Homebuilt Plasma Table Modifications

[Normsthename]

I built my CNC Plasma Table about two years ago and it has really earned its keep in that time
It was originally built as a Wood Router, but all it ever made were Freebies for everyone else!
Because I run a small business making small Motorcycle parts, I decided to convert the machine over to Plasma.
The machines current cutting size is 985mm x 585mm and I want to increase the cutting size to accept a standard off the shelf sheet size.
I originally thought about increasing the table size to accept a 2000mm x 1000mm sheet, but now I think I can fit a 2500mm x 1250mm machine into the available space I have.
Here is a video of the Plasma machine working in its current state.



I use a Hypertherm Powermax 1000 which has a cutting capacity of 12.7mm maximum.
It also has a Torch Height controller (THC) that measures the Tip voltage and adjusts the Z axis to maintain the optimum cutting height.
The machine uses a water table to keep the dust down and also to keep the steel cool so it does not warp while cutting.
I plan on building a new water table for the new machine where I will be able to raise and lower the water level using compressed air

These are the Mods that I have in mind, this is the original machine



First I plan on removing the gantry and cutting the top off of the original table



I will then build a new frame to fit onto the existing table.



I want to build a lightweight gantry, the old machine has a heavy steel gantry that was designed for Wood Routing.
Because of this I have to keep the acceleration speeds right down which affects the cut quality on the corners.
When I cut 1.5mm Stainless Steel it cuts at 3810mm / Minute but if I used a 60A tip on thin material you need to almost double that speed :surprised:



Here I have used 25mm round supported rails for the X Axis and 15mm Hiwin Linear rails mounted onto a 30mm Aluminium Extrusion for the Gantry.
I would like to change the design of the gantry so I can use supported round rail because it is a lot cheaper than the Hiwin Rails, but not sure how I will mount these.......
I will be driving the Y axis using the existing tables X Ballscrew.
I am not sure how I will drive the x axis yet, I have a spare motor so I can have two motors driving.
I was thinking about using rack and pinion for the x axis but I am all ears to any other suggestions
That's it for starters now, all comments appreciated

Andy