Revolutionizing metal fabrication: The rise of plasma cutting cobots in job shops

Collaborative robots—cobots— are increasingly making their presence known on the job shop floor. To support fabricators performing metal cutting functions, Hypertherm Associates^® has developed a suite of technologies to leverage the benefits of plasma cutting cobots. Industrial robots are larger, generally immobile, and designed to work in isolation. Cobots are smaller, easily movable from one workstation to another, and intended to work alongside humans. Both cobots and traditional robots facilitate precise, consistent, and high-quality cutting and fabrication processes. They are ideal for high-mix, low-volume industries—helping to boost productivity, reduce manual labor, and address challenges posed by a decrease in skilled labor. Hypertherm Associates and its Hypertherm^® plasma cutting product lines date back more than fifty-five years when its founders developed a way to create a narrower plasma arc to cut metal with more speed and accuracy. The company’s tradition of innovation continues with a patented, intelligent, one-piece consumable cartridge and cutting torch for its Powermax SYNC^® system series. Integrating this cartridge and a plasma cutting cobot into shop floor operations can lead to improved safety, flexibility, and productivity. Hypertherm Associates also offers Robotmaster^® off-line programming software for plasma cutting to aid in programming processes and complex shapes on a robot. The company has a rich history of integrating cutting technologies with robotics. Over the years, Hypertherm Associates’ channel partners have successfully incorporated these cutting technologies into their robotic systems, leading to advanced solutions in structural steel fabrication, pipe and tube cutting, automotive and transportation, manufacturing and industrial equipment, and aerospace.

You can try it before you buy

For fabricators not ready to commit significant capital outlay for a robot, a smaller scale cobot is a consideration. Cobots offer a lower barrier to entry by requiring a lower capital investment for a fabricator. There are leasing and rental programs for cobots, so job shops can try the technology before making a more permanent and integrated investment. In addition to financing flexibility, cobots deliver physical flexibility. Cobots are portable; they can be moved easily from one work-cell to another within a job shop. They are easy to program—even if the operator has limited computer skills. And cobots require minimal tooling. Because cobots are designed to collaborate with humans, their user interface is becoming more intuitive and user-friendly. Cobots have integrated point-and-click programming, so the operator can quickly define a part radius and smooth out the necessary cutting path. When working in tandem with a human, cobots can apply integrated learning capabilities so that previous actions and movements can inform similar projects in the future.

Intelligent cartridges

Fabricators leveraging plasma cutting cobots on their shop floor are also using smart consumables. Hypertherm Associates developed the single piece Powermax cartridge to make plasma cutting technology more conducive for automation. This new cartridge opens a lot of opportunities for the fabricator. The cartridge replaces the traditional 5-piece consumable stack-up with a single piece that is perfectly aligned. The cartridge enables 24/7 high automation, lasts longer than multipiece consumables, and minimizes the errors that can occur when a human is assembling a five-piece stack. The ease of replacing cartridges allows the fabricator to minimize downtime associated with cartridge changes. The cartridge design provides other benefits as well. The components in the Powermax cartridge are intended to wear evenly, so the cartridge offers a more predictable lifespan, allowing the operator to better anticipate when the cartridge is at its end-of-life—further reducing equipment downtime.

Incorporated into the Powermax cartridge is radio frequency identification (RFID) that feeds information from the plasma tip to the operator’s ERP system. This takes the guesswork out of setting the pressure or amperage, for the operator. The operator simply loads an app onto their smartphone, holds the device close to the Powermax cartridge, and technology does the rest. “The result is more consistency and accuracy in cutting, which enhances the part quality. The Powermax cartridge, available on Powermax SYNC systems are offered in four amperages – 45, 65, 85, and 105 amps – for mild steel cutting. There are also cartridges for extended reach, flush cutting (removing attachments), and fine feature cutting.

Off-line programming

For fabricators feeling the pressure of today’s labor crunch, a cobot connected to Hypertherm Associates’ off-line programming software, Robotmaster®, can be a means to multiply workforce output without multiplying human capital. This can be especially useful for producing three-dimensional pieces like pressure vessels, domes, and I-beams. Robotmaster software seamlessly integrates offline programming and robotic cell simulation to quickly generate accurate robot programs from CAD files. By using Robotmaster, the operator can identify and address, in advance, potential issues such as the robot’s reach limitations or collisions. Robotmaster also has embedded process expertise to determine the required speed and amperage then puts all the plasma knowledge into the robot code. One pressure vessel fabricator cites that their cobot with off-line programming software resulted in zero reworks, elimination of bottlenecks on the shop floor, and a reduction in cycle time from three minutes to eleven seconds. Many of our customers report that their operators, who aren’t skilled in robotics or programming, can perform off-line programming easily. By leveraging the intelligent capabilities within Robotmaster for plasma, the operator also can reduce secondary operations like sanding and grinding often required to prep the piece for welding. A cobot is a great way to introduce robotics onto the shop floor. Hypertherm Associates’ hardware, software, and digital solutions empower job shops to optimize their current workforce by automating repetitive and time-consuming tasks. By doing so, skilled workers can focus on more complex and value-added activities and enhance overall efficiency