Abstract: A welding system includes a power source configured to generate power and deliver the power to a welding torch. The power is provided in accordance with an electrode negative pulse welding regime that includes a cyclic peak, followed by a stabilization phase, then a return to a background level. The stabilization phase has a generally parabolic current shape, and is performed in a current-closed loop manner until a transition point. Resulting weld performance is improved, with a globular-like transfer mode, reduced shorts and enhanced arc stability.

Abstract: Systems and methods relating to securing a torch assembly and a work lead assembly to a plasma cutting power supply are provided. The present disclosure relates to a system and method that allows the torch assembly and the work lead assembly to be readily replaced by the user since the power supply unit need not be opened or disassembled for removal. The present disclosure provides methods and systems for removably securing both the torch assembly and the work lead assembly to the plasma cutting power supply. In one embodiment, the torch assembly and the work lead assembly may be communicatively coupled to the plasma cutting power supply unit via a single cable and a single connector. The connection between the first connector and the first port may be of the quick disconnectable type. The connection between the second connector and the second port may be of the twist lock type, such as a dinse style connector.

Abstract: A retaining cap for a plasma torch is provided that includes fast securing threads. The retaining cap includes internal threads that couple to external threads of a torch body of the plasma torch. The internal and external threads may be multiple start threads having a thread angle greater than 60°. Plasma torches and plasma cutting systems are also provided.

Abstract: A metal fabrication resource performance monitoring method, includes accessing data representative of a parameter sampled during a metal fabrication operation of a metal fabrication resource, the resource being selectable by a user from a listing of individual and groups of resources. Via at least one computer processor, the accessed parameter is processed to determine an analyzed system parameter, and a user viewable dashboard page is populated with graphical indicia representative of the analyzed system parameter, and transmitted the user viewable dashboard page to a user.

Abstract: A plasma torch is provided having an electrode with a frustoconical end portion. The electrode is received by a plunger during a contact start sequence of the plasma torch and is self-releasing from the torch. The electrode may include a shoulder portion that provides concentric alignment and centering of the electrode with respect to the central longitudinal axis of the components. Other components of the torch include a nozzle, a swirl ring, and retaining cup, such that the consumables of the torch may be toollessly removed and installed.

Abstract: Metal fabrication systems, such as welding systems and related equipment may be monitored and parameters sensed or calculated during metal fabrication operations. The parameter values are stored and transmitted to a web based analysis system. Sampled values of the parameters are used to generate graphical presentations that are used to populate user viewable pages. The pages may be configured by users, and systems and parameters of interest selected.

Abstract: Metal fabrication systems and related equipment may be monitored by collecting and transmitting parameter data relating to welding operations to a memory and processing system. Goals for selected parameters may be pre-defined, and certain of these may be standard for corresponding welding systems, locations, operations, operators, and so forth. Upon request a web based report is generated and delivered to a user that indicates the system or systems, comparisons of the actual system performance versus the goals, time periods for the comparisons, and so forth.

Abstract: Metal fabrication systems, such as welding systems and related equipment may be analyzed and performance compared by collecting parameter data from the systems during welding operations via a web based system. The data is stored and analyzed upon request by a user. A user viewable page may be provided that allows for selection of systems and groups of systems of interest. Parameters to be used as the basis for comparison may also be selected. Pages illustrating the comparisons may be generated and transmitted to the user based upon the selections.

Abstract: A plasma torch having a torch handle is provided. The plasma torch handle may be formed from a soft material and a hard material. Additionally, the plasma torch handle includes a thumb contour formed from the soft material and a finger contour formed from the soft material. In one embodiment, the plasma torch handle forms an angle of about 80° with the torch head. Plasma cutting systems having the plasma torch and handle are also provided.

Abstract: Systems and methods relating to securing a torch assembly and a work lead assembly to a plasma cutting power supply are provided. The present disclosure relates to a system and method that allows the torch assembly and the work lead assembly to be readily replaced by the user since the power supply unit need not be opened or disassembled for removal. The present disclosure provides methods and systems for removably securing both the torch assembly and the work lead assembly to the plasma cutting power supply. In one embodiment, the torch assembly and the work lead assembly may be communicatively coupled to the plasma cutting power supply unit via a single cable and a single connector. The connection between the first connector and the first port may be of the quick disconnectable type. The connection between the second connector and the second port may be of the twist lock type, such as a dinse style connector.

