The Challenge
Improving Cut Accuracy and Throughput Without Replacing Existing Cell
The customer needed to upgrade their aging robotic cutting cell to address issues related to:
- Inconsistent cut quality on thick steel base rails
- Limited system flexibility and control with older technology
- High maintenance and downtime due to outdated mechanical systems
- Reluctance to replace the entire cell due to capital constraints
MWES was selected to deliver a cost-effective upgrade to bring modern controls, precision, and repeatability to the existing plasma cutting infrastructure.
The Solution
Upgraded Robot Plasma Cutting System with Improved Precision & Control
MWES delivered a turnkey retrofit featuring:
- Enhanced robot programming to optimize torch movement and arc voltage control
- Integration of new controls for tighter torch-to-work distance management
- Clean integration with existing cell layout and part fixtures
- Operator interface optimizations for easier operation and diagnostics
The upgraded system significantly improved performance without requiring full line replacement, preserving existing infrastructure while enabling modern cutting capabilities.
Summary: The retrofit enhanced precision and uptime of the plasma cell through updated controls, torch management, and optimized software—delivering modern functionality in familiar form.
The Results
Increased Cut Consistency, Lower Downtime & Continued ROI on Existing Assets
Post-upgrade, the cell delivered measurable improvements:
- More uniform and repeatable plasma cuts on base rail sections
- Reduced maintenance requirements and fewer manual adjustments during operation
- Sustained production capacity without major capital investment
- Extended the useful life and utility of existing plasma cutting assets
By modernizing the robot control and torch management of an aging plasma cell, MWES helped the customer enhance quality and reliability while preserving their original investment.
