Victor Thermal Dynamics' next generation Ultra-Cut XT automated plasma power sources and iCNC XT controller for automated CNC plasma cutting system provides tools for productivity and profitability

Victor? Thermal Dynamics? has launched the Ultra-Cut? XT Series of power sources for automated plasma cutting as part of its integrated system of components that deliver higher productivity and lower cutting costs. "The Ultra-Cut XT series is the most advanced power supply available today," says Martin Quinn, CEO, Victor Technologies. "This next generation series provides exceptional cost-performance benefits, and supports our integrated approach of optimizing each component at the cutting table, leading to more profitable plasma cutting."

Higher Productivity and Superior Cut Quality

The Ultra-Cut XT system's superior cut quality enables parts to go directly from the cutting table to welding, painting or assembly without expensive secondary operations. The Ultra-Cut XT delivers ISO Class 3 or better cuts on any material from gauge to 2-inch thick, noticeably reducing bevel and the need for post-cut finishing.

On non-ferrous materials, the Ultra-Cut XT produces superior cut quality and a lower cost per cut using the Water Mist Secondary (WMSTM) process, which incorporates nitrogen as the plasma gas and ordinary tap water for shielding. On stainless steel, the WMS process cuts up to 300 per cent faster and lowers cost-per cut by 20 per cent or more compared to systems that use Argon-Hydrogen for the plasma gas.

Lowering Cost on Thicker Cuts

With the ability to cut 1-inch thick steel at 80 inches per minute (IPM) and 2-inch thick steel at 30 IPM, the Ultra-Cut XT 400 can lower the cost per cut and makes it competitive with the oxy-fuel process.

The Ultra-Cut XT also lowers the cost per cut by using HeavyCutTM consumables for cutting at 300 and 400 A. These consumables use a multiple hafnium insert as opposed to a single insert and feature a two-piece tip that runs cooler. Better cooling extends parts life and cut accuracy across the life of the tip, especially when piercing at higher amperages. These combined features extend consumables life by up to 45 per cent, which in turn reduces cut cost per foot.

Efficiency, Flexibility and Reliability

Compared to previous models, Ultra-Cut XT systems draw 20 per cent less primary current and have an average electrical efficiency of 92 per cent . They meet EU Level Five efficiency standards and help companies everywhere lower utility bills.

The Ultra-Cut XT series is available in 100 to 400-amp configurations for cutting plate up to 2" (50mm) thick. All models feature a common cabinet and components. Users can increase the output from 100 amps all the way up to 400 amps by adding inverter blocks. With its modular design, parts inventory is minimised along with repair time. A LED error display indicates machine status to accelerate troubleshooting, and should an inverter block malfunction, cutting can continue with the remaining blocks.

"The Ultra-Cut XT Series works the way our customers work - intelligently," says Dirk Ott, VP - Global Plasma Automation Brand, Victor Technologies. "The ability to add inverter blocks means fabricators never have to worry about purchasing a system that does not have enough capacity to meet future needs."

Intelligence Inside: The iCNC XT Controller

Apart from the power sources, the iCNC? XT controller provides intelligent control for integrated automated plasma cutting systems and offers a suite of capabilities that optimize cut cost and boost operational efficiency. No other plasma control system can match the iCNC XT's intelligence, simplicity, flexibility and cost savings potential. The iCNC XT enables fabricators to achieve the lowest cost per cut or best quality cut in all situations. The intelligence it brings to an integrated system is like having a plasma expert and production engineer inside the box, yet it offers experienced fabricators the flexibility to use their own cutting parameters and software programmes - ideal tools for productivity and profitability.

Using the iCNC XT can be as simple as entering the material type and thickness, then selecting the desired outcome on the touch screen interface: fastest cut for rapid cycle time or best cut quality so that parts can go straight to the next fabrication step with little or no post-cut surface preparation. Should skilled operators wish to fine-tune variables, they can easily modify them.

The iCNC XT automatically sets and dynamically controls all process variables (e.g., current, voltage, gas pressure, torch height and torch motion). No plasma experience or nesting programme skill is necessary to optimize cut quality, cut speed, cycle time and consumables life. As a result of building intelligence into the iCNC XT, companies can ensure that productivity, quality and profitability remain consistent across all tables and shifts regardless of labor and engineering resources.

Productivity Tools

Building on the iCNC XT's operating simplicity is a suite of powerful software productivity tools that operate with point and click ease. They include:

• Cost Calculator so accurate it can be used for job estimating, which can increase bid competitiveness and/or profit margins.
• Diameter PROTM hole optimisation technology, which sets cutting parameters to create "bolt-ready" holes or maintain cut quality on curves and radii. Only a Victor Thermal Dynamics system using the Water Mist Secondary process can cut bolt-ready holes on nonferrous materials as well.
• A Bridge Tool that assigns cut segments between parts to reduce the number of pierces and cycle time, producing a cost savings of up to 40 per cent.
• Automatic nesting and plate editor tools that lower manufacturing costs by reducing plate waste and idle time.
• A micro-CAD tool and standard part shapes library that enable the operator to design and/or modify parts and cut paths right at the table; there is no need to go back to engineering, potentially saving hours of downtime.

The iCNC XT can be set up to automatically optimize cutting variables and other settings for the job at hand. "The iCNC XT can achieve the desired quality without any input from the programmer or operator," says J.P. Kinos, Vice President Brand Management, Automated Plasma, Victor Technologies. "The iCNC XT also provides advanced features which empower operators to optimize the cutting and nesting process after only a few hours of training," states Kinos.

Flexibility

The iCNC XT incorporates a DXF converter so users can load part drawings directly to the controller, and it is also available as office software for use with any CNC cutting machine capable of reading ESSI or EIA cutting programmes.

Unlike other controllers that force users to adopt proprietary software, the iCNC XT also lets customers continue to use their existing office software and nesting programmes, so there is no need to retrain employees. "The iCNC XT works the way users do," says Kinos. "Fabricators can continue to use their existing programmes or use the system's built-in capabilities. Either way, the iCNC XT will adjust cutting variables to produce the best quality or lowest cost per cut."

The iCNC XT incorporates dual microprocessors. One microprocessor provides real-time cutting control and enables operators to monitor a job in progress while the second microprocessor enables them to set up another cutting programme in a second window. It also features internet-based remote control diagnostics, which enables the Victor Thermal Dynamics customer care team to take control of the iCNC XT and often troubleshoot problems in minutes. The iCNC XT can be specified with any new Victor Thermal Dynamics plasma system, installed as a retrofit and is available as a stand-alone CNC, with or without drives and servo motors.

US-based Victor Technologies provides superior solutions for cutting, gas control and specialty welding equipment under brand names that include Victor, Victor Thermal Dynamic, Victor Arcair, Victor TurboTorch, Tweco, Thermal Arc, Stoody, Firepower and Cigweld. OEM Distributor in India:

(NextGen Plasma Pvt Ltd, 2A, CIT Scheme No: XXXV, Kolkata 700 017. Fax: 91-33-22276582, 24550080. Email: sales@nextgenplasma.com)