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NEURON THC - User Manual

NEURON THC
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NEURON
C N C E L E C T R O N I C S
INDUSTRIAL
TORCH HEIGHT
CONTROL
NEURON CNC ELECTRONICS
08.01.2020
USER MANUAL
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NEURON THC Specifications

General IconGeneral
BrandNEURON
ModelTHC
CategoryController
LanguageEnglish

Summary

System Description

Safety

Safety precautions and warnings for operating the Neuron.THC system.

System Components

Overview of the major components that make up the Neuron.THC system.

Control module

Details on the microcontroller and I/O interface unit of the control module.

Specifications

Features

System Requirements

Power Requirements

Specifies the necessary power input and PSU recommendations for the system.

What Is Plasma

Explains the fundamental principles of plasma as a state of matter and its use in cutting.

Arc Initialization

High Frequency Start

Describes the HF start method, its advantages, and disadvantages.

Blowback Start

Explains the blowback start method and its benefits for CNC systems.

CNC Plasma

Discusses the unique challenges of plasma cutting on CNC machines.

Torch to work distance can impact granularity

Arc OK Signal

Initial Height Sensing

Float Switches

Describes the function and use of float switches for height sensing.

Ohmic Sensing

Explains the ohmic sensing technique for accurate material surface detection.

Corner Lock; Velocity Anti-Dive

Addresses issues with cornering and speed changes affecting torch height.

Head Safety Lock; Kerf Detect

Covers safety features related to kerf detection and potential crashes.

Hole and Small Shape Cutting

Connection diagram

Input signal interface schematic

INSTALLATION

Recommended grounding and shielding practices

Outlines best practices for grounding and shielding to prevent noise.

Voltage Divider Installation - General

Powermax plasma unit. Internal divider 20:1

Powermax plasma unit. Raw Arc Voltage.

Other plasma unit. Raw Arc Voltage.

Setup Main module.

Motor driver differential interface schematic

Proper connection to optocoupler inputs

Incorrect connection to optocoupler inputs sample

Set JP1, JP2 jumpers to 1-2 pins for differential connection:

Set JP1, JP2 jumpers to 2-3 pins for shared ground connection:

Setting up the network

UCCNC configuration

Setup THCOFF signal.

Functions and Definitions

Main parameters

Overview and explanation of the primary operating parameters for the Neuron THC.

Neuron Cut profile

Automatic Voltage Control

Explanation of how Automatic Voltage Control functions in the Neuron THC.

Sample and Hold Arc Voltage Mode

Details on the Sample and Hold mode for arc voltage measurement.

Max Allowable Sampling Error

Defines the maximum acceptable difference in arc voltage measurements.

Set Arc Voltage

How to set the target arc voltage for height control.

Cut Height

Specifies the desired torch height during cutting.

Pierce Height

Defines the torch height during the piercing phase.

Pierce Time

Sets the duration for the pierce delay before cutting begins.

THC Response

Adjusts the gain for closed-loop arc voltage control.

LockHeadDown

Feature to prevent torch diving during specific cutting events.

LockHead Down Level

Sets the threshold for the LockHeadDown feature.

Kerf Detect

Detects voids or gaps in the material to prevent crashes.

Kerf Detect Level

Sensitivity setting for the Kerf Detect feature.

Start IHS Height

Height at which IHS transitions to slower speed.

Skip IHS Within

Skips IHS if the next start point is close to the previous cut.

Transfer Height

Torch height after IHS before arc transfer.

Retry on transfer fail

Number of attempts to restart plasma after transfer failure.

Transfer time

Wait time before attempting a transfer retry.

Jump Height

Height to clear dross puddles after piercing.

Jump Time

Hold time at Puddle Jump Height to clear dross.

AVC Delay

Time for plasma and torch to stabilize before AVC activation.

Partial Retract

Option for partial torch retraction at the end of a cut.

Retract Height

Specifies the height the torch retracts to after a cut.

Messages

Configuration for displaying error messages to the operator.

Plasma Engine

Steps in mm

Defines the value based on torch movement counts per mm.

Automatic Speed

Speed used for automatic rapid moves like retract or approach.

Manual Speed

Speed for manual torch movement controlled by buttons.

IHS Speed

Slow speed for final approach during IHS operations.

