Homemade microplasmable drawings welding machine. Plasmorez from the inverter with your own hands! Instructions, schemes and video materials! Homemade plasmorez from the welding inverter

Make a working plasmorez from the welding inverter with your own hands is not such a difficult task, as at first glance it may seem. In order to implement this idea, you need to prepare all the necessary details of such a device:

• Plasma cutter (or differently - plasma torch)
• Inverter welding or transformer
• The compressor with which the air jet will be created necessary to form and cool the plasma flow.
• Cables and hoses for combining all structural elements of the device in one system.

Plasmorez, including homemade, successfully applies to perform all sorts of work in both manufacturing and at home. This device is indispensable in those situations when it is necessary to perform an accurate, thin and high-quality cut of metal blanks. Separate models of plasma cutters from the point of view of their functionality make it possible to apply them as a welding machine. Such welding is performed in the argon protective gas.

Reverse cable and gas hose for plasma cutting!

When choosing a power source for homemade plasma torus, it is important to pay attention to the current value that can generate such a source. Most often, inverter is chosen for this, which provides high stability of the plasma cutting process and allows you to more economically use energy. Unlike the welding transformer, it has compact sizes and a low weight, the inverter is more convenient to use. The only disadvantage of using inverter plasma cutters is the complexity of cutting too thick billets with their help.

In the photo of the burner from the plasma cutter Abiplas and its composite parts!

When assembling a self-made unit to perform plasma cutting, you can use ready-made schemes that are easy to find on the Internet. In addition, there are videos on the Internet about how to make plasmorez with their own hands. Using the finished diagram when assembling such a device, it is very important to strictly adhere to it, and also pay special attention to the conformity of the structural elements to each other.

Plasma view schemes on the example of the APR-91 apparatus

As an example, when studying the concept of electrical circuit, we will use the APR-91 plasma cutting device.

Schematic diagram of the power of plasma band!
Plasmores Control Scheme
Oscillator scheme!

Details of the homemade device for plasma cutting

The first thing you need to find for the manufacture of a homemade plasma cutter is a power source in which it will generate an electric current with the necessary characteristics. Usually for this use welding inverter devices, which is explained by a number of their advantages. Thanks to mine technical characteristicsSimilar equipment can provide high stability of the generated voltage, which is positively affected by the quality of the cutting. It is much more convenient to work with inverters, which is explained not only by their compact size and low weight, but also ease of configuration and operation.

The principle of operation of the device for plasma cutting!

Due to its compactness and low weight, plasma cutters based on inverters can be used when working even in the most difficult places, which is excluded for bulky and heavy welding transformers. The big advantage of inverter power supplies is their high efficiency. This makes them very economical from the point of view of power consumption of devices.

In some cases, the power source for the plasma cutter can be a welding transformer, but its use is fraught with significant power consumption. It should also be borne in mind that any welding transformer is characterized by large dimensions and considerable weight.

The main element of the apparatus intended for cutting metal with a plasma jet is a plasma cutter. This equipment element provides cutting quality, as well as the effectiveness of its execution.

The size and shape of the plasma jet completely depends on the diameter of the nozzle!

To form an airflow, which will be converted to a high-temperature plasma jet, a special compressor is used in the design of the plasma cutter. The electric current from the inverter and the flow of air from the compressor enters the plasma cutter using the cable hose package.

The central work element of the plasma cutter is the plasma burner, the design of which consists of the following elements:

• Nozzles
• Channels for which air jet is served
• Electrode.
• Insulator, which parallels the cooling function

Replaceable plasmanent nozzles

Some of the above materials during heating can highlight connections dangerous to human health, this moment should be considered when choosing a type of electrode. Thus, when using beryllium, radioactive oxides are formed, and during evaporation of thorium, in combination with oxygen, hazardous toxic substances are formed. A completely safe material for the manufacture of electrodes for plasma burner is a hafnium.

For the formation of a plasma jet, with the help of which cutting is produced, nozzle is responsible. Its production should be paid to serious attention, since the quality of the workflow depends on the characteristics of this element.

Plasma burner nozzle device

The most optimal is nozzle, the diameter of which is 30 mm. From the length of this part, the accuracy and quality of the execution of the cut is depends. However, too long nozzle should also not be done, since in this case it is quickly destroyed.

As mentioned above, the plasma constructor necessarily includes a compressor, which forms and delivers air to the nozzle. The latter is necessary not only for the formation of a jet of high-temperature plasma, but also in order to cool the elements of the device. The use of compressed air as a working and coolant, as well as an inverter that forms the operating current 200 A, it allows you to effectively cut metal parts, the thickness of which does not exceed 50 mm.

Gas selection table for plasma cutting of metals!

To prepare a plasma cutting apparatus, you need to connect the plasma torch with an inverter and compressor. To solve this problem, cable hose packages are used, which is used as follows.

• The cable through which the electrical current will be supplied, connects the inverter and the plasma cutting electrode.
• The compressed air supply hose connects the output of the compressor and the plasma burner, in which a plasma jet will be formed from an incoming airflow.

The main features of the work of plasmoresis

To make a plasma cutter using an inverter for its manufacture, it is necessary to understand how such a device works.

