Do-it-yourself plasma cutter from an inverter, how to remake it

Plasma cutter from a welding inverter

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It is not always possible to find such a device as a plasma cutter in the arsenal of home craftsmen. Many people prefer to make do with a conventional welding machine. However, there are craftsmen who can make a plasma cutter from a welding inverter with their own hands for their own needs. Thus, it is possible to save a considerable amount of money, and the household is replenished with a new device.

Plasma cutter: main functions, device, action

Plasma cutting machines are widely used in production related to the processing of non-ferrous metals. If ordinary steel can be cut with an oxygen or propane torch, then completely different conditions are required for aluminum, stainless steel and other similar materials.

First of all, this is due to the high thermal conductivity of these metals. When using a conventional flame, the surface of the workpiece will heat up immediately over a large area, and this area will undergo deformation.

Using a plasma cutter, the metal is heated at a point, and the width of the cut is minimal. If desired, non-ferrous metal parts can not only be cut, but also welded using a special filler wire. It is quite possible to assemble a working plasma cutter from an inverter. The main thing is to know the general operating principle of such a unit and the interaction of all its components.

The technological process itself can be divided into several components:

• First, the current source generates the required voltage. Next, it is fed into the plasmatron or torch-torch through electrical cables.
• Inside, the plasmatron is equipped with two electrodes – an anode and a cathode. Under the influence of voltage, an arc appears between them.
• Next, air flow is supplied under pressure through the channels. Under its influence, the electric arc is directed outward, with a simultaneous increase in its temperature. Instead of air, technical fluid can be used, the evaporation of which leads to the creation of high pressure. In all cases, an ionized flame with a high temperature (up to 80000C) is formed, which is plasma.
• The cable connected to the mass of the product causes the arc to close in the area of ​​the cut, thereby completing the technological cycle.
• When switching to the welding mode, instead of air, argon or other inert gases are used to protect the weld pool from external influences.

Due to the high temperature, a limited area is heated very quickly. As a result, the metal is cut without overheating the entire product.

The power of a plasma cutter depends on its design and configuration. The model, made for personal needs, is capable of cutting workpieces with a thickness of 10-12 mm, and can be used to weld alloy steel using filler wire. The simplest plasma cutter consists of a power source, plasma torch, compressor and mass. These parts and other components must be prepared in advance before starting assembly.

Preparation of parts and components

It is recommended to start your search for the necessary components with the power source. It is in this place that the current is formed. Most often, a plasma cutter is made from a welding inverter, since this equipment has all the necessary properties. First of all, it is a stable and stable voltage, ensuring high quality of work performed. In addition, inverter devices are characterized by their small size and weight, simple settings and adjustments.

As a result, the plasma cutters themselves are just as compact and are best suited for hard-to-reach places that cannot be reached with conventional equipment.

Inverter power supplies have a very high efficiency, due to which their energy consumption is significantly reduced. If you do not have an inverter, you can use a conventional welding transformer.

However, in this case, you need to be prepared to overcome the difficulties associated with excess weight, large size and high energy consumption.

The next important element after the power source is a cutter operating on the basis of a plasma jet. The quality of the cuts performed directly depends on it.

You will definitely need a compressor that generates an air flow, which later turns into a plasma jet. In addition, you should take care of a special device, consisting of a cable and a hose, through which current and high-pressure air are simultaneously supplied to the cutter. The main part of the plasma cutter is the plasmatron, which requires a separate detailed consideration.

General design of the plasma torch

The design of the plasma torch includes a nozzle, a channel for supplying an air jet, an electrode, and an insulator with a cooling function.

The most crucial moment is the choice of a suitable electrode. Typically, this component is made from beryllium, hafnium, zirconium and thorium. During strong heating, the surfaces of these materials are covered with refractory oxide films, which prevent the electrodes from actively deteriorating.

Some of these elements, when heated, release substances that are hazardous to human health. For example, beryllium causes the appearance of radioactive oxides, and thorium emits fumes that, when combined with oxygen, become toxic. Hafnium is best suited for electrodes, as it is not at all dangerous to people working with it.

The plasma jet required for cutting is formed in a nozzle that requires fabrication. It depends on it how high-quality the work flow will be. The most optimal nozzle diameter is considered to be 30 mm. A neat cut depends on its length. However, the structure should not be too long, as this may lead to its rapid destruction.

The compressor works in conjunction with the plasma cutter. It not only supplies the air flow that forms the plasma jet, but also cools the device components. Together with an inverter providing a current of 200 A, conditions are created for cutting metal up to 50 mm thick.

Bringing the device into working condition begins with connecting the plasma torch to the inverter and compressor. This procedure is performed using a cable and hose package:

• The inverter is connected to the plasma cutter electrode with an electric cable.
• The compressor and plasmatron are connected by a hose that supplies compressed air for further formation of the plasma jet.

Interaction of components in the operation of a plasma cutter

Assembling a plasma cutting machine is greatly facilitated when you have a real idea of ​​how all the parts and components interact with each other during the work process.

At the very beginning, current from the inverter flows to the electrode, after which an electric arc appears. Its temperature in the area between the nozzle tip and the electrode rises from 6 to 8 thousand degrees. Next, compressed air is supplied, entering the nozzle chamber and passing within the strict limits of an electrical discharge. At this moment, the air is heated and ionized by an electric arc, it increases many times in volume and acquires electrical conductivity properties.

