Contact Person
Managing Director
Mr. Dr.-Ing. Michael Schnick
phone +49 3531 500-0
mail sales@kjellberg.de
Digital Condition Monitoring for Plasma Cutting Consumables – Precise, Predictive, Automated
In plasma cutting, the design and condition of consumables such as the cathode and nozzle are crucial for both cost-effective operation and high-quality cutting results. Because these components are exposed to significant thermal stress and wear influenced by various factors, operators have traditionally had to either continuously monitor wear and cutting quality or replace the consumables preventively after a minimum service life.
Both approaches contradict the goal of operator-free manufacturing, as pursued in modern digital production environments: either the process remains dependent on the constant presence of personnel, or the full potential service life of the consumables is not fully utilized.
With the newly developed digital condition monitoring of cathode and nozzle, Kjellberg now offers a targeted solution for the first time. In the Q series plasma , the cutting current and voltage between cathode and nozzle or workpiece are measured with high resolution in real time, resulting in an accurate data driven method that ensures safer operation and longer torch life.
This includes a detailed evaluation of various parameters – Including the timing and waveform of the measurement signals. Combining multiple indicators significantly improves the reliability of condition assessments. At the same time, differential statements can be made on the current state of the cathode and nozzle. The system visualizes the information for the user via a traffic light interface:
- Green: Consumables are in good condition
- Amber: Cutting quality is beginning to decline
- Red: End of service life reached – replace immediately to avoid damage
In addition, the cutting process is stopped in a timely, safe and controlled manner if an imminent end of life of the cathode is detected – reliably preventing damage to the machine, other torch components, the torch head or the workpiece.
The condition data obtained is available to both the operator and the cutting system or robotic cell. In combination with a newly developed pneumatic changeover system, the torch head can be automatically replaced with a unit containing new consumables – fully automated and without operator intervention.
Plasma cutting applications benefit in practice from:
- consistently high cutting quality with fewer unexpected interruptions
- Increased system uptime and reduced maintenance costs
- An average of 30% longer service life of cathode and nozzle
- Objective, data-based maintenance scheduling
- Lower operator workload and readiness for autonomous operation
In combination with the automatic torch head replacement system, the digital condition monitoring paves the way for automated production – including so-called “lights-out” operation.