CNC Plasma Tables That Do All The Work!

Why our CNC Plasma Cutting Machine is the Best in the Industry!

Why does EZ Cut CNC have the best CNC plasma cutting machine on the market? Here’s Why:

All EZ Cut CNC plasma cutting machines come with the following:

Smooth Precise Plasma Cutting

-Automated Torch Height Control (ATH or THC)

-3 Axis Motion Control System

-Quad Capture Torch Lifter

-Ohmic Clip Material Sensing

Quality Heavy Duty Plasma Table Construction

-Engineer aluminum frame and fully welded steel support legs

-Heavy duty gantry and cast aluminum end trucks

-UL Listed

CNC Plasma Cutting Machine Software

-Industry leading integrated computer, keyboard mouse and stand included with CNC plasma cutting machine.

-Automatic nesting and lead in/lead out

-Customizable true shape library complete with plasma cut parameters

Plasma Cutter

-Integrated, factory supplied plasma cutter

-Plasma cutter output options: 80 amps or 120 amps

All tables also include:

-On site cnc plasma cutting table installation

-On site CNC plasma cutter training

-Industry best payment terms

-Unlimited CNC plasma cutter tech support with industry leading guarantee

Stepper vs. Servo Motors – Putting the Debate to Rest

A hot topic among CNC plasma table manufacturers is the Stepper vs. Servo motors debate. Many CNC websites try to explain why the motor they utilize on their CNC Plasma Cutting Table product is better, but given the right setup, either motor is capable and should be viewed as separate technologies. For this reason, we have gathered the following data to help you select the best motor for your CNC cutting needs. We assumed the following for a fair comparison:

  • Both motors have equal power ratings
  • Both motors are the same quality
  • Servo is equipped with an encoder
  • Stepper is not equipped with an encoder
  • The driver provides the same features excluding feedback options
  • The Servo motors are DC Brushed

Servo motors are quite versatile in automated CNC plasma cutting applications. So are Stepper motors and because of motor simplicity they are also found in automated routers and many other industrial applications. Both CNC Stepper and CNC Servo motors are reliable depending on the industrial environment and how well the motor is protected from plasma cutting debris. But the Stepper does not require an encoder, something that requires frequent maintenance which may fail, giving it a slight edge when it comes to reliability in a CNC plasma cutting environment.

Servo motors come in a wide variety of frame sizes, with small to large motors (many in NEMA standard sized) capable of running huge, heavy systems. Stepper motors, also available in a variety of NEMA frame sizes, don’t have as many large size models. Setup is more complex with Servo motors requiring (PID) closed loop variable circuit tuning for correct motor function, whereas Stepper motors only require motor wires to be wired to the motor driver, making them almost plug-and-play.

Every 2000 operating hours, the brushes on Servo motors must be replaced and encoders may also need replacing. But the Stepper motors only wearing parts are motor bearings, which in a CNC cutting environment is almost limitless.

Given low friction and the correct gear ratio, Servo motors do well with low speed applications while Stepper motors provide the most torque at low speed (RPM). Servo motors maintain their rated torque at nearly 90% of their no load RPM. But at 90% of their maximum RPM, Stepper motors lose up to 80% of their maximum torque, this is why direct drive stepper systems are not recommended in CNC plasma cutting applications.

Set up correctly, quality Servo motors have good repeatability with the encoder quality playing an intricate role, please note that typical off shore systems are extremely unreliable and should be avoided. Stepper motors also have good repeatability because of their construction and operation, requiring little or no tuning in a CNC plasma cutting environment. But when Servo motors are overloaded mechanically, they may malfunction and cause catastrophic failure whereas mechanical overload and/or stalling will not damage Stepper motors.

Given their efficiency, Servo motors have a first-rate power to weight ratio. But Stepper motors are less efficient than Servo motors, indicative of a smaller power to weight/size ratio. With light loads, Servo motors yield 80-90% efficiency. But given their output, Stepper motors consume more power, with the majority converted to heat. Due to the Stepper driver, Stepper motors are generally 70% efficient; more than adequate in a CNC plasma cutting application.