Upon entering the nozzle, the conductive air flow is transformed into a plasma jet. Its temperature begins to actively rise and reaches 25,000-300,000C. The plasma stream escapes from the nozzle at a speed of approximately 2-3 m/s. At the moment of contact of the jet with a metal surface, the current flows through it, and the starting arc fades away. The newly formed high-temperature plasma arc performs the cutting function.

Melting of the metal being cut occurs only along the cutting line, which is the main advantage of such equipment. Therefore, it is extremely important to accurately orient the plasma spot with the center of the electrode. Failure to comply with this requirement may lead to disruption of the interaction of the air-plasma mixture and a decrease in the quality of the cut. In order to comply with this condition, air is supplied to the nozzle according to a specially designed tangential principle.

Precautions must be taken before cutting to prevent two plasma streams from occurring at the same time. Such situations arise due to violations of technology and equipment operating rules. In some cases, the inverter fails.

The air flow moves along its path at a set speed of approximately 800 m/s. The current strength is no more than 250 A. Too high a current strength leads to additional consumption of air used in the plasma flow. Thus, making a plasma cutter with your own hands is not very difficult. If necessary, such a device can perform not only cutting, but also welding.

Recommendations for acquisition, assembly and operation

Advice and recommendations from experienced specialists help novice craftsmen correctly equip and independently assemble a structure from an inverter with the necessary parameters.

Therefore, when creating welding equipment, you need to consider the following:

• Before assembly, all elements must be put on paper in the form of a working drawing or diagram.
• The electrical cable and air hose should be placed in a common corrugated pipe. Due to this, the cable will be cooled after strong heating, and the work itself will be more convenient.
• The copper welding wire used for ground must be powerful enough, with a cross-section of 5-6 mm2 and higher. A clamp is installed at the end for reliable contact with the metal. Otherwise, the arc will not be able to turn from the original one into the main one.
• At the outlet of the compressor, a reducer is installed that regulates the pressure on the plasma torch to the established norm.
• If there are no parts for the manufacture of a plasma cutter, a ready-made torch is purchased that meets safety rules and ensures effective work with metals.
• When working with aluminum, it is recommended to use inert gases - argon or neon - instead of air, which protect the surfaces of the workpieces from oxidation at high temperatures.
• During work, you need to protect yourself from molten splashes and toxic substances - use goggles, an apron, gloves, special shoes and a respirator.

Source: https://electric-220.ru/news/plazmorez_iz_svarochnogo_invertora/2019-06-23-1707

Do-it-yourself plasma cutter from an inverter - it’s possible at a reasonable cost

Home craftsmen involved in metal processing are faced with the need to cut metal blanks. This can be done using an angle grinder (grinder), oxygen cutter or plasma cutter.

1. Bulgarian. The cut quality is very high. However, it is impossible to perform figured cutting, especially if it concerns internal holes with curved edges. In addition, there are restrictions on the thickness of the metal. It is impossible to cut thin sheets with a grinder. The main advantage is affordability;
2. Oxygen cutter. Can cut a hole of any configuration. But achieving an even cut is impossible in principle. The edges turn out torn, with drops of melted metal. Thicknesses greater than 5 mm are difficult to cut. The device is not too expensive, but it requires a large supply of oxygen to work;
3. Plasma cutter. This device cannot be called affordable, but the high cost is justified by the quality of the cut. After cutting, the workpiece practically does not need additional processing.

Considering the price that is prohibitive for most home craftsmen, many “Kulibina” craftsmen make a plasma cutter with their own hands.

There are several ways - you can create a structure completely from scratch, or use ready-made devices. For example, from a welding machine, somewhat modernized for new tasks.

Making a plasma cutter with your own hands is a real task, but first you need to understand how it works.

The general diagram is shown in the illustration:

power unit

It can be designed in different ways. The transformer has large dimensions and weight, but allows cutting thicker workpieces.

Electricity consumption is higher, this must be taken into account when choosing a connection point. Such power supplies are little sensitive to changes in input voltage.

Inverters are economical and have higher efficiency. The arc produced using such a power source burns more stable, which has a positive effect on the quality of the cut.

The inverter is lighter and takes up less space compared to a transformer. This makes the device mobile, which allows you to work in hard-to-reach places.

However, there are also disadvantages. The thickness of the cut workpiece is limited.

Plasma torch

The working head with which cutting is performed.

Plasma cutter diagram:

The electrode is supplied with voltage from the inverter to excite the plasma arc. A refractory metal is selected to form a strong oxide.

For example, zirconium, hafnium or beryllium. The nozzle is used to form a plasma jet. Compressed air is supplied to the plasma formation zone, which simultaneously shapes the plasma jet and cools the electrode.

The nozzle parameters determine the cutting characteristics. The cutting speed of the workpiece and the size of the slit to be burned depend on the diameter. The hole size on a typical cutter is usually 3 mm. The quality of processing directly depends on the length. However, a nozzle that is too long gets very hot and wears out quickly.

The cooler (also known as an insulator) partially removes heat from the nozzle, extending its life. In operating mode, the plasma reaches temperatures of more than 25,000°.

Popular: Do-it-yourself welding inverter: it’s simple if you figure it out

Since plasma consists not only of a stream of charged particles, but also of air, it must be supplied in large quantities. This issue is handled by the compressor. If the operating current does not exceed a couple of hundred amperes, ordinary air from the atmosphere is used. The thickness of the metal being cut is less than 5 cm.

