Abstract: In some aspects, methods of disengaging a plasma control circuit within a plasma arc torch of a plasma processing system to place the torch into a safety-locked mode can include providing: a plasma control circuit configured to convey a current from the plasma cutting system through the plasma arc torch to one or more consumables disposed in the torch and an operator interface switch connected to the plasma control circuit and configured to initiate generation of a plasma arc from the plasma arc torch; and activating a switch, separate from the operator interface switch, disposed on the torch and connected to the plasma control circuit to disconnect the plasma control circuit to limit the current, including pilot current, from flowing to the one or more consumables.

Abstract: In some aspects, methods of disengaging a plasma control circuit within a plasma arc torch of a plasma processing system to place the torch into a safety-locked mode can include providing: a plasma control circuit configured to convey a current from the plasma cutting system through the plasma arc torch to one or more consumables disposed in the torch and an operator interface switch connected to the plasma control circuit and configured to initiate generation of a plasma arc from the plasma arc torch; and activating a switch, separate from the operator interface switch, disposed on the torch and connected to the plasma control circuit to disconnect the plasma control circuit to limit the current, including pilot current, from flowing to the one or more consumables.

Abstract: A plasma cutting system is provided. The system includes a power source configured to generate a plasma arc, and a plasma arc torch connected to the power source for delivering the plasma arc to a workpiece. The plasma arc torch defines a multi-function fluid flow path for sustaining the plasma arc and cooling the plasma arc torch such that the plasma cutting system has a power-to-gas flow ratio of at least 2 kilowatts per cubic feet per minute (KW/cfm). The power-to-gas flow ratio comprises a ratio of power of the generated plasma arc to a total gas flow supplied to the plasma arc torch.

Abstract: In some aspects, plasma torch cutting systems can include a housing and a plasma torch power supply within the housing and configured to generate a signal that initiates generation of a plasma arc in a torch head, the power supply including an integrated circuit comprising a plurality of electronic components used to generate the signal that initiates generation of the plasma arc, at least one of the electronic components being at least partially formed of a wide bandgap semiconductor material.

Abstract: A plasma cutting system is provided. The system includes a power source configured to generate a plasma arc, and a plasma arc torch connected to the power source for delivering the plasma arc to a workpiece. The plasma arc torch defines a multi-function fluid flow path for sustaining the plasma arc and cooling the plasma arc torch such that the plasma cutting system has a power-to-gas flow ratio of at least 2 kilowatts per cubic feet per minute (KW/cfm). The power-to-gas flow ratio comprises a ratio of power of the generated plasma arc to a total gas flow supplied to the plasma arc torch.

Abstract: In some aspects, plasma torch cutting systems can include a housing and a plasma torch power supply within the housing and configured to generate a signal that initiates generation of a plasma arc in a torch head, the power supply including an integrated circuit comprising a plurality of electronic components used to generate the signal that initiates generation of the plasma arc, at least one of the electronic components being at least partially formed of a wide bandgap semiconductor material.

Abstract: An improved system for cooling a power supply of a welding or plasma cutting system, and an improved configuration of a power supply. The system cools achieves the improvement in configuration and cooling by mounting electrical components to a circuit board and then to a heat sink. Electrical components are also mounted to a common panel that improves the circulation of air. A central panel supporting the power supply heat sink and components allows a smaller and more compact design while maintaining proper temperatures. Electromagnet cooling is improved by modifying electromagnetic cores to conduct heat to the heat sink, and by the use of thermally conducting polymers.

Abstract: A system and method for identifying a torch assembly associated with a thermal processing system can include a detector that detects a multi-bit binary signal based on a plurality of open circuits or closed circuits with the thermal processing system. Each representative binary signal can comprise an individual physical component. The system can also include a control mechanism in communication with the detector, the control mechanism identifying at least one characteristic of the torch assembly based upon the multi-bit binary signal.

