High performance cuts without heating the surface material

Company overview: Anro

Founded in 1959, Anro is one of the main Spanish companies in the metallurgical sector. Anro is constantly evolving and always investigating alternative and new ways to optimize each of its processes. Since the beginning of its history, Anro has been responding to the demands of both the market and its clients, fundamentally attending to the research and development of new alternative solutions for the construction of structures, the expansion of state-of-the-art machinery, and increasing the safety of personnel. Located in Tomelloso, Ciudad Real, Anro's structures have spread throughout Spain, Europe, and the rest of the world.  

Challenge: Oxyfuel and grinding have major limitations

Anro does big projects for larger companies, including its patented car park designs. Cutting is the first link in Anro’s production chain and a very important aspect of the production process. Since cutting is critical for Anro, the company has CNC equipment to help achieve high performance levels quickly, with precision, and with a very good surface finish.

While the factory is highly automated, Anro has to do some work by hand because some cuts cannot be handled by their CNC machine. One such process is making bevels in preparation for butt joints.

Many companies choose the traditional bevel cutting methods of oxyfuel or grinding, but both of these methods have major limitations. Anro decided to look for a better option. 

Challenges with bevel cutting using oxyfuel

Cutting with oxyfuel requires the use of a highly flammable fuel gas and an open flame to raise the steel’s surface temperature to approximately 962° C (1,800° F). Heating the metal can erode the material strength, weakening future welds. Because oxyfuel cutting is a chemical reaction between pure oxygen and steel, oxyfuel can only cut ferrous metal. Excessive dross is common due to the high temperature required to reach the chemical reaction. This dross must be grinded off to make parts usable, a time-consuming manual process.

Since bevel cutting with oxyfuel requires preheating the material before cutting can begin, using oxyfuel is slower than bevel cutting with plasma. The highly flammable gas – most often acetylene – must be handled, transported, and stored following strict guidelines for safe handling.

Challenges with bevel cutting using an angle grinder

Using an angle grinder for bevel cutting does not produce excessive heat or require using a highly flammable gas, but this process takes longer and requires extra work. It can also cause harm to the operator.

Using a grinder for long periods of time can cause hand-arm vibration syndrome (HAVS), resulting in permanent damage to the operator. HAVS is caused by repeated and frequent use of hand-held vibrating tools. It causes changes in the sensation of the operator’s fingers and can lead to permanent numbness of fingers, muscle weakness, bouts of white finger (Raynaud's), and aches and pains in hands and lower arms. The operator may also experience weakening in grip strength.

Solution: Powermax105 SYNC delivers faster and better bevel cuts

The Powermax105 SYNC is a next-generation, professional-grade air plasma cutter that dramatically simplifies system operation for gouging and cutting up to 32 mm (1 ¼ inches). It features automated system process setup via advanced RFID-enabled SmartSYNC® torches and a revolutionary single-piece cartridge consumable that provides trackable utilization data. The Powermax105 SYNC maximizes productivity through reductions in downtime, optimized cut quality performance, and streamlined consumable inventory management.

Benefits include:

• RFID-enabled SmartSYNC torches and cartridges automatically set the correct amperage and operating mode, eliminating setup errors.

• End-of-life consumable detection eliminates the uncertainty of knowing when to change the cartridge.

• Flexible lead reduces operator fatigue.

• Simplified system operation minimizes the time and costs spent on training and troubleshooting.

• Easily interchangeable torch styles and application-specific cartridges for various types of cutting and gouging enable operators to tackle a wide range of jobs.

• Time-saving hand torch controls allow the operator to adjust the amperage on the fly and change cartridges and applications without returning to the power supply.

• SmartSYNC torches are engineered for rugged, industrial environments and can be used in challenging locations.

• SpringStart™ technology ensures consistent starting and a more reliable torch.

Hypertherm Cartridge Consumables

Hypertherm’s cartridge consumables for Powermax systems change the plasma cutting process, making consumable management easy. The cartridge combines a traditional five-piece stackup into a single-piece cartridge, making change-outs faster, ordering easier, and inventory tracking simpler.

Cartridges are easy to identify. They are color coded by application – green for gouging, yellow for drag cutting, etc. – and laser marked for easy identification of process and amperage. As a result, consumable change-outs take seconds, not minutes, reducing downtime and increasing productivity. Consumable mix-ups are also eliminated. Operators simply select the right cartridge for the job, and with a simple twist onto the torch they are ready to go.

Cartridge consumables wear at the same rate, eliminating costs associated with premature disposal of consumable parts, and operators do not have to constantly uninstall, inspect, and reinstall consumables that wear at different rates.

Optimized cartridge consumable design means cartridge consumables last up to twice as long as standard consumables for handheld cutting, decreasing consumable costs and increasing productivity. Cartridge usage data provides valuable insights for improving cutting operations and consumable inventory management, increasing productivity even more.

Business Impact: Faster, better bevel cuts

The Anro team is very happy with the Powermax105 SYNC. The system’s ease of use and clean quality cuts, combined with the convenience of the one-cartridge consumables, enable faster, higher-quality bevels without requiring welder fitters to spend time preheating the material.

“In this case, I do it with the Powermax105 SYNC, which saves me the effort of heating up the material and reduces the dross considerably. A quick touch up with the grinder is all it takes to get rid of it.” – Miguel Angel Lozano, Welder Fitter, Anro

The team enjoys the convenience of the Hypertherm cartridges and consumables, and the ability to change the current from the torch makes their jobs easier.

Learn how the Powermax SYNC can help your business strike the perfect balance between cut quality, cut speed, and cost. Click the button below, fill out the form, and a Hypertherm product expert will contact you.