In industrial cutters, the current is higher and various gases are used: argon, helium, nitrogen and even oxygen and hydrogen.

The hose-cable control kit supplies both electric current and compressed air (gas).

A detailed description of how to make a plasma torch for a plasma cutter in this video.

How does a plasma cutter work?

After pressing the control key, a current of high magnitude and frequency ignites (literally) an electric arc between the nozzle and the electrode. The temperature at the tip rises to 7000° C.

When the pilot arc fills the entire nozzle, compressed air (gas) is supplied. When exposed to high temperature, the gas ionizes and becomes a conductor. In effect, a short circuit occurs through the air, which turns into a gaseous electrode.

At this moment, a plasma formed by a cone with a temperature of more than 20,000 ° C breaks out of the nozzle. Under such conditions, the electrical conductivity of the hot air inside the plasma flow is equal to the conductivity of the metal.

When the plasma comes into contact with the metal of the workpiece, a classic arc occurs, as in electrode welding. Plasma acts as an electrode. The arc instantly heats the metal at the point of contact. The spot size is equal to the nozzle diameter. The metal, which has turned into liquid, is instantly blown out under the pressure of compressed air. The workpiece is being cut.

If you move the head too slowly, the cut will not be as smooth and will be too wide. The heated edges of the metal will become clumsy. Rapid movement will not allow the molten metal to be blown out efficiently, and the cut will lose continuity.

Plasma cutting machines, in which the nozzle is controlled mechanically, do not have this drawback.

However, the cost of such devices is too high. Self-production is difficult due to the high cost of components. We will consider the possibility of manufacturing a manual plasma cutter with average parameters.

Do-it-yourself plasma cutter from an inverter

The main difficulty is manufacturing the plasma torch itself. More precisely, a cutting nozzle.

The metals from which the tips are turned are not available. Therefore, it makes sense to purchase a ready-made nozzle. The connection pipe for connecting a pressure hose must be installed industrially.

The working area has a temperature of several thousand degrees, so any welding method available at home will not work. The tube will simply fall off. But it will not be difficult to place the finished cutting product in the handle, which is designed for high temperatures. If you are making a plasma cutter from an inverter, such a handle is included in the kit.

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It is also necessary to always have a supply of consumables. The nozzle, no matter what durable metal it is made of, wears out quite quickly. Therefore, a set of 5-10 nozzles and cathodes will not hurt. In addition, it is better to have several different nozzle diameters to work with different metals.

The conductive cable from the inverter is combined with a hose for supplying compressed air. The entire structure must be a single whole, otherwise you can simply get tangled in the hoses during operation.

It is good to use ceramic bushings as a body for the nozzle. It is both a dielectric and a cooler that dissipates excess heat quite well.

A homemade plasma cutter, unlike a conventional welder, needs to control the ignition of the duty plasma. To do this, an oscillator is built into the design of the finished inverter, which provides the primary spark for the igniter.

After the working plasma appears, it must be turned off. For this, a circuit operating using a relay is used. As soon as the current reaches the operating value, the oscillator turns off and the arc operates from the main (load) output of the inverter.

Otherwise, the inverter remains unchanged. The power is enough to power the burner with a metal thickness of up to 20 mm. Typically, large thicknesses are not processed at home.

A homemade plasma cutter cannot do without a compressor. To form a stable working plasma, a pressure of 2-2.5 atmospheres is sufficient. Even a regular car compressor can provide this value.

The whole problem is that during operation a huge amount of air is consumed, and the compressor cannot replenish it at the required speed. If the pressure drops, the working plasma arc will collapse, and it will be impossible to cut metal.

The issue is resolved by installing an air receiver. It serves as an accumulator for accumulating pressure. Short intervals of operation of the cutter do not have time to reduce the pressure, and during breaks the compressor replenishes the supply of compressed air.

You can use brake cylinders from trucks. For example, from Kamaz. However, it would be more practical to purchase a standard compressor kit with a receiver.

Just be sure to equip the kit with a gearbox. It is necessary to be able to set and maintain constant pressure. Buying a compressor will not be burdensome for the budget if you use it for other purposes. For example, for painting with a spray gun.

Using such a homemade product, you can cut both thin sheet metal 1 mm thick and thick steel plates. If you work according to a template, you can cut high-quality workpieces no worse than a CNC machine.

This video contains details of assembling a homemade plasma cutter.

Source: https://obinstrumente.ru/elektroinstrument/svarochnye-apparaty/plazmennyj-rezak-svoimi-rukami.html

Homemade plasma cutter from an inverter welding machine: diagram and assembly procedure

Metal cutting is carried out in several ways - mechanically, arc welding or exposure to high-temperature plasma. In the latter case, an inverter can be used as a power source. To make an effective plasma cutter with your own hands, you will need to familiarize yourself with the diagram and operating principle of the device.

Plasma cutter diagram

Processing of metal surfaces, their cutting and controlled deformation occurs using a jet of air or inert gas. Pressure and the presence of a flammable component (electrode) ensures the formation of a plasma region. It exerts high temperature and pressure on the workpiece area, resulting in its cutting.

Features of manufacturing a plasma cutter based on an inverter welding machine:

• Preliminary calculation of equipment power. The determining parameter is the thickness and properties of the material being cut.
• Mobility of the structure and its dimensions.
• Duration of continuous cutting.
• Budget.