After turning on the inverter, the electric current starts to flow to the electrode, which leads to the ignition of the electrical arc. The temperature of the arc burning between the operating electrode and the metal tip of the nozzle is about 6000-8000 degrees. After ignition, the arc compressed air is supplied to the nozzle camera, which passes strictly through the electrical discharge. Electric arc heats up and ionizes the air flow passing through it. As a result, its volume increases hundreds of times, and it becomes able to carry out an electric current.

With the help of a plasma cutter nozzle from a conductive air flow, a plasma jet is formed, the temperature of which is actively rising and can reach 25-30 thousand degrees. The flow rate of the plasma, due to which the cutting of metal parts is carried out, at the outlet of the nozzle amounts to about 2-3 meters per second. At that moment, when the plasma jet is in contact with the surface of the metal part, the electric current from the electrode begins to flow through it, and the initial arc goes out. A new arc that burns between the electrode and the workpiece is called sharp.

A characteristic feature of the plasma cutting is that the processable metal melts only in the place where the plasma flow affects it. That is why it is very important that the place of plasma impact is strictly in the center of the working electrode. If we neglect this requirement, we can face the fact that the air-plasma flow will be broken, as a result, the cutting quality will deteriorate significantly. To satisfy these important requirements, use a special (tangential) principle of air supply to the nozzle.

It is also necessary to ensure that two plasma flows are not formed simultaneously for the seats of one. The emergence of such a situation, which leads to non-compliance with the regimes and rules of the technological process, can lead to the failure of the inverter.

The main parameters of the plasma cutting of different metals.

An important parameter of plasma cutting is the air flow rate, which should not be too large. A good quality of the cut and the speed of its execution is provided by an air jet rate of 800 m / s. In this case, the current flowing from the inverter unit should not exceed 250 A. When performing work on such modes, it is necessary to take into account the fact that in this case the air flow used to form a plasma stream will increase.

It is not so difficult to make a plasma cutter on your own, for this you need to explore the necessary theoretical material, view the training video and correctly pick up all the necessary details. If there is a similar apparatus made on the basis of a factory inverter in the home use, not only high-quality cutting of metal, but also plasma welding!

In the event that you have no inverter in your use, you can make a plasmorez, taking a welding transformer as a basis, in which case you will have to come to terms with its large dimensions and not low weight. Also, the plasmorez made on the basis of the transformer will have not very good mobility and transfer it from place to place will be problematic!

Factory apparatus for plasma cutting. Our task: make an analogue with your own hands

Make a functional plasmorez with their own hands from the serial welding inverter is not so difficult, as it may seem at first glance. In order to solve this task, it is necessary to prepare all the structural elements of such a device:

• plasma cutter (it is also called plasma torch);
• welding inverter or transformer that will act as an electric current source;
• the compressor, with which the air jet will be created, necessary for the formation and cooling of the plasma stream;
• cables and hoses for combining into one system of all structural elements of the device.

Plasmorez, including homemade, is successfully used to perform various works in both manufacturing and at home. The apparatus is indispensable in those situations when it is necessary to perform accurate, thin and high-quality cuts from metal. Separate models of plasmores for their functionality make it possible to use them as a welding machine. Such welding is performed in the argon protective gas.

When choosing to complete the homemade plasma torus of the power source, it is important to pay attention to the current strength that such a source can produce. Most often, the inverter is chosen for this, providing high stability of the plasma cutting process and allowing more economically to spend electricity. Distinguishing from the welding transformer compact dimensions and light weight, the inverter is more convenient to use. The only minus the use of inverter plasmores is the difficulty of cutting with them too thick billets.

When assembling homemade apparatus To perform plasma cutting, you can use ready-made schemes that are easy to find on the Internet. On the network, in addition, there is a video for the manufacture of plasma bands with their own hands. Using when assembling such a device, a ready-made scheme is very important to strictly adhere to it, as well as pay special attention to the conformity of the structural elements to each other.

Plasma view schemes on the example of the APR-91 apparatus

As a donor, when considering the concept of electrical circuit, we will use the APR-91.

Scheme of the power part (click to enlarge)

Plasmore control circuit (press to enlarge)

Oscillator scheme (press to enlarge)

Elements of the homemade apparatus for plasma cutting

The first thing to be found for the manufacture of homemade plasmores is a power source in which an electric current with the required characteristics will be formed. Most often in this capacity are used, which is explained by a number of their advantages. Due to its technical characteristics, such equipment provides high stability of the formed voltage, which is positively affected by the quality of the cutting. Working with inverters is much more convenient, which is explained not only by their compact dimensions and insignificant weight, but also ease of tuning and operation.

Due to the compactness and a small weight, plasmoreza based on inverters can be used when performing work even in the most hard-to-reach places, which is excluded for bulky and heavy welding transformers. A huge advantage of inverter power supplies is that they have high efficiency. This makes them very economical in terms of electricity consumption by devices.

In some cases, a welding transformer can serve as a power source for plasma band, but its use is fraught with significant electricity consumption. It should also be taken into account that any welding transformer is distinguished by large dimensions and a significant mass.

The main element of the apparatus intended for cutting the metal with a plasma jet is a plasma cutter. It is this element of the equipment that provides the quality of cutting, as well as the effectiveness of its execution.

For the formation of an airflow, which will be transformed into a high-temperature jet of plasma, a special compressor is used in the plasma cutting design. Electric current from the inverter and the airflow from the compressor are fed to the plasma cutter using the Cable Hose Package.

