THC-A2 Automatic Torch Height Control for Mechanized Plasma ...
THC-A2 Automatic Torch Height Control for Mechanized Plasma ...
THC-A2 Automatic Torch Height Control for Mechanized Plasma ...
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<strong>THC</strong>-<strong>A2</strong> <strong>Automatic</strong> <strong>Torch</strong> <strong>Height</strong> <strong>Control</strong> <strong>for</strong> <strong>Mechanized</strong> <strong>Plasma</strong> Cutting<br />
Introduction<br />
<strong>Torch</strong> to Work Distance or standoff during the cutting process is adjusted by monitoring<br />
and controlling the arc voltage. The arc voltage is the same as the power supply output<br />
voltage. <strong>Plasma</strong> power supplies are a current source-they generate a very steady<br />
operating current when the torch is cutting. Voltage, on the other hand varies depending<br />
on the distance between the cathode (the electrode in the torch) and the anode (the<br />
material being cut). Voltage is directly proportional to resistance (Ohms law V=I*R) the<br />
resistance in the arc is a function of the distance. When the torch to work piece distance<br />
increases the voltage goes up, and when the torch to work piece distance decreases<br />
the arc voltage goes down.<br />
The automatic torch height control uses arc voltage to maintain a consistent distance<br />
from the plate while the torch is cutting. This allows the system to maintain proper torch<br />
height regardless of variations in the material, or flatness of the cutting bed. The<br />
operator sets the arc voltage on the remote control according to the cut charts in the<br />
plasma systems operation manual. This voltage setting is usually between 100 and 200<br />
VDC.<br />
After the torch height control has completed initial height sensing (IHS ¹) and the torch<br />
has pierced the plate, motion of the cutting machine is enabled and the torch begins to<br />
move. Once the cutting begins, the <strong>THC</strong> starts sampling arc voltage from the power<br />
supply and comparing it to the target voltage set by the operator. It adjust the torch up<br />
or down to maintain the target voltage.<br />
Each voltage setting corresponds to a specific height that optimizes the arc<br />
characteristics <strong>for</strong> a clean, straight cut. <strong>Torch</strong> height has the greatest affect on bevel<br />
angle of the plasma cut piece. Setting the voltage to high level, that results in more<br />
material being removed from the top of the kerf than the bottom. This causes excessive<br />
top rounding and positive bevel. Setting the voltage too low results in too much material<br />
being removed from the bottom of plate. This causes undercutting or negative bevel.<br />
<strong>Torch</strong> height controls have many features and capabilities. The most important is to<br />
maintain a consistent distance from the plate while the torch is cutting. Moving the torch<br />
up, <strong>for</strong> a safe traveling is also important. Piercing at the right height and collision control<br />
will save you money on torch tips and torch damages.<br />
IHS ¹ is an adjustable parameter that determines the height at which the torch will fire and begin piercing<br />
through the plate.<br />
1
Elements of the <strong>THC</strong>-<strong>A2</strong><br />
1. Stepper motor driven torch lifter can be adapted to most machines fairly easily. This<br />
device moves the torch up and down in response to signals from the control console.<br />
Belt driven mechanism are used to translate motion. It has a robust, rigid and dustproof<br />
construction.<br />
Picture 1. <strong>Torch</strong> lifter.<br />
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2. <strong>Control</strong> console and remote control box, receives input commands, sends output<br />
commands to the torch lift station and monitors position feedback, voltage signals and<br />
other messages. This small box, could be mounted on the table or on the wall.<br />
ATENTTION! Don’t cover fan on the bottom!<br />
Picture 2a. <strong>Control</strong> console and remote control box.<br />
button 1 –Manually up;<br />
button 2 –Manually down and set start mode;<br />
button 3 –Pierce height set and manually “freeze” torch;<br />
knob 5 – arc voltage set knob.<br />
3. Interface card (voltage divider, 1 to 50), „divides“ and filter the arc voltage signal and<br />
sends a smaller signal voltage to the control console. All connections are made trough<br />
screw terminal blocks also in interface card. Best place to install interface card is inside<br />
of the plasma power supply.<br />
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Picture 3. Interface card, voltage divider.<br />
4. Connector cables. 12m and 3m long cable to connect elements of <strong>THC</strong>-<strong>A2</strong><br />
Picture 5. Cables<br />
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Features of the <strong>THC</strong>-<strong>A2</strong><br />
- Arc Voltage <strong>Control</strong>, 50-280 volts, fully automatic, continuously making fine<br />
adjustments throughout the cutting process.<br />
- Max. 200 mm active stroke (vertical torch travel).<br />
- Speed of retract exteeds 150 mm/sec<br />
- Max. adjustment speed 30 mm/sec.<br />
- Max. load 3,5 kg.<br />
- Weight 2 kg.<br />
- Supply voltage 24 VDC (Max. 2A)<br />
- Built-in Ohmic touch-retract initial height sensing (IHS ¹) feature ensures accurate<br />
repeatable initial piercing height settings.<br />
- Pierce height setting from 1 to 25 mm, in 1 mm increments.<br />
- Built-in stall IHS feature is always active and serves as a back-up <strong>for</strong> the Ohmic IHS.<br />
When cutting non-conductive material surfaces, such as painted plate or underwater<br />
cutting.<br />
