Above: A cobot connected to offline programming software— Robotmaster—aids fabricators in producing three-dimensional pieces. Photo: APT Manufacturing Solutions
March, 2025- They aren’t the kind of work colleague asked to join the bowling league or darts team. But collaborative robots cobots are making their useful presence known on the job shop floor. To support fabricators who perform metal cutting functions, Hypertherm Associations has developed a suite of technologies to leverage the benefits of plasma cutting cobots.
“Industrial robots are larger, generally immobile and designed to work in isolation. Cobots are smaller in scale, can be moved easily from one workstation to another and are intended to work alongside humans,” explains Garen Cakmak, director business development and product management, integrated cutting solutions for Hypertherm Associates. “Cobots and traditional robots facilitate precise, consistent and highquality cutting and fabrication processes. They are ideal for high-mix, low-volume industries helping to boost productivity, reduce manual labor and address challenges posed by a decrease in skilled labor,” Cakmak adds.
Hypertherm Associates and its Hypertherm plasma cutting lineage goes back more than 50 years, when its founders developed a way to create a narrower plasma arc to cut metal with more speed and more accuracy. A tradition of innovation continues with a patented, intelligent, onepiece consumable cartridge and cutting torch for its Powermax plasma system series. Integrating this cartridge and a plasma cutting cobot into shop floor operations can lead to improved safety, flexibility and productivity. The company also developed offline programming software for plasma cutting, which aids in programming processes and complex shapes on a robot.
“We have a rich history of integrating our cutting technologies with robotics. Over the years, our channel partners have successfully incorporated these cutting technologies into their robotic systems, leading to advanced solutions in structural steel fabrication; pipe and tube cutting; automotive and transportation; manufacturing and industrial equipment; and aerospace,” notes Russ Diefenbach, business team leader, integrated Cutting solutions for Hypertherm Associates.
ON-THE-GO BOT
For fabricators not ready to commit significant capital outlay for a robot, a smaller scale cobot could be an alternative.
A plasma cutting cobot can lead to improved safety, flexibility and productivity. Photo: Hirebotics
“Cobots offer a lower barrier to entry by requiring a lower capital investment for a fabricator. There are leasing and rental programs for cobots, so job shops can try the technology before making a more permanent and integrated investment,” explains Natalie Adams, Hypertherm Associates’ product marketing manager for integrated cutting solutions.
In addition to financing flexibility, cobots deliver physical flexibility. “Cobots are portable, they can be moved easily from one work cell to another within a job shop. They are easy to program even if the operator has limited computer skills. And cobots require minimal tooling,” states Diefenbach.
Because cobots are designed to work with humans, their user interface is becoming more intuitive and user-friendly. “Cobots have integrated point-and-click programming so, for example, the operator can quickly define a part radius and smooth out the necessary cutting path,” says Diefenbach.
When working in tandem with a human, cobots can apply integrated learning capabilities so that previous actions and movements can inform similar projects in the future.
INTELLIGENT CARTRIDGE
Fabricators leveraging plasma cutting cobots on their shop floor are also using smart consumables.
“We developed the single piece Powermax cartridge to make plasmacutting technology more conducive for automation. This new cartridge opens up a lot of opportunities for the fabricator,” notes Diefenbach. The cartridge replaces the traditional five-piece consumable stack-up with a single piece that is perfectly aligned. “The cartridge enables 24/7 high automation, lasts longer than multi-piece consumables and minimizes the errors that can occur when a human is assembling a fivepiece stack,” he says.
The ease in replacing cartridges allows fabricators to minimize downtime associated with cartridge changes. In addition, “the components in the Powermax cartridge are intended to wear evenly, so the cartridge offers a more predictable lifespan so the operator can better anticipate when the cartridge is at its end of life further reducing equipment downtime,” adds Diefenbach.
Incorporated into the Powermax cartridge is radio frequency identification (RFID), which feeds information from the plasma tip to the operator’s ERP system. “This takes the guesswork out of setting the pressure or amperage, for example, for the operator,” says Diefenbach. The operator simply loads an app onto their smartphone, holds the device close to the Powermax cartridge and technology does the rest. “The result is more consistency and accuracy in cutting, which enhances the part quality,” he explains.
Powermax cartridges, available on Powermax SYNC systems, are sold through authorized Hypertherm plasma partners. They are offered in four amperages 45, 65, 85 and 105 amps for mild steel cutting. There are also cartridges for extended reach, flush cutting (removing attachments) and fine feature cutting.
OFFLINE PROGRAMMING
For fabricators feeling the pressure of the ongoing labor shortage, a cobot connected to Hypertherm Associates’ offline programming software, Robotmaster, can be a means to “multiply workforce output without multiplying human capital,” says Adams. This can be especially useful for fabricators producing three-dimensional pieces like pressure vessels, domes and I-beams.
Plasma cutting three-dimensional pieces and hard to reach areas is more efficient when performed by a cobot. Photo: Vectis Automation.
Robotmaster software seamlessly integrates offline programming and robotic cell simulation to quickly generate accurate robot programs from CAD files. By using Robotmaster, the operator can identify and address, in advance, potential issues such as a robot’s reach limitations or collisions.
“Robotmaster also has embedded process expertise to determine the required speed and amperage, for example, then puts all the plasma knowledge into the robot code,” explains Cakmak.
One pressure vessel fabricator reported that its cobot, using offline programming software, needed zero reworks, eliminated bottlenecks on the shop floor and reduced cycle time from three minutes to 11 seconds.
“A lot of our customers are reporting that even their operators who aren’t skilled in robotics or programming are able to perform off-line programming with ease,” says Adams. By leveraging the intelligent capabilities within Robotmaster for plasma, line operators also can reduce secondary work like the sanding and grinding that’s often required to prep the piece for welding.
“The investment and technical requirements of an industrial robot can be daunting. A cobot is a great way to introduce robotics onto the shop floor,” advises Cakmak. “[Our] hardware, software and digital solutions empower job shops to optimize their current workforce by automating repetitive and time-consuming tasks.”
By doing so, skilled workers can focus on more complex and valueadded activities and enhance overall efficiencies, adds Diefenbach. That might even allow for some extra time to brush up on one’s bowling or darts skills.
Hypertherm Inc, 800/737-2978, hypertherm.com