The latter indicator should not affect the quality, and most importantly, the safety of operation of a homemade plasma cutter. It is recommended to use maximum factory-made components.

Recommendations for choosing components

An inverter welding machine is a source of arc for igniting plasma. It is also used for its intended purpose - the formation of connecting seams. To complete the plasma cutter, you need to purchase only factory models, since homemade ones will not be able to ensure stable operation.

To ensure mobility, you need to buy an inverter with argon arc welding function. Its design provides space for connecting a hose from a source of air or inert gas. The average cost is 19,500 rubles.

Additionally you will need the following components:

• Cutter with the function of supplying electricity, wire (electrode) and air.
• Compressor. It is needed to pump gas; an alternative is refilled cylinders.
• Cable-hose package. These are lines for electricity, an air hose and a wire feeder.

Of the entire list, you can only make a handle for the cutter with your own hands. It is this that most often fails due to constant temperature exposure. The dimensions and performance properties of the remaining components must meet quality standards.

Step-by-step assembly instructions

In fact, the plasma cutter is not manufactured, but assembled from the elements described above. The possibility of connecting individual components is first checked, operating modes are specified - the amount of current supplied from the inverter, the intensity of the air stream, and the plasma temperature.

Additionally, you need to use a pressure gauge to monitor the pressure in the air line. The optimal location is on the inverter housing. On the holder it will interfere with the precise formation of the cut.

Operating procedure:

1. Check the inverter power supply.
2. Check the tightness of the air line.
3. Set the pressure of the inert gas jet to the required level.
4. Connect the negative electrode of the inverter to the workpiece.
5. Checking the arc, activating the air supply.
6. Plasma cutting.

Tips for use

During the cutting process, problems arise - lack of components, unstable installation mode. The likely consequences are the inability to continue work, poor-quality cutting. The solution is to carefully prepare for this event.

Professional recommendations:

• Spare gaskets for the air line. Frequent switching leads to their abrasion and loss of tightness.
• Nozzle quality. With prolonged exposure to temperature, it can become clogged and change its geometry.
• Electrodes are made only from refractory materials.
• The reason for the breakdown of homemade cutters is the occurrence of 2 air vortices, which leads to deformation of the nozzle.
• Be sure to carry out work only in protective clothing.

The video provides practical recommendations for making a plasma cutter yourself:

Source: https://ismith.ru/welding-equip/plazmorez-iz-svarochnogo-invertora/

How to make a plasma cutter from an inverter with your own hands, assembling a plasma cutter, how it works

Until recently, when the need arose to cut metal blanks for various needs at home, the home craftsman did not have a very large choice. Either an angle grinder (angle grinder, commonly known as an angle grinder) or a gas cutter.

But progress does not stand still, and relatively recently a fundamentally different means for cutting metal, more effective and convenient to use, became available to the general public. We are talking about a plasma cutter or, as it is sometimes called, a plasma cutter.

Considering the high cost of factory-made household plasma cutters, the idea of ​​trying to assemble this device at home seems quite rational.

And in order to verify the feasibility of this idea, you can compare the technological features of the work performed using the above devices.

• Angle grinder (angle grinder). Provides a very good level of cut, but only when it comes to straight cutting of metal. It is almost impossible to make a figured cut using a grinder.
• Gas cutter. Provides the ability to cut shapes, but with very low quality. The edges of the cut are uneven, torn, with pieces of molten metal. As a rule, when the metal thickness is more than 5-7 mm, cutting becomes very difficult or almost impossible.
• Plasma cutter. Provides high-quality, perfectly clean seams of almost any configuration and thickness. A positive aspect of using a plasma cutter is the complete absence of residual deformation of the metal after the cutting process is completed, which cannot be said about the first two methods.

Homemade plasma cutter

Assembling a plasma cutter at home is very similar to assembling a construction set. The fact is that all the components of a plasma cutter, without exception, belong to fairly complex technological products. Making these elements at home from scratch not only requires very deep knowledge of the subject and appropriate expensive equipment, but is also unsafe for the health of the home craftsman.

For example, the temperature inside the combustion chamber of a plasma torch is about 20,000−30,000 degrees. Therefore, it is better to buy the elements that make up a plasma cutter, ready-made, with a guarantee of high reliability, than to try to make houses from improvised means and thereby endanger not only your life, but also the lives of your loved ones.

Those who don’t understand anything at all about metalworking need to know at least basic things, for example, that a laser cutter for metal and a plasma cutter for metal are not the same thing.

Components

Any plasma cutter consists of the following elements:

Source: https://chebo.biz/tehnologii/izgotovlenie-plazmennogo-rezaka-iz-invertora-svoimi-rukami.html

How to make a plasma cutter yourself from a welding inverter - Machine tools, welding, metalworking

At industrial enterprises, small workshops, during construction and repair work, a manual plasma cutter is used when it is necessary to weld or cut metal products, as well as special equipment equipped with CNC systems. To perform small-scale work, you can use a plasma cutter assembled with your own hands from an inverter, which is capable of providing high quality cuts or seams, taking into account the operations being performed.

Operating principle of a plasma cutter

When the power source is turned on, current begins to flow into the working area into the internal chamber of the plasma cutter, where the electric pilot arc between the nozzle tip and the electrode is activated. The forming arc fills the nozzle channel, where an air mixture begins to flow under high pressure, which, due to the high temperature of 6000-8000 °C, heats up greatly and increases in volume from 50 to 100 times.