The central working element of the plasmore is plastent, the design of which consists of the following elements:

• nozzles;
• the channel for which the air jet is served;
• electrode;
• the insulator, which simultaneously performs the cooling function.

The first thing to be done before making the plasma torus is to choose an appropriate electrode for it. The most common materials from which electrodes are made to perform plasma cutting are beryllium, thorium, zirconium and hafnium. On the surface of these materials, with heating, refractory oxide films are formed, which prevent the active destruction of the electrodes.

Some of the above materials during heating can be highlighted for human health, which should be taken into account, choosing the type of electrode. Thus, when using beryllium, radioactive oxides are formed, and the evaporation of the thorium is formed with their oxygen compounds form hazardous toxic substances. A completely safe material from which the plasmaton electrodes make is a hafnium.

For the formation of a jet of plasma, thanks to which the cutting is performed, nozzle meets. Its manufacturing should be paid to serious attention, since the quality of the working flow depends on the characteristics of this element.

The most optimal is nozzle, the diameter of which is 30 mm. From the length of this element, the accuracy and quality of the cutting is depends. However, too long nozzle should also be done because it contributes to too rapid destruction.

As mentioned above, in the design of the plasma formation, a compressor is necessarily present that forming and serving the air flow. The latter is needed not only to form a jet of high-temperature plasma, but also for cooling the elements of the device. The use of compressed air as a working and cooling medium, as well as an inverter forming the operating current by force 200 A, makes it possible to effectively cut metal parts, the thickness of which does not exceed 50 mm.

In order to prepare a plasma cutting machine, it is necessary to connect the plasma torch with an inverter and an air compressor. To solve such a task, a hose cable package is used, which is used as follows.

• The cable for which the electric current will be supplied, the inverter and plasma refrigerated electrode are connected.
• The compressed air supply hose connect the compressor and plasma torus, in which the plasma jet of the incoming air flow will be formed.

Features of the work of Plasmoreza

To make plasmorez using an inverter for its manufacture, you need to figure out how such a device works.

After turning on the inverter, the electric current starts to enter the electrode, which leads to the ignition of the electrical arc. The temperature of the arc burning between the operating electrode and the nozzle metal tip is about 6000-8000 degrees. After the ignition of the arc into the nozzle chamber, compressed air is supplied, which passes strictly through an electrical discharge. The electrical arc heats up and ionizes the air flow passing through it. As a result, its volume increases hundreds of times, and it becomes able to carry out an electric current.

With the help of a plasma-cutting nozzle from a conductive air flow, a plasma jet is already formed, the temperature of which is actively increasing and can reach up to 25-30 thousand degrees. The speed of the plasma flux, at the expense of which the parts of the metal are carried out, at the outlet of the nozzle amounts to about 2-3 meters per second. At that moment, when the plasma jet comes into contact with the surface of the metal part, the electric current from the electrode begins to come on it, and the initial arc goes out. A new arc that burns between the electrode and the workpiece is called the cutting.

A characteristic feature of the plasma cutting is that the processable metal melts only in the place where the plasma flow affects it. That is why it is very important to do so that the stain of the plasma impact was strictly in the center of the working electrode. If you neglect this requirement, you can encounter the fact that the air-plasma flow will be broken, which means that the quality of the cut will deteriorate. In order to comply with these important requirements, use a special (tangential) principle of supplying air to the nozzle.

It is also necessary to ensure that there are no two plasma flows at once instead of one. The emergence of such a situation to which the failure to comply with the modes and the rules of the technological process can trigger the output of the inverter.

An important parameter of plasma cutting is the air flow rate, which should not be too large. A good quality of the cut and the speed of its execution provides an air jet speed equal to 800 m / s. Moreover, the current flow coming from the inverter apparatus should not exceed 250 A. performing work in such modes, it is necessary to take into account the fact that in this case the air flow used to form a plasma flux increases.

It is easy to make a plasmorez independently, if you explore the necessary theoretical material, view the training video and correctly pick up all the necessary items. If there is an apparatus based on a serial inverter in the domestic workshop, not only cutting, but also plasma welding with their own hands can be performed.

If there is no inverter at your disposal, you can collect plasmorez and based on the welding transformer, but then you will have to come to terms with its large dimensions. In addition, the plasmorez, made on the basis of the transformer, will have not very good mobility, as it is difficult to carry it from place to place.

Allowed details of various machines and tools are great for the manufacture of devices beneficial in the household with their own hands. If there is an unnecessary welding inverter in the presence, then the homemade plasmorez can be made of it.

How to turn the device for welding metal into a device that is capable of cutting durable material will be described in detail in this article.

One of the simplest metal cutting devices is. Such a device costs small money and consumables for it are also inexpensive. But when performing gas welding works, heating is too large metal square.

For this reason, materials with high thermal conductivity can be swallowed and change color. Both at the melting point of metal and at a significant distance from the thermal exposure of the flame burner.

Advantage of Plasmoreza It is that it is possible to obtain a very thin stream of hot gas, which will affect a small surface area, which will significantly reduce the heating of the part.

Principle of operation of Plasmoreza

3. Compressor. To ensure a long-term compressed air supply to the plasma torus, you must purchase an average power compressor.

