Sensor THC

Sensor THC is engineered as an integrated CNC-based torch height control platform for plasma cutting applications. Rather than relying on separate standalone logic, the system places operational control inside the CNC, creating a single point for setup, process management and diagnostics. This simplifies operation and helps reduce setup time and operator error.

The system incorporates built-in cut charts, automatic process support and closed-loop servo control to manage torch positioning throughout the cut. It is specifically designed to work with Hypertherm cutting process expertise and supports advanced capabilities such as SureCut technology features, including True Hole, TrueBevel and Rapid Part.

With automatic torch height functions, arc voltage sampling and multiple sensing options, Sensor THC is positioned as a high-performance solution for operations that require better cut quality, improved consumable life and consistent output across shifts and operators.

Key points

• Torch height control system integrated into the CNC
• Closed-loop servo control for precise torch positioning
• Built-in cut charts to reduce setup time and operator errors
• Supports custom lifters and unique applications such as bevel, tube and pipe, and waterjet
• Arc voltage range from 50 to 300 VDC in 0.5 volt increments
• Initial height sensing by ohmic contact or position error stall detection
• Supports manual or fully automatic height control
• Includes Auto Arc Voltage Set
• Remote diagnostics through the CNC’s Remote Help capability
• Enables SureCut technology features such as True Hole, TrueBevel and Rapid Part
• Maximum speed rating of 15,200 mm/min (600 in/min)
• Lifter stroke length of 241 mm (9.4″)
• Standard alignment laser pointer included
• Suitable for downdraft and water table applications

Technical advantages

CNC-integrated process control

A major strength of Sensor THC is that its operational logic is located inside the CNC. This creates a more unified cutting environment, simplifying job setup and reducing the complexity associated with separate height control hardware. Hypertherm also embeds cutting process expertise directly into the system through built-in cut charts or part program process codes.

Reduced setup time and operator dependency

Built-in cut charts provide process parameters to both the plasma system and the torch height control, helping reduce job setup time and operator mistakes. Hypertherm states that performance advantages are achievable without operator input, which reduces the need for extensive training and helps maintain consistent output across shifts, operators and locations.

High-performance height control features

Sensor THC includes a broad set of process functions, including automatic kerf crossing detection, skip IHS, IHS offset, automatic retry on arc transfer error, automatic preflow during IHS and support for arc-style marking torches. It also offers complete servo loop adjustments, including proportional, integral, derivative and feed-forward gains.

Improved cut quality and consumable life

Traditional torch height controls often require periodic manual arc voltage adjustments. Sensor THC continuously samples arc voltage and automatically adjusts it to maintain proper torch height throughout consumable life, without requiring operator intervention. Hypertherm states that this improves consumable life and cut quality through automatic arc voltage sampling and position control.

Higher productivity

The system supports Rapid Part technology, which reduces cut-to-cut cycle time and increases parts per hour. It also uses automated Initial Height Sense to minimize the time required for the torch to locate the plate, while automatically skipping IHS where possible based on part geometry and plate characteristics.

Flexible integration and application support

Sensor THC supports custom lifters for special applications, including plasma bevel, tube and pipe and waterjet. It can use optional magnetic breakaway torch mount assemblies and is available with multiple torch mounting block options. The system communicates through discrete motor and I/O wiring, with EtherCAT support to the HPR plasma system.

Applications

Sensor THC is well suited for:

• Mechanized plasma cutting systems using Hypertherm CNC solutions
• Shape cutting operations focused on productivity and cut consistency
• Automated cutting environments seeking lower setup time and fewer operator adjustments
• Plasma bevel applications
• Tube and pipe cutting setups
• Waterjet systems requiring compatible lifter support
• Tables using either downdraft or water table configurations

Why choose Sensor THC

Sensor THC is a strong choice for manufacturers that want integrated torch height control with CNC-based logic, embedded process expertise and minimal operator dependency. It is designed to improve productivity, reduce setup mistakes and deliver better consumable performance while supporting advanced Hypertherm technologies. For operations aiming to standardize cutting quality across shifts and operators, it offers a compelling combination of automation, reliability and process control.