Abstract: Systems and methods relating to securing a torch assembly and a work lead assembly to a plasma cutting power supply are provided. The present disclosure relates to a system and method that allows the torch assembly and the work lead assembly to be readily replaced by the user since the power supply unit need not be opened or disassembled for removal. The present disclosure provides methods and systems for removably securing both the torch assembly and the work lead assembly to the plasma cutting power supply. In one embodiment, the torch assembly and the work lead assembly may be communicatively coupled to the plasma cutting power supply unit via a single cable and a single connector. The connection between the first connector and the first port may be of the quick disconnectable type. The connection between the second connector and the second port may be of the twist lock type, such as a dinse style connector.

Abstract: A system for detecting welding, and cutting parameters is provided. One embodiment of the system includes an input terminal configured to receive signals corresponding to welding or cutting parameters from a first welding or cutting device. None of the signals carry welding power. The system also includes an output terminal configured to provide the signals to a second welding or cutting device. The system includes conductors coupled between the input terminal and the output terminal and configured to carry the signals between the input terminal and the output terminal. The system also includes control circuitry configured to detect the welding or cutting parameters from the signals.

Abstract: A system is provided that includes a torch power unit that includes a compressor and a controller configured to adjust output of the compressor in response to feedback comprising compressor output, or altitude, or atmospheric pressure, or a combination thereof. A method is provided that includes adjusting operational parameters of a torch power unit to account for environmental conditions affecting performance of the torch power unit. A method of manufacturing a portable cutting torch system is also provided. Another system is provided that includes a plasma cutting circuit, a compressor, a motor coupled to the compressor, an interface, and an environmental feedback controller.

Abstract: A plasma torch is provided having an electrode with a frustoconical end portion. The electrode is received by a plunger during a contact start sequence of the plasma torch and is self-releasing from the torch. The electrode may include a shoulder portion that provides concentric alignment and centering of the electrode with respect to the central longitudinal axis of the components. Other components of the torch include a nozzle, a swirl ring, and retaining cup, such that the consumables of the torch may be toollessly removed and installed.

Abstract: A retaining cap for a plasma torch is provided that includes fast securing threads. The retaining cap includes internal threads that couple to external threads of a torch body of the plasma torch. The internal and external threads may be multiple start threads having a thread angle greater than 60°. Plasma torches and plasma cutting systems are also provided.

Abstract: A plasma torch having a torch handle is provided. The plasma torch handle may be formed from a soft material and a hard material. Additionally, the plasma torch handle includes a thumb contour formed from the soft material and a finger contour formed from the soft material. In one embodiment, the plasma torch handle forms an angle of about 80° with the torch head. Plasma cutting systems having the plasma torch and handle are also provided.

Abstract: Nozzles for plasma torches and plasma torch systems utilizing such nozzles are provided herein. One such nozzle may include a body having a first end, a second end having an exit orifice disposed therein, and a passageway extending from the first end to the second end and adapted to enable the flow of plasma gas from the first end, through the passageway, and to the exit orifice. Greater than or equal to approximately 50% of an overall mass of the body is distributed between the second end and a midpoint of the body with respect to a longitudinal length of the body.

Abstract: Systems and methods relating to securing a torch assembly and a work lead assembly to a plasma cutting power supply are provided. The present disclosure relates to a system and method that allows the torch assembly and the work lead assembly to be readily replaced by the user since the power supply unit need not be opened or disassembled for removal. The present disclosure provides methods and systems for removably securing both the torch assembly and the work lead assembly to the plasma cutting power supply. In one embodiment, the torch assembly and the work lead assembly may be communicatively coupled to the plasma cutting power supply unit via a single cable and a single connector. The connection between the first connector and the first port may be of the quick disconnectable type. The connection between the second connector and the second port may be of the twist lock type, such as a dinse style connector.