Find out this video, how to choose a plasma cutting compressor:

Also necessary for homemade plasmores to buy enough copper wires Large diameter. To connect the "mass" to the part of the part and ensuring the plasma torus the necessary amount of electricity.

Independent manufacture of plasma torch

The burner or plasma torus can be made of girlfriend. To assemble this element of homemade plasmores, you will need:

• a pen;
• start button;
• special electrode;
• nozzle;
• insulator.

For the manufacture of self-made plasma torus, a handle from a powerful soldering iron is perfect. As a rule, such a part has a middle hole through which the electric current and compressed air will be supplied.

The best use button is quite large enough to use the device as comfortable as possible while working.

Electrodes will need to be purchased in the store. For self-making plasma torus, it is better to choose products made from hafnia.

To work with metals of various thicknesses, it will also be necessary to buy a set of nozzles.

Plasmane is manufactured in such a sequence:

1. Immediately behind the handle is placed with a metal tube coated from the inside with fluoroplast.
2. An electrode is placed inside the tube, which is almost entirely closed with high-temperature isolation.
3. The electrode is installed using a threaded connection nozzle of a suitable diameter.

Plasmaton is ready to use. Even for the operation of the device, you will need to connect to the air hose from the compressor and electric wire From the inverter.

Look at the video where a person tells how he tried to make plasma torch:

Tok Source

As an electricity source, you can use a welding inverter with the following indicators:

• supply voltage - 220 V;
• power - from 4 kW;
• the ability to adjust the current from 20 - 40 A.

Assembling plasmoreza

When individual parts of the plasmores are ready, you can proceed to the assembly. To work with the homemade device, it was most comfortable as possible, it is necessary to minimize the amount of wires and hoses stretched behind the handle.

For more compact placement of the working wire, it is placed inside the hose by which compressed air is supplied. The wire is securely connected to the electrode, while the hose must also be connected to the burner without the formation of gaps.

Another contact from the inverter will be connected to the resulting part as "mass" therefore it should be equipped with a "crocodile" type terminal.

From this video you will learn how to make a hose package, plume for plasma view:

The process of cutting metal using a plasma cutter is very simple. After supplying electricity, an electric arc is formed. The moment of formation is adjusted by the button, which was previously installed on the plasma torch handle. The air is served from the compressor on the hose and inflates the arc, thereby increasing its temperature that can reach 8000ºС.

In order to glue the arc just to release the button on the handle. Thus, the burner will only work at the moment when it is necessary to cut the metal, which will minimize the effect of overheating, to which homemade products are very sensitive.

An interesting video about Plasmorez do it yourself and what it consists of:

It is important not only to know how to remake the inverter in Plasmorez, but also how to make the work of such a device as efficient and safe.

1. Before you begin the manufacture of a metal cutting device from a welding inverter, you should schedule the main elements of such a system. Independently manufactured drawings and schemes will allow during the work to prevent annoying errors that are most commonly caused by conventional inattention.
2. Despite the fact that the plasma cutter has a very narrow flame that does not even warm the metals with high thermal conductivity, it is recommended when working with aluminum products to use neon or argon as spraying gas that will not allow the surface to be oxidized by high temperature.
3. To maximally reduce the time for the manufacture of plasma bands, it is recommended to purchase the finished burner for the gas cutter. Such a product will make it possible to work as efficiently as possible and safely.
4. When using home-made plasma, it is necessary to adhere to the basic safety regulations. First of all, it is necessary to protect against the effects of electricity and splashes of molten metal. For this purpose, special shoes, gloves and apron are used. It is also necessary to wear safety glasses that will prevent vision from exposure to ultraviolet rays. In the process of cutting metal stands out a large number of Harmful substances, therefore it is recommended to protect the respiratory organs using the respirator.

About how from the inverter to make Plasmorez with their own hands detailed in this article. Before the start of manufacturing plasma cutter, it is recommended to check the performance of the inverter.

For cutting sheet metal, various mechanical devices are used, as well as electrical welding or gas cutter. But besides these methods there are effective method Metal cutting - plasma cutter. The installation of factory production is quite expensive, but it can be replaced by a homemade plasmorez from the welding transformer.

The installation of plasma cutting consists of the following parts:

• plasma cutter or plasma torus, creating a plasma flow;
• welding transformer powered by plasma torch;
• oscillator or an arc gas unit supplying high voltage at the time of starting the cut to form a plasma stream;
• compressor for creating air flow through plasma torch;
• cable connecting the welding machine, plasma burner and cut part;
• hoses for which air or other gas is supplied and, if necessary, coolant.

Plasma head outwardly resembles a burner for a welding semiautoma. The cables and hoses are also connected to it, but from the nozzle instead of the wire there is a plasma stream, heated to 8000 ° C.

Principle of operation of the device

The plasma cutting installation is a kind of hybrid of electric welding and gas cutter - the metal is melted with electricity, and the melt is blowing out the gas flow.

The main part of this apparatus is plasma torch. Inside it is a copper electrode with a rod from a refractory metal - beryllium, thorium, zirconium or hafnium. At the end of the head is a nozzle forming a plasma flow. The nozzle is separated from the electrode by an insulator. The cut is produced by reverse polarity - the electrode is an anode, and the nozzle and cut metal cathode.