Acceleration

Acceleration settings for automatic, manual, and IHS moves.

AVC Acceleration

Acceleration used for moves during arc voltage closed-loop operation.

Slide Length

Defines the lifter's usable travel range (Soft Limit).

Safe Jog Height

Travel distance from Home where fast jog is allowed.

Clear Plate Distance

Distance for expecting Ohmic or Float head clear plate signal.

Pooling period

Time constant for the plugin's main loop.

Input Signal Debouncing

Time constant for filtering input signals.

Dead Band

Arc voltage interval where no AVC occurs.

Push and Jog mode

Enables advanced jog mode for lifter movement.

Reverse Engine

Option to reverse the torch movement direction.

Torch go home after 60 sec in IDLE

Automatically raises torch to zero position after 60 seconds of idle time.

Automatic Collision Avoidance

Safety feature to automatically adjust torch height to prevent crashes.

Using Ohmic on the water table.

Enables/disables preflow in IHS when using ohmic sensor on a water table.

Arc Voltage Converter Tuning

Procedure to tune measured arc voltage for accurate control.

Float Head Microswitch offset setup

Allows setting an offset for the float head switch.

Marking mode

Mode for marking operations, like small corners on holes.

Ref Z axis after

Performs automatic homing after a set number of pierces.

Ventilation

Controls fume extractor motor and post flow time.

Delay Before ArcLost error issue

Sets delay between ArcLost issue and stopping the cutting process.

Torch off before M5 mode

Feature not present in the Neuron Lite controller.

Hardware Reset

Initiates a hardware restart for the Neuron controller.

Plotting

Enables plotting of cut parameters for analysis.

Cut Chart

THC configuration window

Control State

IDLE

State when the plasma system is OFF and motor is holding position.

Homing

State where the lifter moves the torch up to the Upper Limit Switch.

Soft Limit

State when the actual position reaches the programmed Slide Length.

IHS FAST APPROACH

Torch moves down at Automatic Speed to Start IHS Height.

IHS SLOW APPROACH

Lifter moves down at IHS Speed until Tip Sense input signal.

WORKPIECE CONTACT

Lifter senses Ohmic or float head contact, records position.

IHS RETRACT

Lifter moves up at Automatic Speed to Transfer Height.

START PLASMA

Torch holds at Transfer position, waits for plasma start signal.

PIERCE START

Torch moves to Pierce Height, Pierce Time timer initiated.

PIERCING

Lifter holds torch at Pierce Height for Pierce Delay interval.

PUDDLE JUMP

Lifter moves torch to Puddle Jump Height, waits for delay.

CUT PREPARE

Lifter moves torch to Cut Height, sends Motion signal.

SAMPLE

Controller receives new Arc Voltage sample, modifies set point.

CUTTING

Torch height controlled by arc voltage feedback (AVC ON).

MANUAL UP

Lifter jogs up and begins continuous motion at programmed speed.

MANUAL DOWN

Lifter jogs down and begins continuous motion at programmed speed.

RETRACT

Lifter moves torch up to Retract Height.

Sequence of Operation

Requirements and Check List for first Start-up

Pre-Cut Setup

Cut Recovery

Rip Cut

Plate Alignment

Go to Position

Common cutting faults

Neuron Firmware Update Utility

How to optimize cut quality

Tips for table and torch:

General advice for table and torch setup for better cut quality.

Plasma set-up tips

Guidance on plasma setup procedures for optimal performance.

Maximize the life of consumable parts

Strategies to extend the lifespan of consumable parts.

Additional factors of cut quality

Other factors influencing the quality of plasma cuts.

Cut angle

Discusses acceptable cut angles and how to identify issues.

Dross

Defines dross and factors contributing to its formation.

What is dross?

Definition and explanation of molten metal adhering to the part.

High Speed Dross

Cause and solution for dross formed at high cutting speeds.

Low Speed Dross

Cause and solution for dross formed at low cutting speeds.

Corner Dross

Explains dross formation in corners due to speed reduction.

Top Dross

Cause and solution for light dross accumulation on the top of the part.

Additional improvements

Further suggestions for improving cut quality.

Piercing

Factors and considerations for optimal plasma piercing.

How to increase cutting speed