Redefining Plasma Pipe Cutting Retrofits

The Watts W-244 engineered to convey and rotate pipes ranging from 2” to 24” OD. Built on a massive 20’ to 50’ (≈ 6,1 m to 15,2 m) bed, it is capable of supporting 500 lbs per foot (≈ 744 kg/m), reaching a maximum capacity of 20,000 lbs (≈ 9,1 t). To bring this heavy-duty mechanical frame into the modern era, the retrofit utilises the NUM Flexium+ 8 CNC platform. This upgrade replaces aging, proprietary control systems with a modern, scalable architecture that provides the robust processing power required to handle complex 3D pipe profiles.

The motion control system is the core of this transformation. The Watts W-244 features a four-axis profiling carriage moving on precision-machined and hardened tracks. The motion is divided into four critical synchronised axes: X (Axial along pipe), A (Tilt across pipe), B (Tilt along pipe) and C (Rotate pipe). All axes are now powered by NUMDriveX (MDLUX) digital drives. For the primary rotation (C-axis), a high-torque NUM SPX126 servo motor provides the necessary precision and IP67-rated durability. To streamline the retrofit workscope and maintain mechanical compatibility, Hudson motors with NEMA-compatible mounts were selected for the X, A and B axes. The inherent flexibility of the NUMDriveX platform allows the system to control these third-party motors with the same high-level algorithms used for NUM’s own motors, ensuring optimum performance across the entire drive train. One significant technical advantage of this hardware suite is the inclusion of the FXSO000523 Backtrack On Path function, which allows operators to safely retract the plasma torch along its stored path – a critical feature for maintaining part integrity during unforeseen process interruptions.

Complying with IEC 61131, it supports advanced features like G93 (inverse time feedrate), custom G-code cycles and custom homing routines that allow the integrator to modify the behavior of the homing process to suit unique mechanical constraints. To tie the hardware and software together, the FXServer SDK gives the integrator the ability to use any type of programming interface to communicate with the NUM system. This enables them to embed the Flexium control system within the PypeServer interface for everything from simply sending G-code files to achieving fine-tuned, real-time user control.

The mechanical efficiency is further supported by a floating pipe clamp with a locking mechanism that eliminates “pipe walk” during rotation. Material handling features a hydraulically controlled lift deck with a machine conveyor on the cutting bed and hydraulically actuated off-loader arms to transfer finished parts off the cutting cell.

This retrofit benefit lies in the seamless “design-to-cut” workflow enabled by PypeServer. By connecting the NUM CNC directly to industry-standard design software – including Revit, AutoCAD, SDS2 and Tekla Structures – PypeServer eliminates the manual data entry. Through a combination of PypeServer’s Cloud+ software add-ons and status tracking system, fabricators can move projects from the drafting table to the machine floor instantly and have full visibility on progress.

(Source: NUM AG)