- At the beginning of cutting start make arc voltage controlled adjustments after first<br />
“freeze” (first X-Y acceleration) or after delay 0,7 sec (in case when CNC control don’t<br />
have “edge freeze output).<br />
-Collision control. Breakaway is designed to reduce or eliminate damage to the torch<br />
due to accidental collision.<br />
- Upper and lower travel-limit stops. Upper could be set (O-ring on the belt).<br />
- Compatible with most plasma power supplies, with steady operating current and witch<br />
all machine torches. Also compatible with fine plasma.<br />
- Independent of the systems electronics, and only require a computer controlled output<br />
in minimal hook up..<br />
- Manually up and down buttons,<br />
- HV/HF ignition resistant. <strong>Control</strong>ler is 100% galvanic isolated (including analogue arc<br />
voltage signal).<br />
- Dustproof, simple, robust and rigid mechanic allows <strong>for</strong> easy maintenance and repair.<br />
- <strong>THC</strong>-<strong>A2</strong> units are easy to install.<br />
5
Installation and setup of ROBOTORCH <strong>THC</strong><br />
CAUTION: Portion of this install may include opening your plasma power supply and<br />
attaching wires. MAKE SURE THE UNIT IS UNPLUGGED prior to removing any cower<br />
or making any connections. <strong>Plasma</strong> units have HIGH VOLTAGES present that can be<br />
dangerous or lethal. IF YOU ARE NOT EXPERIENCED WORKING WITH HIGH<br />
VOLTAGES DO NOT ATTEMPT TO INSTALL THIS OR ANY OTHER DEWICE<br />
INSIDE YOUR PLASMA UNIT YOURSELF. SEEK PROFFESSIONAL HELP.<br />
1. Install Interface card (voltage divider). Best place to install interface card is inside of<br />
the plasma power supply. The connections are made trough the screw terminal blocks.<br />
Picture 6. Terminal block<br />
Block number Will be connected<br />
1 and 2 (CNC) input to computer controlled output of CNC controller, such<br />
as the one that turns plasma torch ON and OFF.<br />
3 and 4 (PL) output to plasma trigger switch<br />
5 and 6 and 7 (COL) output to CNC controller. 5 and 6 are normally open, 6 and 7<br />
normally closed. Will be switch if horizontally collision<br />
happens.<br />
8 (OS) to torch tip (ohmic touch-retract initial height sensing). NOT<br />
tip voltage! Ohmic touch-retract initial height sensing<br />
functioning if 12 is connected to.<br />
9 and 10 (FR ) edge “freeze” input. Stops making adjustments to avoid drop<br />
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the torch if cutting speed will be slow down. (Need edge<br />
“freeze” output in CNC controller).<br />
11 (-) to ( - ) The Tip Voltage (Arc voltage). About 300 VDC open<br />
circuit.<br />
12 (+) to ( + ) The plasma machine chassis.<br />
DB9 to <strong>THC</strong>-<strong>A2</strong> control console<br />
2. Install the control console and remote control box. It could be in the table or mounted<br />
in the wall. Don’t cover cooling holes on the bottom! The control console had 2 DB9<br />
connectors. One of them must be connected to the interface card (voltage divider) and<br />
other to the torch lift station.<br />
Connect power supply. It works with 100-240 VAC and trans<strong>for</strong>m it to 24 VDC.<br />
3. Mount the torch lift station with 4 screws and connect (DB9 connector) it with cable<br />
(shipped with) to the control console. Mount the torch. If torch is mounted like in picture<br />
13:<br />
- set upper limit (move small rubber O-ring in the belt up or down).<br />
-collision control switch must by push down, otherwise <strong>THC</strong> don’t work and in remote<br />
control you will see “COLLISION ”<br />
Final setup and testing<br />
1. Switch power ON. (Don’t switch plasma power supply ON )<br />
2. <strong>Torch</strong> must move up to the limit and stop.<br />
3. In LCD you will see Picture 7.<br />
4. Now you could set arc voltage and pierce height.<br />
5. If CNC controller relay connect screws 1 and 2 in terminal block, torch move<br />
down and little bit up to the pierce height. Check, haw heavy it pushes down by<br />
sensing blade surface. If ohmic sensor is connected properly it will sense it very<br />
soft. This test is reasonable to do with thin plate<br />
6. In LCD you will see Picture 10. <strong>Torch</strong> will move up to the limit, and down again.<br />
7. Switch plasma power supply ON.<br />
8. If you start cut now, you will see arc voltage picture 8 in the LCD. If you will push<br />
pierce height set button now, torch will be freeze and no torch height adjustments<br />
occurs.<br />
9. If a vertically collision happens, the torch will jump up to the pierce height and<br />
continuing cutting. In LCD you will see Picture 11.<br />
10. If a horizontally collision happens, plasma and CNC controller will be switch OFF<br />
and all stops. In LCD you will see Picture 12.<br />
11. Place torch in a right place, turn <strong>THC</strong> power OFF, wait a second and turn it ON.<br />
Everything is OK again.<br />
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Picture 7a.Power ON and torch up. Start torch height<br />
adjustments after first “freeze” (AFF). Pierce height 8<br />
mm.<br />
Picture 7b.Power ON and torch up. Start torch height<br />
adjustments after delay 0,7 sek (DEL). Pierce height<br />
8 mm.<br />
Picture 7c.Power ON and torch up. After delay<br />
0,7 sec (DEL) stepper motor will be disconnected and<br />
cutting with mechanical surface follower is possible.<br />
Picture 8a. Cutting<br />
Picture 8b.Cutting with mechanical surface follower<br />
Picture 9. Cutting and no torch height adjustment<br />
(edge “freeze feature”).<br />
Picture 10. Cutting, no plasma arc<br />
Picture 11. Vertical collision during cutting<br />
Picture 12. Horizontal collision, <strong>THC</strong> and motion stop.<br />
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