True limits of HPR260

Background

In 2010, a Latvian metal fabrication company operated a Hypertherm HPR260 High Definition Plasma System integrated on a CNC cutting table. HPR260 was one of the best plasma power supply units made by Hypertherm between 2007-2019. Later in 2009 system upgraded with XD water cooled shield solution. Specifically designed for True Hole technology.

The machine was in perfect technical condition, but its performance was limited by internal engineering procedures and machine operator misconceptions.

System was used only for cutting up to 25 mm mild steel, despite being technically capable of 25–40 mm O₂/Air cutting.

Problem

When asked why they didn’t use the plasma for thicker materials, the response was:

“Because it can’t do that.”

Solution

During a site visit, I suggested a live demonstration:

“Let’s take a 40 mm plate, no edge start, no pre-drill or pre-pierce, and simply cut it.

HPR260 performed a clean 30mm and 40 mm cut using O₂/Air, with full pierce achieved at standard process parameters. See picture gallery.

Note! Hypertherm recommended pierce above plate is no more than 32mm for mild steel.

Outcome

The test proved that for years, the company had been operating at only 50–60% of the system’s real potential. By switching from plasma to oxy-fuel to cutting. Metal fabrication companies must sell tons per day not hours.

Conclusion

The HPR260 had no problem. The problem was perception.

Key Insight

This case illustrates a common pattern in industrial production:

• CAPEX is spent on hardware

• OPEX knowledge determines performance

T-Index

Customers technology performance value: 60%

*Picture quality improved as pictures was taken with 2010 smart phone technology.