Abstract: An improved cooling system for a power supply of a welding or plasma cutting system. The cooling systems includes a heat sink with a panel forming a plurality of enclosed channels. The cooling system also includes a passage defined by walls, and a passage in a heat sink between an inlet port and outlet port. The channels and passages extend from a central portion of the power supply to an end, and a majority of the airflow passing through the power supply is directed through the channels and passages. The method includes step of directing a majority of the airflow through the cooling system via the channels or passages.

Abstract: An improved cooling system for a power supply of a welding or plasma cutting system. The cooling systems includes sections that are divided. One section contains electrical components and remains relatively clean, and does not receive an airflow from a fan. Another section does not contain electrical components and channels a majority of the airflow into and out of the power supply. The section channeling the majority of the airflow shields the section with the electrical components from a majority of the airflow. The method includes step of forming and disposing the structure of the cooling system.

Abstract: An improved system for cooling a power supply of a welding or plasma cutting system, and an improved configuration of a power supply. The system cools achieves the improvement in configuration and cooling by mounting electrical components to a circuit board and then to a heat sink. Electrical components are also mounted to a common panel that improves the circulation of air. A central panel supporting the power supply heat sink and components allows a smaller and more compact design while maintaining proper temperatures. Electromagnet cooling is improved by modifying electromagnetic cores to conduct heat to the heat sink, and by the use of thermally conducting polymers.

Abstract: This invention relates to methods and apparatus for controlling a power supply of a plasma arc system. According to the method, any AC input voltage within a range of input voltages is provided into the input stage and a rectified output voltage is thereby generated. The rectified output voltage is provided into the power factor corrected boost stage and a DC signal is thereby generated. The DC signal is provided into an auxiliary power supply and a regulated power signal is thereby generated. The regulated power signal is provided into a digital signal processor module and an output control signal is thereby generated. The output control signal is provided into the inverter stage and a plasma arc current is thereby generated.

Abstract: A system for controlling a plasma arc torch circuit uses two different current thresholds to control pilot current, thereby reducing nozzle wear while maintaining a reliable arc and an adequate transfer height. Specifically, by using a Hall effect current sensor to monitor low levels of current in the lead that normally carries high current, it is possible to determine more accurately (1) when there is a low level of pilot arc current that can be ramped to a higher level, and (2) when the level of transferred current is capable of reliably sustaining a transferred arc such that the pilot arc can be extinguished. Thus, the current can be removed from the nozzle, at the precise moment in time that the torch can reliably sustain the transferred arc, thereby saving wear on the nozzle. In addition, the system of the present invention can save nozzle wear when used in combination with circuits that compensate for discontinuities in the workpiece by decreasing the current to the workpiece to a pilot arc level.

Abstract: An arc control circuit in a plasma arc torch, having an electrode and a nozzle, maintains a plasma arc during operation of the torch. The circuit includes a power supply electrically coupled to the electrode, nozzle and a workpiece. A logic device opens a power switch electrically coupling the nozzle to the power supply, disconnecting the nozzle from the supply, when a transferred arc is formed between the electrode and the workpiece. An amplifier is electrically connected to the power supply. The amplifier compares a sensed current to an operating current. The amplifier increases the output voltage of a power supply to maintain the operating current in coordination with an increasing distance between the workpiece and the torch. A comparator is electrically connected to a logic device and compares the output voltage of the power supply to a maximum voltage. When the output voltage of the power supply exceeds the maximum voltage, the comparator sets the logic device.

Abstract: The Detector Module derives a synchronization signal from the half-wave crossovers of the AC power line. A half-wave peak detector detects the peak voltage of each half wave. An impulse detector detects the voltage of any impulses occurring during a half-wave. A common mode detector detects the peak value of each half-wave across the common mode terminals. A microcomputer is provided together with a clock/calendar for recording threshold values and for each half-cycle if a SAG or SURGE is detected; the time that the SAG or SURGE was initiated; the voltage of the half cycle of greatest SAG or SURGE during the event and the number of cycles is recorded. For LO and HI AVERAGE an average resistor stores the average of the peak values for each of the last thirty-two half cycles and that average is compared with the threshold to determine if an event has occurred. If an event has occurred, the duration and the lowest average occurring during the event is stored.