Plasma cutting is the process of cutting conductive metals using plasma. Most metals are pretty hard to cut or manipulate. They require special tools that cut first and effectively. Plasma is a matter that exists on its own, just like liquid, solid, and gas. It is the fourth state of matter. When the matter is exposed to heat, it changes its state based on the temperature. Ice, for example, is in a solid state. When it is slightly heated, it changes from ice to water in a liquid state. After further heated, that changes from water to steam, which is the gas state. When exposed to very high temperatures, steam will change to plasma – the fourth state of matter. 

Plasma Cutting Process

In short, plasma cutting is a process that uses a high-speed ionized gas jet flowing from a throttle orifice. The high-speed ionized gas, H. Plasma, conducts electricity from the plasma cutting torch to the plasma. First, the plasma heats the workpiece by melting the material. Then, the high-speed flow of ionized gas mechanically blows out the molten metal and cuts through the material.

Plasma can conduct electricity because it is iodized. This supper heated substance is what is used in plasma cutting systems to cut metal. A conductive gaseous substance to transfer energy to any conductive compound from a power supply. Cutting metal using plasma cutters is much cleaner and faster than the oxy-fuel. 

How Plasma Cutting Works

To cut metal, steam or gas has to be extremely heated with an electric current. The process of using a plasma cutter is quite simple. First, the charged gas or steam is forced to flow through a small orifice. Since the gas will be quite dense and coming out of the orifice very fast, it will melt the workpiece and, at the same time, blow away the molten metal. This is called a plasma torch. Next, the constricted gas flows through a copper nozzle. As much as plasma cutters are used to cut conductive metals, not all conductive metals are effectively cut using this technique. The reason being that they have a low melting that leads to low-quality finishes. Such allows include copper, brass, casting ions, and more. 

Among the metal materials that can be cut using plasma cutting include stainless steel, titanium, nickel alloys. Initially, the plasma cutting method was commonly used in metals that did not bring out their desired results using the oxy-fuel metal cutting method. Most plasma cutting systems move around while cutting metals. The workpiece stays at the same point as the plasma cutter cuts it. The cost of buying a plasma cutting torch is low, making it affordable to have several torches on the cutting table.

Let’s now define and explain what a cutting plasma sensor is and what it does:

What are Plasma Cutting Sensors? 

Sensors are vital devices found in many machines that work domestically or commercially. For example, a mouse is used on a computer. The type of sensor found in a mouse sense motion optically. A smartphone, on the other hand, has touch sensors that respond once they are touched. This triggers certain actions in the device depending on where they are touched. 

To simply put it, a sensor is a device used to measure the physical inputs in a machine or an object. Once it has measured the inputs, it will relay the information into understandable data. The data needs to make sense to humans or another device. Raw data is mostly converted into electronic data by sensors. Thermometers have the simplest way of relaying data which is transmitted into visual data. There are many applications around, which use sensors, plasma cutters being among them. 

Working of Sensors

Plasma cutters and other metal cutting devices such as the laser cater rely on sensors to make them safe and prevent damage from the collision. Automated plasma cutters use programs to run them. Therefore, when a new program is created, it needs to be confirmed first. Failure to confirm the new program may cause machines to collide with one another in the metal cutting process, leading to expensive repairs. 

Collision sensors are commonly used in plasma cutting systems to prevent accidents that may lead to serious injuries. When a serious injury occurs, and it affects the operator, it affects productivity. Dynamic variable crash sensors use pressure drives to send stop signals to the system controller whenever there is a danger of collision, impact, or overload. At the same time, these type of sensors absorbs shock, release the air chambers, and provide protection for every axis. Collision sensors are also used in other applications such as arc welding, parts mounting, loading and unloading equipment, and material handling. 

Types of Sensors used in Plasma Cutting 

800 Series Flow Sensors 

What makes the 800 series flow sensors great for plasma cutters is that it is calibrated to measure water at 25 °C or 77 °F. This flow sensor for plasma cutters is only used to measure water given its velocity. Using this sensor with other fluids besides water affects its accuracy levels. The 800 series flow sensor has several benefits when used with water, including measuring flow rate that ranges from 0.2 to 227 LPM / 0.05 to 60 GPM. 

8000XHT Series Sensors for Plasma Cutters 

The 8000XHT Series flow sensor is ideal after reliable and accurate flow rate measurement in plasma cutting machines. The 8000 series flow sensor is designed to measure fluids that can transfer the heat of about -60 °C to 200 °C. Some of the benefits you’ll get from this type of flow sensor are that it measures flow rates of about 0.95 to 60 LPM / 0.25 to 16 GPM. In addition, the accuracy levels produced by this type of flow sensor are full-scale accuracy of 3%. 

Conclusion 

Plasma cutters are expensive equipment that requires high-quality devices to run. If you are serious about running a plasma cutter, you have to invest in buying the right and perfect plasma cutter. In addition, sensors are essential tools to protect expensive plasma cutting tools or instruments and avoid serious accidents that can lead to major injuries.