First time user - Sporadic cutting errors (Solved?)

hey gang. first off would like to give a big shout out to the Langmuir team for their support so far. we recently purchased a legacy crossfire 2x2 machine and ending up completely frying the USB board in the box by accident, and they sent us an updated box that allows us to use FireControl and all the proprietary stuff, so big thank you to you guys.

to begin: I am completely new to plasma cutting and cnc machines. I have used laser cutters for fabric before, but played no part in setting any of that up. now I’m trying to set up the crossfire for plasma cutting and its been quite the experience. I’ve gotten some great cuts, some not so great cuts, but every issue so far I’ve been able to figure out. the only thing I’m worried about is that I don’t entirely understand what the cutting issues im getting are stemming from.

I personally think it has something to do with the plasma cutter I’m using.(Plasma Cutter TL-50C-NHF | Non-Touch Pilot Arc NHF Version – Tooliom) the issue is that the plasma cutter will randomly choose when to cut and when not to cut.

here are some successful ones:

I successfully got the G cut out (its a little messy, didn’t have the pressure set right yet) and the wheel spacer is clearly janked up looking, but was just a test piece and was successful in that I traced an image, matched all the measurements, and cut the design out accurately for part fabrication. those were cut out of 16 gauge mild steel. I thought I had figured out all the kinks so I decided to up the ante with 10 gauge steel and…

this is a “completed” cut, but it failed to cut out quite a few things:

so what might cause something like this? It started to cut out the inner space, but then just stopped. moved on to some of the letters, cut them out as it should have, but then it completely gave up on those little flag bits at the bottom, and just picked some really random sections to ignore. In some sections I heard air and it just wasn’t arcing. in other sections it was just ignoring any instruction to fire entirely. any thoughts on this? I don’t know enough about plasma cutters to really list what it might be you guys would need to pinpoint anything, so feel free to ask me any questions and I’ll try to facilitate. Thank you for any help!

Are you using a machine torch or hand torch/ If hand torch don’t use the drag standoff attachment on torch head your cut height will be way to high off material. Can you post pic of how your torch is mounted. As far as not cutting all of design you might have open paths or not on same layer?

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heres the torch setup. it has no attachment on the torch head so we can get as close to the material as necessary. As far as I can tell the design is all on one layer. would the fact its a .dxf exported from illustrator have anything to do with that? It’s pretty easy to design things in illustrator for me and seems to import into / export cut paths from fusion pretty seamlessly

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Make sure your plasma cutter is set to 2t function. 4t will cause it to cut and not cut at unexpected times.

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I believe we did have it set on the 2t function

Are you able to run a cut simulation in your CAM program and see it cuts everything there?

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Work clamp is connected directly to the material?

What @Knick said. My first thought is the cut profile did not pick everything up in CAM.

What CAM are you using (SheetCAM or Fusion360)?

Can you show a screen grab of the simulation of the cut pattern in your cam program?

If you are hearing air but no torch, it could be your air pressure is dropping below the threshold for proper torch firing mechanism.

If the air is good and the simulation is good, I would then turn to:

  1. Loose connection of the wire (or damage of the wire) for torch on/off - check continuity
  2. EMI is interrupting FireControl: Laptop on battery or plugged it
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the simulation cuts everything ive instructed it to.

work clamp is connected directly to the material.

my laptop is plugged into its charger. could that be the issue, despite it being a non-high frequency cutter?

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I am using Fusion 360. This is my cut pattern

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+1. Cuts being stopped part way through a loop feels like an air issue.

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Well, the cut path shows all contours selected.

And I think you were on 2T vs 4T, otherwise you would have had some of the ‘rapids’ cutting.

I would contact Langmuir thru their support webpage:
https://www.langmuirsystems.com/support/crossfire

Although your plasma cutter is not on the list of machines that they have found compatible, there could be something about that. Perhaps they may consider trying a USB isolator for your problem. It is curious how it is actually following the pattern but choosing to skip or interrupt certain parts of a contour. Almost like EMI.

It looks like you’re cutting the outside contour first which will create an island that will cut randomly.

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The color dots on Fusion 360 are counter-intuitive. Red means ‘start’ and green means ‘end’ or stop.

Now I am confused. Maybe I have it wrong…I gotta check. Yes: Red is begin, Green is end.

But I am starting to doubt my “insufficient air” idea since it skipped the first contour:

image

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To me, the fact that it COMPLETELY cut the outside contour and had trouble with the interior is the clue…

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Try running laptop on battery unplugged

Thats what puzzles me. especially because on 16 gauge metal at 25 amperage it seemed to do just fine. but once it was ramped up to 40 for 10 gauge it started having issues

If you’re cutting the outside first then the ONLY current return for the cut is through the slats. That won’t be as tricky at 25amps vs 40…

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the outside is cut last. I make sure to cut out the interior before it cuts out the actual piece

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