A Servo motor’s encoder determines the motor’s resolution, giving Servo motors a wide range of available resolutions while Stepper motors have 1.8 or 0.9 degree resolution, with micro-stepping allowing for higher resolutions in non-direct drive applications.

Servo motors are adept at accelerating loads while Stepper motors, though capable of accelerating loads, may stall and skip steps if the motor is not powerful enough or geared correctly. The current draw of a Servo motor is proportional to the load applied, making heat produced quite low. For short periods of time, Servo motors can supply 200% continuous power. While Stepper motors don’t have reserve power, they do brake very well; something that is critical in a CNC plasma cutting application. Available in DC and AC, Servo motors have a wider power availability range than Stepper motors.

Servo motors produce hardly any noise. Due to the control process, Stepper motors have a slight hum but a high quality driver can reduce noise levels, again avoid direct drive systems. Servo motors don’t have resonance issues as they don’t vibrate. Due to their high RPM, Servo motors require more gearing ratio, making a direct drive Servo motor setup rare. Internal parts and external encoders make Servo motors more mechanically complex than Stepper motors, which are simple in design, without proprietary consumable parts.

Finally, using the same power rating, quality Servo motors cost significantly more and are not as accessible to consumers as quality Stepper motors.

Stepper and Servo motors are both capable motors for CNC plasma cutting applications, given the right setup, and should be viewed as separate technologies. For more information, contact us.

Plasma vs. Oxyfuel on a CNC Cutting System

With faster cut speeds, superior cut quality and the ability to cut several kinds of metals, it’s easy to see why EZ Cut CNC plasma cutting is fast becoming the CNC cutting technology of choice worldwide. While experienced CNC oxyfuel users can cut thick mild steel with good results, understanding the benefits of CNC plasma cutting is crucial for custom metal fabricators looking to expand their CNC plasma cutting capabilities.

Automated CNC metal cutting requires intense heat that changes the chemical structure of the metal. Two factors that contribute to CNC thermal cut quality are dross and heat-affected zone. The thermal CNC cutting process produces molten waste material, called slag or dross that solidifies on the top or bottom of the metal plate. Depending on the CNC cutting process you’re using, dross can be easy or quite difficult to remove. The faster the automated torch moves in the CNC cutting process, the smaller the heat-affected zone and heat tint area. Heat-affected edges are dark, warped and potentially unfit for secondary welding until the affected area is removed.

With CNC automated oxyfuel cutting, a chemical reaction between the oxygen and steel produces iron oxide dross. Many CNC automated oxyfuel users are also concerned with metal discoloration, or heat tint. With CNC automated plasma cutting, a high-temperature, electrically charged gas melts the metal and blows the molten material away from the cut. Dross is easily knocked off, making grinding down or chiseling off unnecessary, resulting in more production for custom metal fabricators. Cuts using an automated CNC plasma cutting system on 1inch plate with a Powermax 1650 automated CNC plasma cutter and automated CNC plasma torch resulted in a smooth dross-free cut while a cut with an automated CNC oxyfuel machine torch resulted in a rougher edge and sporadic dross. The automated CNC oxyfuel cut produced a heat tint area 5 times the size of the hint tint area on the automated CNC plasma cut. Take advantage of CNC plasma cutting’s faster plasma cutting speeds and custom metal fabricators will spend less time on secondary operations to remove heat-affected zones.

Even before considering how much less time is spent on preheating and secondary operations, EZ Cut’s automated CNC plasma cutting systems offer significant productivity gains for custom metal fabricators with CNC plasma cutting and piercing times up to 8.5 times faster than CNC oxyfuel cutting systems. When cut speeds are compared for EZ Cut CNC plasma cutting tables combined with industry leading CNC plasma cutting systems like Hypertherm and Thermal-Dynamics to CNC oxyfuel cutting, speeds on ½” (12 mm) mild steel, EZ Cut CNC plasma tables range from just slightly faster to 8.5 times faster than oxyfuel depending on the CNC plasma system that was used on the plasma cutting table. EZ Cut CNC offers CNC plasma cutter tables with automated CNC production cutting and pierce capacity all the way to 2″ (50 mm) at speeds considerably faster than CNC oxyfuel cutting.

