| 3 Major Types of Flame Plasma CNC Pipe Cutting Machine | |||
| CNC Control Axis | 3 Axis | 5 Axis | 6, 7 Axis |
| Model | CNC-CP3-(600,660)/L | CNC-CP5-(600,660, 1400)/L | CNC-CP6-2000/L CNC-CP7-(2500,3000)/L |
| Pipe Diameter | Φ48- Φ600/660 mm | Φ80- Φ600/660/1400 mm | Φ600- Φ2500/3050 mm |
| Pipe Length L | Depending on pipe diameter, from the minimum 1,500 to 2000mm, to the Max. 6000, 9000, 12000 mm | ||
| Pipe Wall Thickness | Depending on pipe diameter, thickness changes in scope of 3- 100mm | ||
| Thermal Cutting Technology | 3- 35mm for plasma cutting, 6- 100mm for Oxygen fuel flame cutting | ||
| Cutting Kerf Bevel | ±45° for pipe diameter smaller than Φ2000mm, ±50° for pipe diameter large than Φ2000mm | ||
| Thermal Cutting Speed | 100- 3000mm/min. for plasma cutting, depending on pipe wall thickness 100- 1000mm/min. for Oxygen fuel flame cutting | ||
| CNC Controller | Industrial computer specialized developed for CNC Pipe Cutting Machine, 6 axis interconnect control (W axis does not need CNC control), with open control axis for future expansion | ||
| CNC Control Axis Definition | X Axis: Cutting torch moves along pipe length direction Y Axis: Pipe axial clockwise and counterclockwise ±360° infinite revolve Z Axis: Cutting torch moves up and down along pipe radius direction | On the basis of X, Y, Z axis: A Axis: Cutting torch swing along pipe radius direction B Axis: Cutting torch swing along pipe longitudinal direction | On the basis of X, Y, Z, A, B axis: V Axis: Cutting torch moves along pipe radius direction W Axis: Friction roller (Pipe support) moves along pipe radius direction |
The Lefthand Scrolling Photos: Different function units and components of Wuxi JACK CNC Pipe Flame Cutting Machine with plasma
1) Structure: It is erected stationary gantry, with length as the max. length of workpiece pipe. Cutting torch mechanism is assembled onto its overhead horizontal beam. Alongside the gantry, there is fixture and support racks/ rollers for laying long length pipes;
2) For small and medium models (CNC-CP3,5-600,660 and CNC-CP5-1400), the upper section of mechanical frame is rather simple, just a horizontal beam;
3) For large models (CNC-CP6,7-2000,3000), for operator convenient operation and observation during pipe cutting, there is overhead isle parallel with the mechanical frame, the same height as that of cutting torch mechanism;
4) Mechanical Base Bed: Its lower section is array of upright columns for holding the entire mechanical main frame;
1) As central function unit on pipe cutting, this high precision complicated mechanism is installed on mechanical horizontal gantry, and guided with precise guiderail, guaranteeing smooth, precise and stable movement, and hence constant and high level cutting performance;
2) As critical unit, structure and operating style of cutting torch differs among 3 Axis and 5/6/7 Axis configuration;
There are 2 different types, based on pipe diameter range of machine:
1) For small models of machine, CNC-(CP3,5)/(600,660), with configuration for pipe diameter smaller than Φ660mm, pipe clamp is by means of rotating chuck claw;
2) For medium and large models of machine, CNC-(CP5,6,7)/(1400, 2000, 2500, 3000), with configuration for pipe diameter larger than Φ1400mm, pipe does not need to be clamped. It has sufficient weight to withstand minor vibration caused, such pipe holding is by means of 2 rows of friction Rollers;
4. Electric Control System: Industrial level computer and its operating system, HMI (Human machine interface), dedicated for CNC Pipe Cutting Machine use.
