Abstract: Disclosed herein are a method for welding electrode taps of a secondary battery which improves insulation defects generated during welding between the electrode taps and lead parts and an electrode assembly manufactured thereby. The method for welding electrode taps includes performing main welding to connect electrode taps protruded from electrode plates provided in a battery and lead parts electrically connecting the electrode taps to external terminals and having a lead film on the surfaces thereof and, in main welding, a welding part is formed in a partial section of an overlapping region between the electrode tap and the lead part, and a non-welding section is formed between the welding part and the lead film.

Abstract: A method of determining a failure event of consumable for a plasma torch is provided. The method includes monitoring at least one of an operating current or an operating voltage during a transfer arc mode of the plasma arc torch. The method also includes determining when at least one parameter associated with the operating current or the operating voltage exceeds a tolerance threshold for a time period indicative of the failure event. The method further includes shutting off at least one of the operating current or the operating voltage of the plasma arc torch when the at least one parameter exceeds the tolerance threshold for the time period.

Abstract: Systems and methods for selectively making non-spherical metal nanoparticles from a metal material. The metal target surface is ablated to create an ejecta event or plume containing nanoparticles moving away from the surface. Ablation may be caused by laser or electrostatic discharge. At least one electromagnetic field is placed in front of the solid target surface being ablated. The electromagnetic field manipulates at least a portion of the nanoparticles as they move away from the target surface through the electromagnetic field to create coral-shaped metal nanoparticles. The distance between the electromagnetic field and metal surface can be adjusted to yield metal nanoparticles of a desired size and/or shape.

Abstract: An electric storage apparatus including a welding structure between an electric storage device and a bus bar includes the electric storage device including an external terminal that includes a first connection surface, the bus bar including a second connection surface that overlaps the first connection surface, a first weld portion that is formed extending over the external terminal and the bus bar in a region where the first connection surface and the second connection surface are opposed to each other, and a second weld portion that is formed extending over the external terminal and the bus bar in the region where the first connection surface and the second connection surface are opposed to each other, the second weld portion directly overlapping the first weld portion in a region where the first connection surface and the second connection surface overlap each other.

Abstract: A method to prepare a core-shell-shell FeCo/SiO2/MnBi nanoparticle wherein the morphology of the MnBi shell is formed by synthesis of the MnBi layer in an applied magnetic field is provided.

Abstract: A plasma cutting system for measuring or monitoring the voltage between a plasma torch and the material being cut to determine a voltage or voltage signature and comparing that measurement against predetermined values to indicate that an initial pierce of the material is complete, and based on the measurement, moving the torch or the material to a different location for additional cutting.

Abstract: A method of controlling the position of a tilt/tilt style plasma arc torch relative to a workpiece for a bevel cutting operation is provided that includes: calculating a bevel pivot length, wherein the bevel pivot length is a function of a torch height; piercing the workpiece with the plasma arc torch; adjusting a position of the plasma arc torch by at least one linear offset value based on the bevel pivot length; rotating the plasma arc torch about its center of rotation to the desired cutting angle and maintaining a torch center point; and translating the plasma arc along its longitudinal axis to maintain a desired arc voltage between the plasma arc torch and the workpiece.

Abstract: A method of controlling a position of a plasma arc torch relative to a workpiece for a bevel cutting operation is provided that includes: calculating a bevel pivot length, which is a function of a torch height; piercing the workpiece with the plasma arc torch; rotating the plasma arc torch about its center of rotation to a desired cutting angle; translating the plasma arc torch along at least one of X, Y, and Z axes to maintain a torch center point; and translating the plasma arc torch along at least one of the X, Y and Z axes to achieve a resultant displacement along a longitudinal axis of the plasma arc torch to maintain a desired torch height.

Abstract: The present invention relates to an apparatus for adjusting a position of a plasma arc torch. The apparatus includes an elevation apparatus configured to raise and lower the plasma arc torch with respect to molten silicon, a rotary apparatus configured to circumferentially rotate the plasma arc torch with respect to the molten silicon, and an angle adjustment apparatus configured to adjust an angle of the plasma arc torch with respect to the molten silicon. In addition, a plurality of plasma arc torches is provided and radially disposed at predetermined intervals. Therefore, time consumed to melt solid silicon to form the initial molten silicon is reduced, and casting speed is increased. In addition, fusibility of a source material can be improved, the source material can be stably melted, and economic continuous casting and a high quality silicon ingot for a solar cell can be manufactured.

Abstract: The present invention is directed to a system for welding together segments of a pipeline. The system includes an external alignment mechanism for externally supporting and manipulating the orientation of pipe segments in order to align relative segments. The system also includes an internal welding mechanism for applying a weld to an interior face joint of the two abutted pipe segments. The internal welding mechanism including a torch for applying a weld, a laser for tracking the weld profile and guiding an articulating head of the torch, and a camera for visually inspecting the weld after the weld is applied.

Abstract: A method for metalworking using an adjustable vacuum and support system for evacuating particulate matter, smoke, excess gas, and molten metal from a work area during welding and for providing adjustable support to a welding head. The vacuum system has a vacuum head and a vacuum nozzle. An adjustable mounting bracket has a first portion fixed to the vacuum head and a second portion securable to the welding head. The bracket arrangement establishes pivotal and slidable couplings between the welding head and the vacuum head. The vacuum nozzle has a support surface for being rested on a surface of a workpiece to support the vacuum head and the welding head. The support surface can be a base bevel surface at the tip of the nozzle, and an opposed suction bevel surface can have a nozzle aperture interposed therealong.

Abstract: A plasma cutter tracing system includes a positioning apparatus and a tracing apparatus. The positioning apparatus is configured to permit the tracing apparatus to traverse along an X-axis, a Y-axis, and a Z-axis and the tracing apparatus is configured to hold a plasma cutter and position the plasma cutter in a plane substantially parallel to a plane defined by a working surface which receives a workpiece to be replicated thereon.

