four-jaw self-centering chuck	1 PC.
6	Control system unit (PC, electrical cabinet, monitor, etc.)	1 PC.
7	PowerMAX 105 plasma inverter power supply	1 PC.
8	Compressor including fittings, 5m hose, faucet, reducer (optional)	1 PC.

Specifications.

dimensions
Coordinate table with tube processing module (length, width, height), mm		4000x2250x1550
Control stand (length, width, height), mm		500x600x1650
Table working area parameters
Working area size, mm		3500x1650
Distance between table surface and portal, mm		150
Working area parameters for profile processing
Range of diameters of processed pipes		32 ... 500 mm
Maximum section of a square pipe		350 x 350 mm
Maximum machining area along the axes:
	X axis	3300
	Y-axis	+/- 140 mm (280 mm)
	Z axis	300

Movements
The largest displacements along the X (longitudinal) / Y (transverse) / Z (vertical) axes mm		3100x1530x150
Positioning accuracy, mm		+/- 0,1
Repeatability, mm		+/- 0,1
Rapid movement speeds along the axes (X / Y / Z / A), m / min.		up to 20/20/4/20
Axis transmission type
X		Toothed belt - rail M1
Y		Toothed belt - rail M1
Z		Ballscrew 16 * 10
AND		Toothed belt
Electrical equipment
type of drive		Stepper drive
X		2 * PL110
Y		PL110
Z		PL86
A		PL110
Plasma inverter power supply brand *		Hypertherm PowerMAX 45 - 105, MAXPRO 200
Voltage		380 V
Power consumption Hypertherm PowerMAX 105		15 kWt
Compressor power consumption		7.5 kW
CNC system type		Mach3 v.3.043.022
Power consumption of machine controls		< 2 кВт

Main advantages and benefits

possibility of combined processing Sheet + Profile
available hardware programming algorithm
optional selection of support types for pipes of different size type.
wide range of processed pipe diameters from 30 to 500 mm
the possibility of processing a profile of the "corner" type.
powerful welded bed (maximum weight of the cut sheet over three tons)
30 mm linear guides of the world famous HiWin brand provide high rigidity of the portal
water table with removable "sacrificial" sheets allows cutting metal without additional ventilation, water also prevents deformation of metal sheets, ease of cleaning the table from slag
4 powerful stepper motors (110 mm flange) with a toothed belt gear for gantry movement (X, Y, A axes) and 1 stepper motor (86 mm flange) for Z axis ensure high speed and precision of gantry movements.
x axis is built on two stepper motors, which eliminates possible distortions of the portal at high speeds and accelerations.
automatic control system of cutting height THC manufactured in the USA, with high accuracy (up to 0.01 mm) adjusts the height of the plasma cutter above the metal, which ensures the maximum quality of the cut on any metal.
proprietary metal search system before starting a cut with high speed defines the zero point Z.
high-quality electronic components of the machine and high-quality anti-interference wiring ensure trouble-free operation
inductive end sensors, wiring in metal hoses
ease of assembly of the machine, ease of use (training time no more than 2 days)

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