1) This is the 1st and basic decision by customer and producer, for purchasing on CNC Pipe Cutting Machine, that how many controlling axes is proper for software and hardware control system of machine industrial computer;
2) The way to make decision: Customer raise request on pipe cutting, in terms of expected pipe diameter and cutting kerf, and supplier (Wuxi JACK) engineers propose the most application configuration of CNC control accordingly;
3) Based on diameter range of pipe, together with expected finished cutting kerf on pipes, control axis in machine has below options of:
1) Function: 3 Axis model has the basic function of pipe length cut off and hole cutting in straight edge;
During work, cutting torch moves in 2 axis and pipe rotates in 1 axis:
a) X Axis: Cutting torch moves forward and backward along pipe lengthways body, without slant angle tilting, based on expected cut off length;
b) Z Axis: Cutting torch moves straight up and down, adaptable on different diameters of pipe;
c) Y Axis: Pipe infinitely revolve in 0°- 360° scope, so that continuous cutting trace can be formed along periphery of pipe;
i. The X, Y, Z Axis indication on pipe cutting: (Fig.6)
ii. Design sketch on 3 axis CNC Pipe Cutting Machine: (Fig.7)
3) Applicable Pipes: 3 Axis CNC control pipe cutting is applied in small diameter and thin wall pipes: From Φ48mm/ 80mm to Φ600mm/ Φ660mm diameters, of 3- 6mm pipe wall thickness: For such small dimension of pipes, there is no obvious difference between straight edge and slant edge;
4) Background and Current Status: 3 axis CNC Pipe Cutting Machine is the earliest model starting on application of the machine, providing rich experience and data for developers of machine. Nowadays, with rapid development of software and hardware technology, 3 axis configuration is gradually phased out, because 5/ 6/ 7 axis have far more powerful function and acceptable cost/ price increase, which is more profitable for customer use.
a) As shown in the above 1st photo, 5 Axis control is capable of ±45°- ±50° cutting torch tilt together with 0°- ±360° infinite swiveling, so that oblique edge cutting kerf can be acquired on pipes;
b) This is especially useful for producing intersection connection between pipe branches, as shown in the above 2nd photo;
c) Importance: 5 axis model covers medium range of pipe size: The max. diameter of pipe can be Φ600mm, Φ660mm, Φ1400mm, which has extensive application, and cost effective solution for customer;
d) Plasma cutting also sees the largest use for 5 axis model machine, because for larger models, with increasement of pipe diameter from Φ2000mm, also thickness of pipe increases, which is more applicable for Oxygen flame cutting;
As shown in the above 3rd photo, on the basis of X/ Y/ Z axis in 3 Axis control, adding on:
a) The 4th A Axis for controlling cutting torch ±45°- ±50° tilt along pipe axial direction, leftward and rightward when facing with cross section of pipe;
b) The 5th B Axis for controlling cutting torch ±45° tilting along pipe radial direction, forward and backward;
i. Together with X axis cutting torch longitudinal movement and Z axis pipe ±0°- ±360° revolve, the reach scope of cutting torch and degree of freedom greatly expands;
ii. Cutting Torch: Correspondingly, as shown in the above 4th photo, the cutting torch mechanism in 5 Axis machine has more degree of freedom: The linear motion together circular trace movement;
5 Axis is used for cutting on:
a) Small to medium diameters pipe: From Φ48mm/ Φ80mm up to Φ1400mm;
b) With thin to medium level wall thickness: From 3mm to 50mm;
c) The typical specifications of pipe are from Φ660mm to Φ1400mm diameters, with 3- 50mm pipe wall thickness.
a) Function: 7 Axis large model machine has the same function as 5 Axis and 6 Axis models, the difference is, with further increasement of pipe diameter, from Φ2000mm to Φ3050mm, only V axis cutting torch movement can not cover full range of large diameter pipes cutting;
b) W Axis: By this time, shown as below, the 7th W Axis should be introduced, which is for controlling lateral movement of pipe supporting friction roller beds along pipe radial direction:
Design sketch on from left to right, effectiveness of W axis in Wuxi JACK 7 Axis Large CNC Pipe Plasma Flame Cutting Machine: (Fig.10)
a) Pipe Specifications: 7 Axis large machine is usually used to cut on large diameter pipes: From Max. Φ2500mm to Φ3050mm diameter, with 3- 100mm pipe wall thickness;
b) The above 1st to 4th photos demonstrate on flame cutting on carbon steel large pipes, at customer working site of Wuxi JACK 7 Axis large model machine.
