Automatic Torch Head Changer - a new level of automation in plasma cutting

Plasma and oxy-fuel cutting technology has been known for over 70 years, yet it continues to evolve dynamically. This time, inspired by the automatic tool-changing systems commonly used in laser cutting technologies, we collaborated with plasma system manufacturer Kjellberg to develop an automatic torch head changing system. This solution not only improves productivity and operator ergonomics but, above all, significantly enhances the efficiency of manufacturing processes.

Szafir Enhanced with customized solutions

One of the projects based on this concept was developed using the Szafir CNC cutting machine. It was on this platform that work began on a solution created in cooperation with a leading plasma system manufacturer. The project's objectives included:

• reducing machine handling time and, consequently, lowering production costs,

• improving cutting quality,

• increasing operational safety,

• reducing material losses generated during the production process,

• creating a tailor-made solution for a customer in Canada.

The developed system was equipped with a Kjellberg plasma unit – in this case, the Q4500 model. The plasma source was mounted on a Flex 3D bevel cutting head which, after extensive design work and testing, was fitted with a patented automatic torch head changing system housed in a dedicated cartridge, known as the Automatic Torch Head Changer.

How does the system work?

Based on arc voltage monitoring, the machine detects when consumable components have reached their wear limit and signals the need for replacement. The operator initiates the replacement procedure, after which the cutting head automatically moves to the cartridge containing replacement consumable sets.

This solution significantly reduces maintenance time related to consumable replacement while simultaneously improving operator safety.

A Tailor-Made solution

For this project, a Szafir cutting machine was delivered to a customer in Canada. The machine was equipped with five high-performance IHT/GCE oxy-propane torches and a Dual Flex 3D head, enabling three-dimensional plasma cutting.

This customer-specific configuration, enhanced with the automatic torch head changing system, is designed for intensive, continuous operation. Such a combination of technologies is ideally suited for demanding production environments, including heavy industry and high-volume manufacturing.

Savings through optimization - marking reimagined

The marking process does not require the same current intensity as cutting. Performing marking operations with a standard cutting torch and consumables designed for high-amperage cutting may result in excessive plasma arc impact on the material. Consequently, the marking line can become too deep, leading to unwanted weakening of the material structure.

While marking can technically be performed using the same consumables as cutting, components intended for high-current applications (typically used for cutting thick plates) produce significantly more aggressive marking lines and wear out more quickly during the process.

Using consumables designed for lower current levels, intended for processing thinner materials, allows for a more precise and controlled marking result while simultaneously reducing consumable wear.

Development driven by customer needs

The needs of customers and partners working with Eckert continue to evolve. For our team, this is a clear signal that technological progress cannot slow down. That is why our Research & Development Department continuously works on new solutions that address the challenges of modern manufacturing.

Since 1990, Eckert has been delivering technologies that not only meet the expectations of even the most demanding industries but also generate measurable benefits through the optimization and improvement of production processes.