integrated solutions guide

7/22/2019 Integrated Solutions Guide

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Integrated Plasma Cutting SolutionsPerformance you can trust


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Contents

1 3 Hypertherm world leading cuttingtechnology: Performance you can trust

Integrated Plasma Cutting Solutions

4 5 Step 1:Program

6 7 Step 2:Set up

8 11 Step 3:Produce results

12 Reliability and diagnostics

13 Product selection guide

For the latest product information and complete

specifications visit www.hypertherm.com


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Hypertherm

The world leader in cutting technology

Hypertherms mission is to provide customers throughoutthe world with the best cutting equipment and service in theindustry. Since 1968 we have had a single goal: leveragetechnology to cut the cost of cutting metal. Because of ourlong-standing commitment to customer-focused innovation,Hypertherm holds more plasma cutting patents and has more

customers worldwide than any other brand. In customer testinHypertherm systems consistently outperform the competition cut quality, productivity, and operating costs. With Hyperthermyou can have confidence that our solutions will help maximizethe productivity and profitability of your cutting operation.

Hypertherm facts

Hypertherm engineers have developed over 75 patentedplasma cutting technologies to provide customers withindustry-leading performance.

Hundreds of thousands of Hypertherm cutting systems arein use throughout the world.

Hypertherm has achieved a majority market share in plasmacutting worldwide.

Hypertherm wall of patents

Each Hypertherm associate owns shares in the company.Share ownership is a powerful motivator, with clear benefitsfor Hypertherm customers: every product we design is builtwith the highest quality.


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Step 1 = Program using the nesting andprocess optimization softwareHypertherms off-line nesting and process

optimization software automatically nests partsand applies optimal cutting techniques in theNC Code (Numerical Control ProgrammingLanguage).

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From part program to finished part,Hypertherms integrated cutting solutionsmake it easy to produce consistent results.

Performance you can trust

It is like having your best operator equipped with the latest

technology on every shift

Hypertherms automated cutting products have over 40 yearsof innovation and cutting process expertise built into them.Our nesting and process optimization software, computernumerical controllers (CNCs), torch height controls (THCs),and plasma systems work together seamlessly to get the mostout of your cutting operation. It is like having your best operatorequipped with the latest technology optimizing cut quality,productivity and operating cost every day.

Hypertherms integrated cutting products:

Embed process expertise to make it easy to:

Train new operators to cut like a pro within minutes

Maintain more consistent performance fromoperator-to-operator, shift-to-shift and site-to-site

Produce a dramatic improvement in hole quality thatoutperforms anything previously possible with plasma

Achieve up to a 100% increase in the number of partsproduced per hour through cut-to-cut cycle time reductions

Optimize consumable life without requiring operator adjustment

Make it easy for your cutting table provider and Hypertherm toaccess the system within seconds via Remote Help


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Step 3 = Produce results

Hypertherms integrated nesting and process

optimization software, CNC, THC and plasmasystems work together seamlessly to optimizecut quality, parts per hour and cost per part.

Step 2 = Set up on the CNC

The off-line nesting and process optimization

software interacts with the CNC software tomake it easy for the operator to set up a joband cut like a pro.


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4

Step 1: Program using the nesting andprocess optimization software

Build Hypertherm expertise into your partprograms to eliminate operator variability

Hypertherms nesting and process optimization softwaremakes it easy to:

Import part drawings

Efficiently nest them on the plate

Apply optimal cutting techniques

Generate the NC code

The resultant NC code will be used by the CNC to complete thejob. Embedding Hypertherms cutting techniques into the partprogram will help you achieve more consistent results (cut quality,productivity and consumable life) from operator-to-operator,shift-to-shift, and site-to-site. In less than an hour you will beprogramming jobs like an industry pro.

Easily import CAD:

2D and 3D CAD/CAM file import and conversion

Industry-specific design files

Nest parts efficiently to maximize material utilization.

Hypertherms superior nesting optimization capabilities delivermeasurable material savings by placing the parts efficiently onthe plate; full sheets or remnants.


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6

Step 2: Set up on the CNC

Setting up a job and cutting like a pro isas easy as 1, 2, 3

In customer testing, new operators were cutting high-quality partsin less than 5 minutes without any training. The expert cuttingtechniques that are built into the software will ensure consistentlyoptimized cut quality, productivity and operating cost with minimal

operator intervention.

1. Select the program on the CNC

The operator selects the job created using Hypertherms nestingand process optimization software.

The software automatically sets the optimal cutting parametersin the CNC that are specific to the parts being cut and theequipment being used to cut them.

The operator does not need to set torch height, pierce delay,cut speeds, and kerf compensation.

When using Hypertherm plasma systems with auto gascapabilities the operator does not need to set amperage,plasma/shield gas type, and plasma/shield gas flows.

