Groove cutting innovation
For 25 years, Linde Co., Ltd. has been a leader in the design and development of rotating equipment, specializing in flame and plasma cutting solutions. Their innovative rotating devices are widely used by other manufacturers, allowing for precise cuts at ±45°. Automated plasma bevel cutting demands advanced CNC systems, as angular errors require complex height adjustments that standard components cannot handle. Traditional straight-edge cutters struggle to control the bevel angle or ideal flash point effectively through arc voltage alone.
The plasma beam, while powerful, is slower than a laser beam, which travels at light speed. The plasma beam can only reach supersonic speeds, and if the exit position changes rapidly during cutting, it may lag behind the movement of the cutting head. Incorrect parameter settings can significantly reduce cutting accuracy.
During plasma cutting, gas is ionized between the nozzle (cathode) and the workpiece (anode). At contact, energy is released, vaporizing metal at temperatures exceeding 30,000°C. When cutting a square, the anode's weak points may cause uncontrolled melting at edges or corners, resulting in waste or defective parts due to misaligned electric fields.
Magnetization and inertia affect the quality of the cut. While these physical properties cannot be fully eliminated, their impact can be minimized with advanced control technology. Key areas of adjustment include torch height, cutting speed, and slit offset. For bevel cutting, torch spacing must also be compensated.
Linde recently introduced a high-performance CNC universal cutting machine, the "KingP4500," using Aikeman’s advanced CNC technology. This machine integrates multiple functions—plasma and flame cutting, drilling, milling, and marking—all on a single platform. It features a plasma rotating device for bevel cutting, a flame unit, a drill collar tapping system, and a pin marking machine, all controlled via a gantry axis.
This machine plays a crucial role in research and development, especially in handling complex plasma and flame cutting tasks. Linde’s specialized machine requires seamless integration of various process control technologies, going beyond standard components to deliver optimized automation.
Medium-sized manufacturers often lack the resources to keep up with rapid advancements in control technology. Partnering with automation experts allows them to focus on core competencies while benefiting from proven solutions. By leveraging existing industry applications, machines can be developed faster and more cost-effectively.
Aikeman Group, with over 50 years of experience in electronic control systems, has become a key player in cutting technology. Its Embedded Control Systems division provides tailored CNC solutions, helping companies like Linde achieve precision and efficiency.
Perfect groove cutting requires accurate height and angle adjustments. In plasma cutting, the distance between the nozzle and the workpiece is typically measured via arc voltage. However, when cutting grooves, the nozzle angle changes, making traditional height control insufficient. To address this, Linde uses a scanning pen to measure the workpiece surface before cutting, allowing the CNC system to adjust the Z-axis in real time. The B-axis angle further compensates for nozzle height, ensuring precise results.
Intelligent control systems play a vital role in plasma cutting. Linde’s machine uses internal compensation tables to manage torch positioning, cutting speed, and offset. These tables are created using workshop-oriented programming (WOP), allowing technicians to refine their knowledge directly on the machine. Operators can add workpoints dynamically, improving accuracy, especially in edge regions where nonlinear relationships occur.
To simplify operation and ensure independence from CAD/CAM systems, all adjustments are handled internally by the machine. Linde uses “PROfi rst CAM†software, enhanced by Aikeman’s preprocessor, which embeds control-specific commands. This ensures the controller remains independent of the CAD/CAM system used.
Aikeman’s NC operating system supports essential cutting functions, including Z-adjustment, tangential tool reset, path-dependent speed control, and nested conversion. These features enhance performance and reliability.
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