Due to the internal shape of the tapering nozzle, which has the shape of a cone, the air flow is compressed, heating up to an outlet temperature of 25,000 - 30,000 °C, forming a plasma jet that cuts the processed blank. Moreover, the initially activated pilot arc goes out and the working arc between the electrode and the metal product is activated.

The resulting products from the effects of plasma combustion and metal melting are removed due to the force of the jet.

Fig. 1 Carrying out metal cutting operations where cutting or welding of a product is necessary, using a hand-made homemade one or a professional plasma cutter.

The optimal indicators for the workflow are:

1. gas supply at speeds up to 800 m/sec;
2. The current indicator can be up to 250 - 400 A.

Scheme 1. Drawing of the plasma cutting process of the workpiece.

A manual plasma cutter assembled using an inverter is mainly used for processing workpieces and is characterized by its low weight and economical power consumption.

Selection of plasma cutter components

To assemble a plasma cutter using drawings (based on an inverter), you need the following units with your own hands:

1. pressure gas supply device - compressor;
2. plasma cutter;
3. electrical device - an inverter that provides current to form an electric arc;
4. high pressure working hoses for air supply and protected electrical cable.

To supply air, we select a compressor taking into account the output volume for 1 minute. Manufacturing companies produce 2 types of compressors:

1. piston apparatus;
2. screw device (which has lower power consumption, is lighter, but 40-50% more expensive).

Rice. 2 Plasma cutter (device) with a cable set for the cutter and connection to the workpiece (as an anode).

Piston compressors are divided into oil and non-oil based, based on the drive principle - with a belt or direct connection of elements.
When operating compressors, a number of rules must be observed:

1. at negative ambient temperatures, it is necessary to preheat the oil contained in the crankcase;
2. It is necessary to regularly change the air (inlet) filter;
3. strictly control the oil level in the crankcase;
4. At least once every six months it is necessary to completely clean the units from foreign impurities;
5. Upon completion of work, it is necessary to relieve pressure (using a regulator) in the system.

During repair work, products from ORLIK KOMRESSOR (Czech Republic) are often used. The ORL 11 device allows cutting workpieces using a current of 200-440 A and an air-gas flow coming under pressure.

The equipment set includes:

1. compressor;
2. block of main filters for the air-gas mixture;
3. gas dryers;
4. receiver.

At the outlet of the unit, purified air free of oil, dust and moisture arrives. An example of screw compressors is the CA series product from Atlas Copco (Sweden). The device is equipped with an automatic condensate removal system for air purification.

A plasmatron is a special device in which, using an electric current, an electric arc is formed that heats air supplied under pressure in a chamber to form a cutting plasma stream.

The cutter consists of elements:

1. special holder with electrode;
2. an insulating gasket separating the nozzle and the electrode assembly;
3. plasma generation chambers;
4. output nozzles for the formation of a plasma jet (see drawings);
5. supply systems;
6. tangential plasma supply elements (on some models) to stabilize the arc discharge.

According to the method of performing work (welding or cutting), cutters are divided into:

1. Double-flow, used in reducing, oxidizing and inert environments.
2. Gas inert (using helium, argon), reducing (hydrogen, nitrogen).
3. Gas oxidizing (the air-gas mixture includes oxygen).
4. Gas using a stabilizing (gas-liquid) arc.

The plasmatron cathode is made in the form of a rod or inserts made of tungsten, hafnium, and zirconium. Plasmatrons with a sleeve cathode, used for cutting using an air-gas flow under pressure, have become widespread.

To cut products in an oxidizing environment, a hollow cathode made of copper with a forced cooling system using water is used.

Rice. 3 Portable device (inverter) for plasma cutting.

Double-flow plasma cutters (inverter) are equipped with 2 coaxial nozzles, external and internal. The gas entering the internal nozzle is considered primary, and the external one is considered additional, and the gases can have different compositions and volumes.

A plasma cutter with arc stabilization due to the supply of a gas-liquid flow has a difference, which is the supply of water to the torch chamber to stabilize the state of the arc discharge.

To activate the working arc, a workpiece is used as an anode, which is connected to the inverter using clamps and a cable.

As a power plant for carrying out the plasma cutting process, a device (inverter) is used that provides the necessary current strength, which has a higher efficiency than a transformer, but the transformer’s metal processing capabilities are much higher.

Scheme 2. Drawing of the plasmatron power supply with your own hands.

Inverter advantages:

1. the ability to uniformly change parameters;
2. light weight;
3. stable state of the working arc;
4. high quality cutting or welding.

The equipment set also includes a set of high pressure hoses for connecting a stationary compressor and an electrical connecting cable.

To assemble a plasma cutter with your own hands, a device diagram is developed indicating the necessary units that meet the required characteristics, which should include all additions and changes used during assembly with the necessary calculations of the most important indicators. You can assemble a homemade plasma cutter with your own hands using ready-made blocks and assemblies produced by specialized companies; in this case, it is necessary to make accurate calculations and coordinate the output parameters of the ongoing processes.

Features of marking plasma cutters

Plasma cutters produced by industrial enterprises can be divided into 2 categories:

1. machine cutting units;
2. manual.

Hand cutters are more affordable if you need to do it yourself. Manufactured models have special markings:

1. MMA - the device is designed for arc welding using an individual electrode;
2. CUT - a device (plasma cutter) used for cutting metal;
3. TIQ - the device is used for work where argon welding is necessary.

