KERF Solution

200A Autocut XT from Thermal Dynamics and a CR PLASMA control system.

The Kerf machine was purchased second-hand with a Burny Controller and a Kaliburn Plasma Source. There were a number of issues, and it was decided to remove all old control and plasma and refit the CR PLASMA retrofit solution

• New driven Z axis - with a 200A AutCut XT
• New modern PC based controller
• New Hoses and Cables on all machine functions
• New Modern AC servo motors.
• The client gave the machine a lick of paint too, which made all the difference.

CR PLASMA KERF Retrofit Solution

First tests in a 5mm plate

The machine, now on modern control and updated servos and Z axis system, is able to hold sub-tenth mm tolerance on torch positional repeatability.

With the new CR PLASMA height control system, the Z axis keeps the torch to work distance on point.

First tests in a 10mm plate

Machine up and running, cutting out a nest in 10mm at 100A. The supplied system came with the full nest package from CR PLASMA to allow optimal alignment of parts in the next before importing into the machine.

Photos

Kerf Retrofit Summary

This Kerf Retrofit involved reviving a second-hand kerf cutting machine that was initially non-functional due to an outdated Burny controller and power source. The machine, originally acquired at a low cost, was intended for high-definition cutting but struggled to operate.

Retrofit Process

• Power Source Upgrade: The retrofit utilised a 200-amp Auto-Cut XT plasma system, aligning with the client's structural cutting needs (10-15mm plate).
• Servo Motor Overhaul: The existing brushed DC servos were outdated and expensive to maintain, so they were replaced with closed-loop AC brushless servo motors. This improved performance, reduced maintenance costs, and ensured long-term supportability.
• Mechanical Enhancements:Existing gearboxes were modified with custom interface plates to fit the new servo motors.
• The original Z-axis torch lifting system was replaced entirely with a CR PLASMA Z-axis system.
• New IFM induction sensors were installed for precise X, Y, and Z homing

Controller System Upgrade: A CR PLASMA Controller was installed in a rolling console, featuring a high-spec, passively cooled PC with an industrial TFT touchscreen.

Outcome

• The retrofitted kerf machine now operates efficiently with modern components, reducing long-term costs.
• The machine is now fully supportable with off-the-shelf parts, ensuring affordability and easy maintenance.

This retrofit transformed a failing system into a high-performance, cost-effective, and future-proof plasma cutting solution. 🚀