Understanding the difference between CNC operating cost and CNC operating cost per part or per foot/meter is important. The cost of everything required for CNC cutting per hour divided by the total number of feet or meters cut in an hour is the operating cost per foot or meter. Consumables, electricity, gases, labor and overhead are the costs that go into cutting. To calculate the cost per part, take the total length of required cuts to make the part and multiply it by the cost per foot or meter. Secondary operations and the labor involved inflate the cost of CNC automated oxyfuel cutting when compared to automated CNC plasma cutting tables. Multiply the hours custom metal fabricators spend on secondary operations by the labor rate, and the savings associated with automated CNC plasma cutting is clear. Factor in the greater number of parts per hour that can be produced and the money saved on each part, and the CNC plasma’s profit potential is obvious to serious custom metal fabricators looking for an automated CNC cutting table.

EZ-to-use controls, lack of gases to regulate and automatic torch height controls make EZ Cut CNC plasma cutting tables easier to learn than CNC oxyfuel tables. It takes time and practice for CNC oxyfuel users to master setting and maintaining flame chemistry. Because many CNC plasma cutters run on compressed air, mixing and regulating gases isn’t required. In fact, the parameters are already set if you’re using mechanized plasma with a CNC plasma cutting table and automated EZ cut CNC gas console.

Because it cuts by creating a chemical reaction between oxygen and iron, CNC oxyfuel cutting can only be used to CNC cut mild (carbon) steel whereas CNC plasma cutting systems can be used to CNC plasma cut any electrically-conductive metal such as stainless steel, aluminum, copper, brass and mild steel. EZ Cut CNC Plasma tables can also cut rusty, painted, decking and even stacked metal. CNC plasma bevel cutting and CNC cutting expanded metal are difficult with CNC oxyfuel, but simple with automated CNC plasma table systems.

Acetylene, propane, propylene and natural gas are the most commonly used gases with CNC oxyfuel cutting, with acetylene the most popular as it creates a hotter flame and faster pierce times than the others. Unstable and flammable, acetylene is extremely sensitive to excess pressure and temperature, including static electricity. Each year, acetylene explosions cost millions of dollars to custom metal fabricators in property damage and serious injury to those in the vicinity. CNC Plasma systems use safer gases like nitrogen and oxygen, requiring less special handling.

Understanding the benefits of CNC plasma cutting technology is essential to increasing custom metal fabricators productivity and profits. With faster cut speeds, cut quality and ability to cut several kinds of metals it’s easy to see why EZ Cut CNC plasma cutting systems are leading the industry in CNC plasma cutting technology.

EZ Cut CNC Recommends Thermal Dynamics Plasma Cutters

If you are looking to cut small intricate metal art or large sheets of metal for HVAC applications, Thermal Dynamics plasma cutters will do the job right. Thermal Dynamics has been around for years and their plasma cutters have lots of research and development incorporated in them.

EZ Cut CNC has teamed up with Thermal Dynamics to offer you the best plasma cutters for our CNC plasma tables. We were looking for reliability, support and value and we found all of those with our Thermal Dynamics plasma cutters.

Check out our CNC plasma cutting tables and see if we can improve your business by streamlining your plasma cutting operations.

Single vs. Dual Side Drive CNC Cutting Systems

CNC cutting systems have evolved greatly over the last 20 years from large heavy oxy fuel systems that carried large cast iron beams with multiple Oxy Fuel torches and large gas regulating manifold systems, to modern, dedicated CNC plasma cutting systems. Today’s CNC plasma cutting systems are low, sleek CNC plasma tables that are designed and engineered to carry a dedicated CNC plasma cutter at cutting speeds exceeding 500 ipm depending on material and thickness.