The installation is running as follows:

• when the unit is turned on, the voltage from the welding transformer is supplied to the electrode;
• using the oscillator between these elements, an auxiliary electrical arc arises, limited by additional resistance;
• this arc warms up the gas supplied to the plasma torus to 8000 ° C, which turns it into the plasma and increases the pressure inside the head;
• the flow of air or other gas flow of plasma is blowing out of the nozzle;
• at the exit of it, the plasma is compressed into a narrow beam, the speed of which can reach 1500m / s, and the temperature of 30000 ° C;
• when the plasma is contacted and the current cut, the current begins to go through the mass of the transformer;
• the current relay installed in sequentially with the part shuts off the oscillator and auxiliary arc.

The thickness of the metal is depends on the strength of the welding transformer.

Information! With a current of more than 100A plasma torch and the cable suitable for it needs to be cooled with flowing water or other coolant.

Advantages and disadvantages of plasma cutting

Plasma metal cutting has advantages over other ways:

• the ability to cut any metals and alloys;
• high processing speed;
• clean cut line without influx and material flows;
• processing is done without warming cut parts;
• no flammable materials are used, such as oxygen cylinders and natural gas.

The disadvantages of plasma cutting are:

• complexity and high installation price;
• for each operator with plasma torus, a separate transformer and control panel are required;
• the angle of cut is no more than 50 °;
• big noise when working.

What do you need a transformer

The power supply of the plasma arc is a transformer with a rectifier. The current and the speed of the metal cut is depends on its power, and the thickness of the material is cut from the output voltage.

You can connect the plasma cutting unit not only to a special transformer, but also to the welding machine with the necessary characteristics.

It is impossible to do without such a device for several reasons:

• The transformer on the principle of its work limits the current in the secondary winding. When powering the plasma torus directly from the network, the device will operate in the CW mode, so the current current and power consumed will exceed any permissible values.
• The welding machine during operation performs the role of a separation transformer. When the plasma torus is connected without it, the burner and item will be under voltage, which is dangerous for people's lives.

Scheme

Like any electrical installation, the plasma cutting unit is assembled according to electrical circuits.

Principal

This scheme contains all installation elements regardless of their location. The main purpose of this drawing is to show links between the details and simplify the understanding of the installation.

The following elements are depicted on the device schema:

• feeding transformer with rectifier;
• oscillator;
• current relay;
• resistor limiting the current auxiliary arc;
• contactor shutting down this arc;
• a starter comprising a device;
• the turning on the cut button;
• compressor with control equipment.

Information! Power chains can be pictured with thick lines.

Control

The control circuit shows all buttons and regulators that are on the console or directly on the plasmatone:

• compressor switching buttons;
• air pressure regulator;
• in the presence of coolant buttons and regulators of its stream;
• ammeter;
• voltmeter;
• water and air duct sensors;
• the cut button (may be on the plasma torch handle).

Information! All these elements are also depicted on the concept.

Connections

The connection scheme contains cables and hoses connecting all the elements between themselves. It indicates the cross section and the length of the wires, as well as the connection location.

How to make a plasma cutter

The plasma cutting tool is a cutter, or plasma torch. It creates a flow of air, transformed into a plasma heated to 30000 ° C, which cuts the metal.

You can make it yourself. It is desirable to use the finished design as a sample. Consists of plasma torus of several main elements:

• Central holder with a replaceable electrode. With a current of cutting to 100a and metal thickness up to 50 mm, the holder is made from a copper rod, in more powerful devices inside there are channels for water cooling. For the ignition of the arc, the distance between the electrode and the nozzle must be 2 mm, therefore, to adjust the plasma torus, the central rod is made movable.
• Isolator between the central electrode and the outer case. A portion of the insulator, close to the nozzle, is wears and is made by replaceable from fluoroplast.
• Outer housing with a replaceable nozzle. The plasma is formed in the chamber between the electrode and the nozzle. In the manufacture of a water cooled device inside the walls contains cooling fluid channels.
• Replaceable nozzles, cable - power and for auxiliary arc, hoses.

Information! Water-cooled in devices power cable Without insulation and is located inside the hose feeding water to the burner.

One way to make such a device is to make it from the burner for argon-arc welding. It has most of the necessary elements:

• tungsten electrode Ø4mm with the possibility of adjusting the position;
• terminal and cable to supply current to it for welding;
• guide channels and hose for gas supply to the nozzle.

For refinement it is necessary:

• remove the thin-walled brass nozzle;
• instead of it, instead of an insulating gasket from the fluoroplastic of the cylindrical shape with a thread outside and inside the cylinder;
• top on the gasket turn the brass housing with the mounting for the copper nozzle;
• to the body solder or press the clamp cable for auxiliary arc;
• in the handle, install a microswitch that includes the cut mode.

Replaceable nozzles

Replaceable elements that wear out during operation are electrodes and nozzles:

• The electrode is made of copper with an insert from the refractory metal - beryllium, thorium, zirconium and hafnium. The insert is in the center, opposite the hole of the nozzle. Auxiliary short-term arc appears between the edge of the electrode and the nozzle, the working permanent between the insert and the part, so the insertion is the most wearing element and is replaced with the electrode.
• Nozzle forms a plasma jet formed by an electrode. The optimal size of the nozzle is 30mm, the center is the hole Ø2mm. During the operation of the plasma, passing through it, increases the diameter of the channel, which makes the gas flow is wider, and the cut is less neat. Therefore, nozzle, like the electrode, should be changed periodically.