Manufacturing enterprises produce equipment for metal cutting:

1. Profi CUT 40 (RT-31 burner, permissible cut thickness – 16 mm, air-gas mixture flow rate – 140 l/min, receiver volume 50 l);
2. Profi CUT 60 (P-80 burner, permissible workpiece cutting thickness - 20 mm, air-gas mixture flow rate - 170 l/min.);
3. Profi CUT 80 (burner R. – 80, permissible cutting thickness of the workpiece – 30 mm, air-gas mixture flow rate – 190 l/min.);
4. Pro CUT 100 (burner A-101, permissible cutting thickness of the workpiece - 40 mm, air-gas mixture flow rate - 200 l/min.), receiver with a volume of 100 l.

Making a CNC plasma cutter with your own hands

A CNC-equipped plasma cutter must have a unified assembly using drawings made on the basis of the prepared technical specifications for the product, which include:

1. work table;
2. belt transmission;
3. function control unit;
4. step elements;
5. linear guides;
6. cutting height adjustment system;
7. CNC control unit;

  The smallest inverter welding machine

Scheme 3. Drawing of an inverter device for plasma cutting.

Drawings of all plasma cutter blocks can be purchased taking into account the required power and installation characteristics and financial capabilities, or you can do it yourself if you have experience and knowledge.

To complete and assemble a CNC machine, it is necessary to manufacture a number of elements using drawings:

1. table base for welding;
2. a durable frame is assembled and then painted;
3. support posts are attached;
4. the water table is assembled;
5. fastenings and the slats themselves are installed;
6. linear guides are mounted;
7. the table cover is installed;
8. guides are installed together with the portal;
9. the portal is equipped with a motor and signal sensors;
10. the guides, the Y guide motor and the positioning control rack are mounted;
11. a guide equipped with a motor is mounted;
12. a metal surface signal sensor is mounted;
13. a tap is installed to remove water from the table;
14. connecting cable channels XZY are laid;
15. the wires are insulated and covered with cladding;
16. the working cutter is mounted;
17. The CNC device is assembled and installed.

Carrying out operations for the manufacture and assembly of a CNC plasma torch should only be carried out in the presence of qualified specialists. The device diagram (drawings) must include all the necessary elements to ensure high quality of work and safety of metal cutting.

Equipping enterprises with CNC equipment can increase labor productivity and the complexity of operations.

Make production processes performed using CNC equipment more economical by increasing labor productivity and reducing the processing speed of products.

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Source: https://stanki-info.com/kak-samomu-sdelat-plazmorez-iz-svarochnogo-invertora/

Recommendations on how to make a plasma cutter from an inverter with your own hands - Machine

A plasma cutting machine is a fairly popular piece of equipment that allows cutting any metals in many areas of production. Plasma cutters are used not only in enterprises.

Recently, they have begun to appear in home workshops.

But, since almost every workshop already has welding machines, it would be wiser not to buy a ready-made plasma cutter, but to make one from an inverter with your own hands.

Why do you need a plasma cutter?

In some cases, a plasma cutter is an indispensable tool for processing metal products, since the temperature of the plasma leaving its torch reaches 25-30 thousand degrees. Thanks to these characteristics, the scope of application of plasma cutters is quite extensive:

• production of various types of metal structures;
• laying of pipelines;
• fast cutting of any metals, including high-alloy heat-resistant steels containing titanium, nickel and molybdenum, the melting point of which is above 3000°C;
• shaped cutting of thin-sheet materials (conductive) due to high cutting precision.

In addition, plasma cutters (as an alternative to laser cutters) are used as part of automatic lines at large enterprises for cutting parts of various configurations from sheet materials.

It is necessary to distinguish between concepts such as plasma cutting and plasma welding. The latter is available only on expensive, professional equipment, the cost of which starts from 100 thousand rubles.

Inverter or transformer

There are various methods, as well as drawings and diagrams, according to which you can make a plasma cutter. For example, if it is made on the basis of a transformer welder, then the plasma cutter diagram provided below is suitable, which describes in detail what parts are needed to manufacture this module.

If you already have an inverter, then in order to convert it into a plasma cutter, you will need a little modification, namely adding an oscillator to the electrical circuit of the device . It is connected between the inverter and the plasma torch in two ways, as shown in the following figure.

• The oscillator can be soldered independently according to the diagram provided below.
• If you make a plasma cutter yourself, then choosing a transformer as a current source is not recommended for several reasons:

• the unit consumes a lot of electricity;
• The transformer is heavy and inconvenient to transport.

Despite this, the welding transformer also has positive qualities, for example, insensitivity to voltage changes. It can also cut thick metal.

But the advantages of an inverter-based plasma cutting machine over a transformer unit are obvious:

• light weight;
• high efficiency (30% higher than that of a transformer);
• low electricity consumption;
• High-quality cutting thanks to a more stable arc.

Therefore, it is preferable to make a plasma cutter from a welding inverter than from a transformer.

Typical plasma cutter design

To assemble a device that will make air plasma cutting of metals possible, you will need to have the following components available.

Source: https://regionvtormet.ru/metally/rekomendatsii-kak-izgotovit-plazmennyj-rezak-iz-invertora-svoimi-rukami.html

How to make a plasma cutter yourself from a welding inverter

instrument.guru > DIY > Making a plasma cutter with your own hands from an inverter

It is almost impossible to carry out work related to cutting metal without the use of special tools. That is why every man who is engaged in such work should have in his arsenal a device for manual plasma cutting; it is distinguished by its small size and makes it possible to cut metal sheets into pieces of the required sizes at home.