2. Load the plate and consumables

The CNC software prompts the operator with the specificmaterial type, thickness and size to be loaded onto the cuttingtable.

The consumables that need to be loaded into the torch areidentified with pictures and part numbers on the CNC display.

3. Align the plate

The CutProWizard guides the operator through a step-by-step

process of aligning the plate.


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If the operator needs help they can haveaccess to cutting optimization tips with theclick of a button.

Hypertherms instruction manuals for theCNCs, THCs, and plasma systems are all

available on the CNC. Available in multiplelanguages, these support tools help the operator andmaintenance teams maximize the performance of thecutting table.


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8

Step 3: Produce results

Optimized cut quality, productivity and

operating cost = greater profitability

Hypertherms integrated nesting and process optimizationsoftware, CNC, THC, and plasma cutting systems haveover forty years of cutting innovation and process knowledgebuilt into them. Our products are designed to work togetherseamlessly, making it easy to optimize cut quality, parts perhour and cost per part.

Optimize cut quality

Hypertherms integrated nesting and process optimizationsoftware, CNC, THC, and plasma systems provide:

Automatically applied cutting techniques to ensure consistentlyoptimized quality

Monitoring and automatic adjustment for:

Arc voltage as the consumables wear, to ensure that qualityis maximized throughout the life of the consumables

Kerf compensation based on material thickness, amperageand speed to produce tighter tolerances and moreconsistent quality

Cut quality optimization tips on the CNC that are easily accessedwith the click of a button

Hypertherm plasma cuts fine-feature parts with superior qualityand consistency, reducing the cost of secondary operations.


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Cross section of a hole

Revolutionary plasma performance:True Holecut quality

Our patent-pending True Hole* cutting technology for mild steproduces significantly better hole quality than what has beenpreviously possible using plasma. This is delivered automaticawithout operator intervention.

Hypertherms True Hole cutting technology for mild steel isa specific combination of cutting parameters (process gastype, gas flow, amperage, piercing methodology, lead in/outtechnique, cut speed, and timing) that is optimized for eachmaterial thickness and hole size. This new process is exclusiveavailable for use on Hypertherms HPRXD auto gas plasmasystems and is automatically applied by our nesting andprocess optimization software and CNC software to mild steeholes with hole diameter to thickness ratios as low as 1:1.

*Achievable on a True Hole enabled cutting table combined with MTC ProNest2010,

CNC, THC, and HPRXD with auto gas systems. Consult with your table manufacturer

for more details.

12 mm (1/2") hole cut without True Hole technology

12 mm (1/2") hole cutwith True Hole technology

With True Hole technology,taper is virtually eliminated anthe ding is reduced and biaseto the outside of the hole.Dross is still present but canbe easily removed.

Without True Hole

With True Hole

With True Hole you achieve partdesign dimensions more consistentlyso secondary operations are neededless frequently.


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0

20

40

60

80

100

Pre-flow

IHS

Table motion

Retract time

Cutting

ArcGlide THC with Hyperthermssuite of integrated plasma

cutting products

ArcGlide THC(stand-alone)

CommandTHC

Seconds

0

100

200

300

400

500

600

ArcGlide THC with Hyperthermsuite of integrated plasma

cutting products

ArcGlide THC(stand-alone)

CommandTHC

Numberofpartsperday

1 0

Increase parts per hour

Hypertherms patented plasma technologies, embeddedcutting techniques and active process monitoring optimize cutquality and minimize time-consuming secondary operations.

Hypertherms easy to use nesting and process optimizationsoftware coupled with the patent-pending CutPro Wizardon the CNC make job set up extremely fast and easy.

Part processing time 203 mm flange (8") Number of parts 203 mm flange (8")

Example part 203 mm flange (8")

100% increasein the numberof parts

Achieve up to a 100% increase in thenumber of parts produced per hour throughcut-to-cut cycle time reductions

Rapid ignition and motion optimization techniques programmedinto the software minimize wasted time in between cuts andincrease the number of parts produced per hour by up to 100%.

80% reductionin cut-to-cutcycle time


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Improper cut height due to not adjusting arc voltagefor electrode wear

Reduce cost per part

Optimized process and torch height settings are automaticallyapplied by Hypertherms software. This reduces the chance ofoperator error and helps ensure optimal consumable life.

Hypertherms patented LongLifetechnology reduces currentand gas flow at the end of a cut to minimize electrode hafniumwear and produce industry-leading consumable life that can bas much as twice the life of any competitor.

Hypertherms nesting and process optimization softwaremaximizes consumable life by automatically managing cutlead-outs and arc shut-off timing to avoid extinguishing thearc prematurely by using a controlled ramp down.

Optimize consumable life without requiringoperator adjustment

Using Hypertherms proprietary techniques, the ArcGlideTHautomatically and continuously samples and adjusts arc voltato correct for consumable wear. This results in proper torchheight for optimal cut quality over the life of the consumableswithout requiring operator adjustment.