Gas selection

Despite the fact that any metal can be cut by the air flow created by the compressor, for each metals there is the optimal composition of the gas:

• copper, brass and titanium - nitrogen;
• aluminum - a mixture of nitrogen with hydrogen;
• high-alloy steel - argon.

How to make a welding transformer

The plasma power supply is a welding transformer. Like some other elements it can be made independently.

Necessary parameters

The plasma cutting transformer differs from a conventional stroke voltage welder and is 220-250V. This is necessary to create and maintain an arc between the electrode and the part being cut. The power and current of the secondary winding depends on the intended thickness of the metal:

• 20a, 2.5 kW - 6 mm;
• 50a, 6kW - 12 mm;
• 80A, 10kW - 18-25 mm.

The power source is needed with a "soft" characteristic, the voltage during operation is 70V. For the operation of the auxiliary arc, the current 5a is sufficient. It is limited to resistance to 30-50, made of thick nichrome wire.

Information! Use the usual or invertor welder will not work. These devices have insufficient tension of XX.

How to calculate

The calculation of the supply transformer is reduced to the determination of the necessary sections of the magnetic pipeline, the primary and secondary winding and the number of turns.

For a device intended for cutting metal up to 12 mm at a current 50a, a non-stroke voltage 200V and a 220V network voltage, these parameters are:

• magnetic pipeline cross section - 107 mm²
• primary winding - 225 turns with copper wire Ø4,7 mm;
• secondary winding - 205 turns with copper wire Ø5.04 mm².

Making a transformer

Due to the fact that the transformer must have a "soft" characteristic, coils are arranged separately from each other. When using the O-shaped core, they are on different rods, on the W-shaped magnetic circuit of the winding are located along the middle part.

Winding coils are made according to the calculated parameters on the frames of their electrical cardboard. The finished windings are wrapped with a glass bench or a melted ribbon and are covered with paint.

After winding windings and assembling the magnetic pipeline on the transformer, the diode bridge of 4 diodes with radiators collected on the textolite platform is connected. The collected transformer is placed in the housing, and the output of the windings and the diode bridge is connected to the terminals on the front panel. The connection is performed according to the schematic diagram, given the presence of ammeters, voltmeters, starters and other details.

The oscillator connected in series with a welder has a high output voltage of high frequency. Therefore, the diodes in the rectifier must be used high-frequency or install a separate diode bridge, specifically for auxiliary arc.

Other components

In addition to the plasma torch and the transformer in the plasma cutting unit there are other elements.

Compressor

The most common working gas is compressed air. It can be used when cutting almost all metals and alloys. The source of compressed air is the compressor. It can be used any design, minimal performance depends on the thickness of the metal:

• 16 mm - 140l / min;
• 20 mm - 170l / min
• 30 mm - 190l / min.

For more stable operation, a receiver requires a capacity of 50 liters, the pressure being created by the compressor must be more than 4,5bar.

Cables and hoses

To work with air-cooled plasmores Cable hose package consists of the following elements:

• Power cable. Its section depends on the rated power of the device. With current 50a, sufficient for cutting metal with a thickness of 10 mm and wire in vinyl insulation it is 6 mm². When using a cable in a heat-resistant isolation, the cross section decreases accordingly. These cables are required 2 - one in the hose cable package for the electrode and the second for the mass.
• Wire for auxiliary arc. The cross section is enough 1.5 mm². According to the allowable heating, the cable is allowed more subtle, but it has insufficient mechanical strength.
• Air hose. Inner diameter 10 mm.
• Wires for connecting the microswitch.

Oscillator

This is an instrument that increases the voltage of the XX of the welding transformer to the value that ensures the appearance of an electrical arc without the pre-contact of the electrode and the mass.

Oscillators used in plasma cutting units are connected in series with a transformer and add to a constant voltage of 220V variables, a frequency up to 250 kHz and voltage up to 6kv.

By itself, this device does not give out a current dangerous to people's health and, moreover, it is not capable of creating an arc for welding or cutting metal. The main purpose of this device in creating a spark between the electrodes. This spark is a conductor and "paves the way" for a welding rectifier.

Tip! Instead of oscillator, the use of electronic ignition of the car is allowed.

Final assembly

The assembly of the improvised plasma cutting unit is to connect all the elements by cables and hoses:

• the cable for the electrode, mass and auxiliary arc is connected to the corresponding terminals on the welding transformer;
• the air hose is attached to the compressor receiver;
• the wires going to the micro switch on the handle are connected to the control circuit.

Check

To check the collected device, it is necessary to produce a test of metal:

• supply power to the transformer;
• after 10 minutes, turn off and check the windings for heating;
• if they are cold, feed food again;
• turn on the compressor;
• after filling out the receiver, open the air faucet and send the air flow through the plasma torch;
• by pressing the microswitch button to light the auxiliary arc;
• when presented it is preparing a test metal.

After completing the test, turn off the machine from the network and check all the elements to heat up again.