• Operating principle of a plasma cutter
• Selecting elements to make a plasma cutter from a welding inverter
• Homemade plasma cutter from a welding inverter - assembly
• Homemade CNC plasma cutter
• Expert advice for long-term operation of a self-made plasma cutter

Unfortunately, the cost of the device is quite high, so men create a plasma cutter with their own hands from an inverter.

Operating principle of a plasma cutter

When the electrical power source is turned on, the current begins to move into the functional zone of the internal chamber of the plasma cutter, where the pilot electric arc is activated , which is located between the electrode and the nozzle tip. This arc fills the nozzle channel, into which air enters using high pressure. Due to the high temperature, which varies from 6 to 8 thousand degrees, the air heats up and its volume increases by about 50–100 times.

Further, due to the fact that the internal shape of the tapering nozzle is presented in the form of a cone, the flow of air directed into it is compressed, while heating up to a temperature that at the outlet ranges from 25 to 30 thousand degrees.

It is this process that contributes to the emergence of a plasma jet, which is used to cut the processed blank.

In this case, the initially functioning pilot arc goes out and the working arc, which is located between the metal product and the electrode, is activated.

All products formed as a result of plasma combustion are removed due to the force of the jet.

In order for the plasma cutter to function at the highest level, the device must have the following indicators:

• gas supply must be carried out at a speed not exceeding 800 m/s;
• The current indicator should vary from 250 to 400 A.

Selecting elements to make a plasma cutter from a welding inverter

In order to create a plasma cutter from a welding inverter with your own hands, you need to prepare the following materials:

1. Welding inverter with the appropriate power for the plasma cutter. In order to choose the right element, you need to tell the seller at the time of purchase what thickness of metal you plan to cut. Taking this value into account, the seller will select the best inverter options for you.
2. Plasma cutter (you can use a plasma torch dot as a replacement). When choosing this element, the main role is also played by the thickness of the metal that will be cut with a plasma cutter.
3. A compressor that circulates air. It is important to pay attention to its power, which should be exactly the same as other elements for a homemade plasma cutter.
4. Cable-hose package . Its goal is to combine all the above elements.

Homemade plasma cutter from a welding inverter - assembly

Before you assemble a plasma cutter with your own hands, you need to determine whether all the elements you selected to create this tool are compatible with each other. If you have not assembled a plasma cutter before, it is recommended to consult with more experienced craftsmen; after analyzing the capacities of each individual element, they will give you their conclusion. The ideal option would be to create a plasma cutter collection circuit.

The creation of the apparatus must be carried out in special protective clothing.

So, the scheme for creating a plasma cutter with your own hands is as follows:

1. Prepare all the elements necessary to assemble the device and put on protective clothing.
2. Select an uninterruptible power supply.
3. Take an inverter, a cable of the required thickness and electrodes. A prerequisite is that the electrodes must be made of materials such as zirconium, thorium, beryllium or hafnium. These materials are most suitable for high-quality air plasma cutting. It is worth noting that hafnium is used much more often than other listed materials and provides greater safety in the process of cutting metal sheets. All of the above elements in the specified order are combined with each other, resulting in an electric arc.
4. A hose should be connected to the compressor. It is through the hose that air will enter the plasma cutter. The second side of the hose is connected to a plasma cutter or plasma torch.
5. Test the operation of the device on a small piece of metal; aluminum works great. During the inspection, special attention must be paid to the safety of the connections present.

If everything is done correctly, then the device can already be used.

Homemade CNC plasma cutter

Before you start assembling a plasma cutter with your own hands, you need to prepare drawings that will contain the following elements:

• Desktop;
• Belting;
• block for controlling various functions;
• step elements;
• linear type guides;
• system for adjusting cutting height;
• plasma cutter control unit.

You can either create diagrams of various plasma cutter units yourself, or, if you do not have the necessary knowledge, buy them from professionals.

Next, to create a CNC plasma cutter, you need to perform the following steps:

1. The base is being prepared for welding the work table.
2. A durable frame is mounted, which is subsequently subjected to a painting procedure.
3. The support posts are being attached.
4. The water table is being collected.
5. The mount is installed and the slats themselves are mounted.
6. Linear type guides are installed.
7. The facing part of the table is being installed.
8. Guides and portal should be installed.
9. The portal is equipped with a special motor or sensor that emits signals.
10. The guides, the guide motor U and a rack with teeth, which adjusts the positions, are installed.
11. The control unit is installed, which is then equipped with a motor.
12. The metal surface signal sensor is being installed;
13. A tap is installed to collect water from the table surface;
14. Cables are being laid that connect channels X, YZ
15. The wire is insulated and then covered using a cladding.
16. The work cutter is being installed.
17. The CNC machine is completely assembled.

In order for the device to turn out as desired, its diagram on paper must be done professionally, so it is advisable to entrust the creation of the diagram to professionals.