There are several ways of classification on CNC Pipe Cutting Machine:
1) Based on CNC control axis, it can be divided into 3/ 5 / 6 / 7 axis configuration;
2) Based on the max. diameter of pipe, it can be divided into specifications of Φ600mm/ Φ660mm/ Φ1400mm/ Φ2000mm/ Φ2500mm/ Φ3000mm ...;
3) Based on mechanical structure of pipe fixture, it can be divided into chuck claw fixture style, and friction roller style.
1) CNC-CP3-600/660, for cutting on pipes with diameter up to Φ600mm- Φ660mm, of chuck claw fixing type on pipe secure, 3 axis CNC control;
2) CNC-CP5-600/660/1400, for cutting on pipes with diameter up to Φ600mm- Φ660mm- Φ1400mm, of friction roller type for pipe support, 5 axis CNC control;
3) CNC-CP6/7-2000/2500/3000 Φ2000mm- Φ3000mm for cutting on pipes with diameter up to Φ2000mm- Φ2500mm- Φ3050mm, of friction roller type for pipe support, 6, 7 axis CNC control.
1) Significance: This series CNC-CP3-600/660/L is the earliest product for CNC control pipe cutting. It can be viewed as starting point with basic configuration and function in this product family;
2) Using Feature: This basic model has the lowest manufacturing cost, quotation and hence running cost, and simplest operation;
3) Applicable Workpieces: This series of CNC Pipe Cutting Machine is for cutting off small to small medium pipes, and cut holes into pipes. Typically diameters from Φ48mm, Φ60mm to Φ600mm, with thickness less than 10mm. For such small thickness, slant rim is not a must for subsequent joint fabrication and assembly, and hence no need to cut oblique groove;
4) Without function of cutting torch swing, all the cutting kerf, be it length cut and hole cut, are all straight edge;
5) Max. pipe length can be designated by customer.
1) Importance: This model has wide application in the field of CNC control pipe cutting;
2) Strong Capability: Based on X, Y, Z axis, and adding on the 4th and 5th axis of A and B, this series of machine can cut out slant edges along both internal cut hole, and external rim when cutting off pipes;
3) Pipe Fixture: Considering relatively small diameter of pipes, fixture is still in the structure of 3 claw chuck.
When to Use:Applicable Pipe Holder:
1) Applicable Pipe Diameters: When diameter of workpiece is from Φ2000mm to larger: Φ2500mm, and Φ3050mm, the 6th V axis and 7th W axis should be introduced to the large size machine, to cover the sophisticated motion control fulfilment on large dimension pipes;
2) Technical Feature: In the case of 7 Axis control, for enforcement on the 7th W axis, one row of friction rollers is stationary style, and the other row is movable under motor drive.
As 1st operation equipment focusing on cylindrical workpieces: Pipe /tube / tanks/ Pressure Vessels, the main related equipment with CNC Pipe Plasma Flame Cutting Machine, in sequence of process technology:
1) Pipe Welding Rotator (Welding Roller Bed): For fabricating on finished pipe with circumferential and longitudinal seam welding;
2) Column and Boom Welding Machine (Welding Manipulator): For carrying out longitudinal seam welding on external and internal walls of pipes. Workpiece pipes are laid onto welding turning rolls of Welding Rotator during operation;
With wide variety of design on mechanical main frame, the machines can accomplish on different type welding tasks on:
1) Pipes, flanges and cylinders of different diameters, and made of different materials: Carbon steel, stainless steel;
2) With different welding modes: SAW, GMAW, TIG, MIG...;
3) On longitudinal and circumferential welding seams on internal and external walls;
3. CNC Pipe Steel Structure BOX H Beam End Face Milling Machine: For polishing on end face of pipes after fabrication, before painting and assembly;
4. Flame Plasma CNC Plate Cutting Machine:
Also with Oxygen fuel flame and plasma cutting, here the workpiece is changed from 3 dimensional pipe to 2 dimensional metal steel plate, which reduce quantity of CNC control to 3 axis accordingly.