Safety Instructions for Plasmorez

The process of plasma cutting in non-compliance with the rules of work is dangerous to the health and life of people. The main harmful factors are:

• Spray molten metal. During the cut, the plasma flow melts the metal and blows it out of the part being cut. The falling molten drops into combustible substances lead to their fire, and the skin entering strong burns, up to IV degree (charring). To protect, it is necessary to direct the flow of plasma away from people and combustible materials.
• Harmful gases and dust. During the cut, the metal is only melted, but also burns. Food smoke is harmful to health. In addition, pollution is burning on the surface of the details. Therefore, the workplace must be equipped with exhaust ventilation and work in the respirator.
• Bright light. During the operation of electrical welding and cutting by plasma formed by electric arc, an ultraviolet appears in addition to visible light. This type of radiation leads to the back of the retina. To protect the workplace, it is struck by portable shields, and the cutter must use the protective shield.
• Temperature. After the work is completed, the part of the part remains heated to a high temperature and touching them can lead to burns. In order to avoid similar injuries to the cut parts, it is possible to touch only in protective mittens or after a while, sufficient to cool the edges.

The average cost of transformer plasmores collected by their own hands

The cost of homemade plasmoreza depends on the price of components. Ideally, such a device is collected from a variety of old trash and spare parts existing in the workshop.

In any case, it is necessary to focus on the price of the shopping plasma view, which depends on the thickness of the metal cutting, the availability of additional accessories, manufacturer companies and other factors.

The average cost of such devices depends on the thickness of the metal cutting:

• up to 30 mm - 150-300 thousand rubles;
• 25 mm - 81-220 thousand rubles;
• 17 mm - 45-270 thousand rubles;
• 12 mm - 32-230 thousand rubles;
• 10 mm - 25-20 thousand rubles;
• 6 mm - 15-20 thousand rubles.

Tip! Different producers have a different price for components, so one of the ways to save is to purchase all the details separately and assemble the device yourself from the finished elements.

Plasma cutting parameters of various metals

Despite the fact that all materials can be cut in one mode, to improve the quality of processing, various metals and alloys require different cutting modes, gas and equipment settings:

• Carbon steel - air, nitrogen, oxygen. The diameter of the nozzle is 3 mm, the speed of the cut is 0.3-5.5 mm / min.
• Stainless steel - air, nitrogen, hydrogen-argon mixture. The diameter of the nozzle is 3 mm, the speed of the cut is 0.3-5.5 mm / min.
• Aluminum - nitrogen, hydrogen-argon mixture. Nozzle diameter 2-3 mm, cutting speed 0.1-1.6 mm / min.
• Copper and alloys - air over 40 mm, nitrogen - 5-15 mm. The diameter of the nozzle is 3-3.5 mm, the speed of the cut 0.4-3 mm / min

Information! The speed of the reserve depends on the installation current and the thickness of the part. At the same time, it is important that the end of the arc "does not lag behind" from its start.

Plasma metal cutting is a modern processing method. The presence of such an apparatus made from the welding transformer, in the workshop expands the capabilities of the wizard.

Plasmores are widely used in non-ferrous metals. Unlike conventional steel, which can be cut off by a propane-oxygen flame, a stainless steel or aluminum will not be processed, due to the greater thermal conductivity of the material. When attempting to cut the usual flame, the heating is exposed to a wide part of the surface, which leads to deformation in this area. Plasmorez is able to spot metal, producing a cut with a minimum width of the cut. When using an additive wire, the device can be revived with colored types of steel. But this equipment is quite expensive. How to collect plasmorez independently from the welding inverter? What principle does the device work? What is the scheme of equipment? Is it possible to make a cutter pistol yourself, or better buy this element? The following are answers to these questions, including thematic video.

Make the plasmorez from the inverter with your own hands in the event that it is good to understand the principle of operation of the apparatus and elements involved in the process. The essence of the functioning of the plasmore is as follows:

1. The current source produces the required voltage supplied by cables in the burner cutter (plascript).
2. There are two electrodes (cathode and anode) in plastent), between which arc is excited.
3. The air flow supplied under pressure and special twisted channels sends an electric arc to the outside, at the same time enhancing its temperature. In other models, a fluid that evaporates creates a graduation pressure. The resulting high-temperature ionized flame (as it looks outward) and there is a plasma.
4. The mass cable pre-connected to the product contributes to the closure of the arc on the cut surface, which makes it possible to work the plasmoresis.
5. In the case of welding, an argon or other inert mixtures that protect the welding bath can perform in the role of the supplied gas, protecting the welding bath from the external environment.

The temperature of the arc, due to the acceleration of the air flow, can reach 8000 degrees, which allows you to instantly and point to heat the necessary section of the metal, producing cutting, and not overheating the rest of the product.

Plasmores differ in power and configuration. Small models are capable of cutting a metal with a thickness of about 10 mm. Industrial machines work with steels with a thickness of up to 100 mm. Often these are large machines on the brackets that are served by the telhelmi sheets. Plasmorez, made at home, will be able to separate the stainless steel and other metals to 12 mm. It will be possible to perform curly cuts in the sheet (circles, spirals, wave-like shapes), as well as the welding of alloy steel with an additive wire.

The easiest homemade plasmissez must have four components of the node:

• power supply;
• plasma torch;
• compressor;
• mass.

Tok Source

The product assembly must be started with the search for a suitable current source. In industrial models, powerful transformers are used, allowing to obtain a large current strength and capable of cutting the thickness of over 80 mm. But at home, it does not have to work with such values, and such a transformer will be very buzzing.