Expert advice for long-term operation of a self-made plasma cutter

At this stage of time, experts have identified several main points that should be taken into account if you have a plasma cutter made from an inverter:

1. Be sure to have a certain number of gaskets in stock. This is due to the fact that the plasma cutting process uses gas, and gaskets are needed so that the hoses can be connected. In addition, if the device is often transported, then it is simply impossible to do without gaskets, and their absence can cause a complete stop in the work process.
2. The cutter nozzle is exposed to very high temperatures, so this is the element that wears out most often. Be sure to have an extra nozzle in stock.
3. When selecting materials for creating a plasma cutter, proceed from the specific power of the device you need.
4. When selecting electrodes , it is advisable to choose a material such as hafnium, since during the heating process it does not release chemical elements hazardous to human health.
5. Work with a plasma cutter must be carried out in a special suit and in compliance with safety measures. Otherwise, spontaneous combustion or burns may occur to the welder.
6. Be sure to use cutters made in factories, since cutters made by yourself introduce disturbances into the vortex air flow.

If you follow all the above rules in the process of creating a plasma cutter with your own hands from an inverter, then the device will not only be of high quality, but much better than in specialized stores. In addition, according to the calculations obtained, the service life of devices created with one’s own hands is much longer than when buying a plasma cutter in a store.

Source: https://steelfactoryrus.com/kak-samomu-sdelat-plazmorez-iz-svarochnogo-invertora/

Homemade plasma cutter from a welding inverter: how to assemble it yourself, instructions and diagram

What tool does every handyman need? What is suitable for quickly cutting metal or making homemade items? The correct answer is a plasma cutter.

It is a must have for every handyman. This tool is available in any hardware store. However, we note that the price is very high.

A good device will cost at least 350 US dollars. This will not be affordable for everyone.

Introduction

Buying inexpensive components will not end well. Low quality equals poor results of a product or work. Factory devices are difficult to maintain. They are practically not intended for self-service.

A plasma cutter bought in a store has complex characteristics. When you want to fix something on it yourself, you will lose the warranty. Such a problem will lead us to a solution.

The first decision is to assemble the device yourself. Decision number two is to purchase a device that has been used. If you do not use the tool every day, you can make a homemade device.

You can make a device from a transformer or a welding inverter. A homemade plasma cutter can handle all the work you need.

We will tell you how to construct a machine yourself from a welding inverter, what parts and characteristics it has. And how to work with such a device correctly.

Peculiarities

To work with this tool, first of all, you must be able to cut metal and know all carving technologies. First, let's look at what plasma thread is.

This is one of the metal processing methods based on cutter plasma. We won’t remind you what plasma is. Let's look at plasma cutting technology in more detail, and like this:

• All types of metal can be carved. The characteristics of the metal are not important.
• Fast plasma cutting when using thin structures and parts.
• When carving, the cut heats up and therefore the parts will remain in good condition.
• Clean and even cut, without any flaws.
• Safety in use. No gas cylinder is used.
• Cutting metal of all types, shapes, sizes. There are no work restrictions.
• Used with all necessary parts. There are no restrictions on the type of metal.

There are many types of plasma cutters, but we will mention only two. Types of apparatus: transformer, inverter and others. Some are used for working with thin parts, others for welding thick metal parts.

Source: https://prosvarku.info/prisposobleniya-i-detali/samodelnyj-plazmorez-iz-svarochnogo-invertora

DIY plasma cutter from a welding inverter

A plasma cutter is often used by welders when they need to cut metal products. It is not at all necessary to use purchased products that are sold separately. You can make a plasma cutter from a welding inverter with your own hands. This tool may be well suited for home use. It provides a high quality cut with a thin layer of cutting. With its help, you can process various workpieces with a high level of accuracy.

DIY plasma cutter from a welding inverter

If you decide to make a homemade plasma cutter from a welding inverter, then first of all you should pay attention to the current strength. Its value is determined by the power source. In this case, an inverter is a much better option than a transformer as it offers more stable operation.

It also has economical power consumption, unlike its direct competitor. Naturally, in terms of such a parameter as the thickness of the workpiece being cut, it is inferior to a transformer. In all other parameters, the inverter turns out to be more convenient. It is not so massive and dimensional, and its efficiency is noticeably higher.

All this affects the quality of work.

To assemble the structure completely, you can use ready-made parts that are sold in relevant stores. It is possible that all the components may already be available at home. During assembly, you must strictly adhere to the diagram, as well as the construction of its individual elements. It is advisable to select a longer nozzle, but not too long, since over time it will need to be replaced due to high wear.

Plasma cutter operation diagram

A plasma cutter made from a welding inverter allows this type of equipment to fulfill its main purpose, namely, to supply highly heated air to metal products. Temperatures can reach over a thousand degrees, which heats up the oxygen. As a result of heating, it enters the surface of the metal product under pressure. This causes the metal to be cut. To speed up this procedure, additional ionization of the medium by electric current should be provided.

The diagram of the plasma inverter and its power part is as follows:

Diagram of the power part of the plasma cutter

The plasma inverter circuit (device control) has the following form:

Plasma inverter circuit

Plasma cutter design

A plasma cutter can be made from a welding inverter if you have the following parts:

• Compressor is a device that supplies powerful air flow under pressure;
• Plasma torch - looks like an ordinary welding cutter, with its help all basic cutting procedures are performed;
• Electrodes - some types of equipment are equipped with them; they are used to ignite the arc;
• The nozzle is the most functional structural element of an inverter plasma cutter, since it makes it possible to determine the complexity of the work based on its shape and other parameters;
• Plasma cutter is an element performed in the form of indirect or direct impact.

Source: https://svarkaipayka.ru/oborudovanie/svarochnie-apparaty/plazmorez-iz-svarochnogo-invertora-svoimi-rukami.html