Proper cut height automatically maintainedby ArcGlide THC

Partially worn electrode

Unacceptable cut quality

Partially worn electrode

Proper cut quality

Numberofconsumablestarts

(Labt

est4

-secondd

uration)

HPR with proper torch heightautomatically maintained

by the ArcGlide

HPR without theoperator adjusting

for electrode wear

0

500

1000

1500

2000

2500

3000

3500

Number of consumable starts with < 0.25 mm (0.010") deviation from propercut height without operator intervention (130 A) 12 mm (1/2") mild steel

Cut quality and consumablelife optimized automaticallywithout operator intervention

Consumable life and cut quality optimizedConsumables discarded prematurely

Proper cut heightPlate contact candamage consumables

Number of starts

relying on operatorinterventionfor optimizedcut quality andconsumable life


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Proven reliability, on-board diagnostics,and Remote Help maximize uptime

During development Hypertherm systems endure rigorousreliability testing procedures that are equivalent to years ofuse in extreme operating environments. The equipment issubjected to a wide range of temperatures, humidity levels,vibration, electrical noise, dust and incoming voltage toensure that the products are extremely robust.

Hypertherms preventative maintenance and troubleshootingtips are available on the CNC for all of our equipment(CNC, THC, and plasma systems). This makes vital systeminformation easily accessible when you need it.

Hypertherms CNC can be used to run CNC, THC, plasmasystem and other table component diagnostics.

Remote Help

Remote Help is an Internet based tool that allows your table

manufacturer and Hypertherm to be virtually in your factorywithin minutes. Part program, CNC, THC, plasma system,and cutting table motion diagnosis and repair can often beaccomplished without an on-site visit. Hypertherms RemoteHelp utility allows cutting system diagnostics over theInternet to help avoid costly downtime.

Remote Help features include:

Fast and secure connectivity

Safe remote access to the CNC to view and modify setups

Secure and rapid file transfer

Up to 15 participants can join the same sessionAbility to conduct HyPerformance Plasma system diagnosticsremotely

Useful for technical training

Free access for all participants

Hypertherm support engineer(if needed)

CNC machine Table manufactusupport engine

Central, securewebsite


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EDGETi MicroEDGE EDGEPro

Computer numerical controllers (CNCs)

Torch height controls (THCs)

Sensor PHC ArcGlideTHC

Powermax HySpeedHSD130 HyPerformancePlasma HPRXD

Mechanized plasma systems

To learn more about these products go to www.hypertherm.com

MTC nesting and process optimization software

NestMaster TurboNest ProNest


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ProNest

TurboNest

NestMaster

EDGEPro

MicroEDGE,Mariner,VoyagerIII

EDGETi

ArcGlideTHC

SensorTHC,CommandT

HC

SensorPHC

HyPerformancePla

smaHPR400XD,

HPR260XD,HPR1

30XD

HySpeedHSD130

,HT2000

MAX200,Powerm

ax1650,Powermax1250,

Powermax1000,Powermax45

Cut quality

HyDefinition cut quality

True Hole cutting technology

Conventional LongLife O2and air cut quality

Conventional non-LongLife O2and air cut quality

Automatic arc voltage adjustment as consumables wear withoutoperator input

Automatic kerf compensation based on material thickness, amperageand speed

Productivity (parts per hour)

Increase parts produced per labor hour due to rapid job set ups, fast cutspeeds, less secondary operations and fewer consumable changes

Minimize cut-to-cut cycle time with rapid ignition techniques

Minimize cut-to-cut cycle time and avoid collisions using tool pathoptimization techniques

Operating cost (cost per part)

Increase parts produced per labor hour due to rapid job set ups, fast cutspeeds, less secondary operations and fewer consumable changes

LongLife ramping technology for significantly longer consumable life

Optimize consumable life for HyPerformance and LongLife processesusing lead out optimization for proper ramp downs

Optimize consumable life using automatic arc voltage monitoring andadjustment without operator input

Part nesting efficiency to minimize material waste

Optimize consumable life using automatically set pierce and cut heights

Ease of use

Cutting process parameters automatically set up by the off-line software

Easy job set up using the CutPro Wizard

Plate type and consumable part number prompts for the operator on the

CNC

Cutting optimization tips on the CNC

Instruction manuals for CNC, THC, and plasma systems on the CNC

Diagnostics

Remote diagnostics over the internet

Off-line nesting or CNC software diagnostics for the part program

= Best

= Better

= Good

= Not a key contributor

Product selection guide

Hypertherm HyPerformance HPR CutPro True Hole MTC ProNest ArcGlide LongLife NestMaster TurboNest EDGE Sensor Powermax HySpeed

Step 1 Step 2

MTC CNC THC Plasma

Step 3

integrated solutions guide

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