One key feature of a quality CNC plasma cutting table is the use of drive motors on both X axis drives, commonly referred to as XA ( master Side ) and XB ( slave side ), hence a dual drive system on the X axis. Original dedicated oxyfuel systems typically used a single drive on the master side and a follower bearing on the slave side. This design worked well due to the slower travel speeds that Oxyfuel requires vs. conventional CNC plasma cutting systems.

When one looks at the design of a single side drive CNC cutting system, the mechanics are the same as a cantilever, i.e. it is pinned at only one side as the bearing on the slave cannot accommodate any of the load of the carriage or the CNC mechanized plasma torch. For argument sake, let’s say that the carriage and torch is a combined total weight of 20 lbs at the master drive. The weight calculation at the slave is now 100 lbs on a 5 ft gantry; add to that the torsional loading of the CNC plasma system changing direction at 500 ipm and you will end up with bridge whip.

Bridge whip, in final part quality to the custom metal fabricator, is movement away from the master drive side and you will lose part definition towards the slave side. Holes will become oblong and corners rounded. Designers of single side drive systems have tried to reduce this by increasing the truck length on the master side; typically on a 5 ft system it will require a 5 ft truck. This now increases the overall length vs. a dual drive system. At most fabrication shops floor space is at a premium and not to be wasted with additional parking space.

Before a custom metal fabricator decides on a single side drive CNC plasma cutting system, they should ask to see two parts cut, one from the master side and one from the slave.

How to Research a CNC Cutter

Below are some suggestions that potential customers should keep in mind as they finalize their buying decision.

References

Any large manufacturer of CNC Plasma cutting equipment should be able to provide qualified potential customers several names of fabricators in the potential customer’s market that they can speak with regarding the CNC plasma cutting system that they are interested in. At EZ Cut CNC we typically provide:

  1. A new customer reference who has recently been through the purchasing/receiving/installation and training, a customer that has had the system up and running. This customer will be able to discusss why they chose EZ Cut, how the transaction went, how the machine was received and how the training went
  2. .A customer that has had a EZ Cut system for ~ 6months. This customer will be able to discuss the learning curve of using a CNC Plasma cutting table, the support they received from EZ Cut and most importantly how the system is earning the customer money.
  3. A customer that has had a system for a length of time. This customer will be able to discuss the quality of the CNC Plasma cutting machine, what types of repairs, if any the machine has undergone and what type of support has been given from the manufacturer of the system.

Machine Visit

Any large respectable manufacturer of CNC plasma cutting equipment should be able to arrange a machine visit either in the factory or at a customers location. With the potential investment of $30-$40k, one would expect to be able to at least see a system in operation. Over the past seventeen years in business we at EZ Cut have heard our competition make every excuse in the book to not take a customer to see a system. Again – do not be a victim of smoke and mirrors on the Internet.

Sample Part

The old saying” the proof is in the pudding” still stands today. Qualified CNC plasma cutting customers should ask for a sample part be cut on the same machine/plasma combination that they are looking at. Remember you as the consumer are buying a system to sell a finished part. At EZ Cut we believe that you should be allowed to see a finished cut part to your specification prior to putting a deposit down.

Do not accept plasma manufactures factory supplied cut samples. You are making a substantial investment, so ask for your part on the same machine / plasma combination that you are interested in.

Although the sales department at EZ Cut feels that they are industry leaders in capital equipment selling, it is the machine quality, customer service and ultimatly the CNC plasma systems ability to produce industry leading parts at a fraction of the price that really sells our systems.

Please do your research, ask the questions, speak with references, view a system and ask for a sample – we are sure that this will make your choice EZ!

CNC Plasma Cutting has Never Been Easier!

Cutting metal with an EZ Cut CNC plasma cutting table has made it easier for it’s customer to accomplish all automated plasma cutting needs. Our industry leading easy to use EZ G Code software gives anyone the capability to cut any shape they need from the plasma cutting table quickly and easily.

Pair our CNC plasma tables with a Hypertherm plasma cutter and you have yourself a plasma cutting machine that can effortlessly cut metal that’s up to 1″ thick.

All EZ Cut

CNC plasma cutting machines

are proudly made in the USA.


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