You can take an ordinary inverter as a source of current, which is four times cheaper than the simplest plasma cutting machine itself. It will exceed the operation of the transformer, issuing a steady voltage with high frequency. This will ensure the stability of the burning of the arc and the required quality of the cut. The inverter will be convenient and in view of small sizes, in case of field work with plasmoresis. Light weight will make it easier to transport the device to the desired place.

Plasmorez from the inverter, in the finished form, must correspond to a number of key requirements:

• eat 220V;
• work at a power of 4 kW;
• have a current strength adjustment range from 20 to 40 A;
• idle 220V;
• nominal mode of operation 60% (with a cycle of about 10 minutes).

To achieve these parameters, the product must be equipped with additional equipment, strictly according to the scheme.

Plasmoreza scheme and its work

How to make plasmissez well shown on some videos on the network. There you can also find important schemes for which the device is collected. To read the designations, elementary electrical engineering skills are needed and the ability to understand the conditional designations.

Plasmores diagram provides in reality the possibility of performing the work by the device. This happens as follows:

1. Plasma torus has a process start button. Pressing the button includes relays (P1), feeding the current to the control unit.
2. The second relay (P2) allows the current to the inverter, and at the same time connects the electric valve that performs the blowing of the burner. Air flow dries the burner chamber and frees it from possible Okalin and garbage.
3. After 3 seconds, the third relay is triggered (P3), which feeds the electrodes.
4. Simultaneously with the third relay, the oscillator is launched, ionizing air between the cathode and anode. An arc is excited, called duty.
5. When the flame is made to the product connected to the mass, the arc is ignited between the plasmatone and the surface, called the working.
6. The Relo Herroc cuts out the flow of current on the ignition.
7. Cutting or welding material is carried out. If the contact with the surface was lost (the arc came to the already cut place), then the relay of Herron again works on the ignition of the duty arc.
8. After turning off the button on the plasma torus, any type of arc goes out, and the fourth relay (P4) starts a short-term flow of purge air to remove the airborne elements from the nozzle.

Plasma torch assembly

Plasma cutting and welding performed with a burner (plasma torus). It can have different modifications and sizes. Making a model working on water in home conditions is quite difficult, so it is worth buying such a "gun" in the store.

Make plasma torus with the air system is much simpler. Homemade versions of plasmores are most often such. For the assembly with their own hands will be required:

• handle with holes for cables (can be used from old soldering iron or toys);
• start button;
• special electrode;
• insulator;
• swirlar streams;
• nozzles for different metal diameters;
• tip with splash protection;
• remote spring for maintaining the gap between the nozzle and the surface;
• nozzles for the removal of chamfering and nagar.

Welding and cutting with the same device can be carried out on different thicknesses of the metal due to the replaceable elements of the plasma torch. For this, a variety of nozzles are provided, differing in the diameter of the outlet and the height of the cone. It is they who direct the formed jet of plasma for metal. Purchased nozzles separately in the store. To buy every kind of several pieces, since they will be melted, which will require, with time, replacement.

The nozzles are attached to a special clamping nut, whose diameter allows you to skip the nozzle cone, and hold it a wide part. Immediately behind the nozzle is an electrode and an insulating sleeve, which does not give a light arc in an unforeseen place. After, there is a mechanism for the twist of the air flow, which enhances the effect of the arc. All this is placed in the fluoroplastic body and is closed with a metal casing. Some of these elements can be made independently, and others better buy in the store.

The store plasma torch may differ and the air cooling system, which will allow the device without overheating longer. But if the cutting will be carried out briefly, then this is not necessary.

Used electrodes

Electrodes play an important role in ensuring the process of burning the arc and the cutting of the plasma torus. In their manufacture use beryllium, hafnium, thorium and zirconium. Due to the formation of a refractory surface film, the electrode rod is not overheated and premature destruction when working with high temperatures.

Buying electrodes for homemade plasmores should be found out from what material they are. Beryllium and thorium give harmful evaporation, and are suitable for working in a special environment that ensures proper protection of the welder. Therefore, for home use it is better to purchase electrodes from Gafnia.

Compressor and cable hoses

Most self-made plasmores include a compressor and air supply path to the burner. This is an important part of the device, which allows to develop an electric arc temperature to 8000 degrees, and ensuring the cutting process. Additionally, the compressor blows the channels of equipment and plasma torus, which causing the system from condensate and removing trash particles. The possibility of passing compressed air on the burner contributes to the cooling of working parts.

You can install a simple compressor used in painting with a pulverizer to its plasma torch. Connecting to the machine is performed by a thin hose and the corresponding connector. The inlet establishes an electric valve that regulates the supply of air into the system.

The channel from plasmores to the burner contains an electrical component (cable for the electrode washing), therefore it is used a thicker hose, for example, from the old washing machine, the power supply wire is placed inside. The served air will simultaneously cool the cable. Mass are performed from the wire with a cross section of more than 5 mm square, with a clip at the end. If the contact of the mass is bad, the duty arc will not be able to switch to the working one. Therefore, it is important to buy a strong and reliable.

Collect Plasmorez at home with video and purchased components are quite possible. The working inverter and the scheme will serve as the basis for the purpose of realizing the goal. And the above tips will help better understand the process and purpose of each element in the assembly.