Abstract: A torch height adjustment mechanism includes a welding torch head connected to a torch plate; a first four-bar linkage between the torch plate and a linkage interface; a second four-bar linkage between the linkage interface and a mounting plate for connecting the torch-height adjustment mechanism to an automatic welding unit; a shaft providing rotational movement to the second four-bar linkage; and means for communicating rotational movement of a first link of the second four-bar linkage to a first link of the first four-bar linkage to translate the torch plate vertically without rotation along a path between a raised position and a lowered position.

Abstract: A plasma treatment system includes a plasma arc torch, a tee attached to a hollow electrode nozzle of the plasma arc torch, and a screw feed unit or a ram feed unit having an inlet and an outlet attached to the tee. The plasma arc torch includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that a centerline of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel.

Abstract: A movement device, particularly for cutting torches of the plasma type, comprising a working head that can move along three Cartesian axes which are mutually perpendicular and supports a cutting torch for cutting mechanical pieces and the like, elements being comprised for the combined rotary and translational motion of the cutting torch with respect to the working head in order to vary the inclination of the cutting flow with respect to the mechanical piece or the like being worked on; the center of instantaneous rotation of the cutting torch, with respect to which the elements for combined rotary and translational motion operate, substantially coinciding with the focal point of the cutting torch.

Abstract: A lattice pallet 13 having a large number of supporters for placing a plate 14 is installed to a table 12 so as to be freely fittable and removable. Bringing in of the plate 14 is performed by the method of raising the lattice pallet 13 with a crane with the plate 14 already having been loaded upon the lattice pallet 13 in a different location, transporting them over the table 12, and lowering them down onto the table 12. Directly after cutting has been completed, the lattice pallet 12 is raised and separated from the table 12 with the manufactured product and the left over material carried upon it and is taken away to a different location, and another lattice pallet 13 with another plate 14 mounted upon it is brought in with the crane upon the table 12, and the task of cutting this other plate 14 is commenced.

Abstract: The invention features methods and apparatuses for cutting a section of a pipe having a non-linear longitudinal axis. A mounting structure attaches to a first portion of the pipe. A track is connected to the mounting structure and defines a drive plane. A moveable structure is coupled to the track and configured to move circumferentially along the track. A tool holder is connected to the moveable structure and positions a cutting tool relative to a cutting plane in a second portion of the section of pipe, the cutting plane substantially perpendicular to the non-linear longitudinal axis at a cutting location on the pipe. The mounting structure adjusts to position the track such that the drive plane is parallel to the cutting plane, separated from the cutting plane, substantially non-perpendicular to the non-linear longitudinal axis at the first portion on the pipe.

Abstract: The embodiments disclosed herein provide a device suitable for assisting cutting and/or marking metal, such as sheet metal, comprising a template member, and optionally, an attachment component such as a magnetic component. The template member may further comprises a solid substrate material or a solid component and an outer edge and/or a window component. The device is configured so that the magnetic component allows the template member to be affixed to a metal object so that the outer edge and/or the window component may be used as a guide for cutting the metal, and allows the component to be removed from the metal when it is no longer needed for cutting.

Abstract: Provided is an apparatus, such as an arc mitigating device, which can include a first plasma generation device and a second plasma generation device. The second plasma generation device can include a pair of opposing and spaced apart electrodes and a low voltage, high current energy source connected therebetween. A conduit can be configured to direct plasma between the first and second plasma generation devices, such that the second plasma generation device receives plasma generated by the first plasma generation. The plasma from the first plasma generation device can act to reduce the impedance of an area between the pair of opposing electrodes sufficiently to allow an arc to be established therebetween due to the low voltage, high current energy source.

Abstract: The embodiments disclosed herein provide a device suitable for assisting cutting and/or marking metal, such as sheet metal, comprising a template member, and optionally, an attachment component such as a magnetic component. The template member may further comprises a solid substrate material or a solid component and an outer edge and/or a window component. The device is configured so that the magnetic component allows the template member to be affixed to a metal object so that the outer edge and/or the window component may be used as a guide for cutting the metal, and allows the component to be removed from the metal when it is no longer needed for cutting.

Abstract: A plasma arc torch is provided that includes a torch body and a torch height controller. The torch height controller includes a movable part mounted to the torch body and a fixed part connected to a robotic arm. The movable part and the torch body are biased toward a workpiece and are translational relative to the fixed part.

Abstract: A casing is used for being rotatably disposed in a plasma jet system. The casing is rotated around a central axis. The casing comprises a main body and a plasma nozzle. The main body has a first cavity. The plasma nozzle is disposed under the main body and has a second cavity and a straight channel. The second cavity is connected to the first cavity. The straight channel is located at a side of the plasma nozzle opposite to the main body and connected to the second cavity. The straight channel has an extension axis which is substantially parallel with the central axis and separated from the central axis by an interval. Plasma generated by the plasma jet system jets out through the straight channel.

Abstract: A torch spacing apparatus for a plasma or flame cutting machine includes a gantry that is guided to travel in an X axis. Mounted to the gantry is at least one carriage that is/are guided to travel in a Y axis. Mounted to each carriage are selected tooling having at least two cutting torches mounted thereon with an active cutting tool in an active cutting position. The carriage is mounted to enable tooling substitution whereby the torch spacing apparatus includes a substitution mechanism which is operatively attached to the carriage and tooling such that the said substitution mechanism is adapted to allow the position of a cutting torch or active cutting torch to be substituted with another cutting torch currently in the active position to space the torches accordingly by rotating the cutting tools about a Z axis.

Abstract: A plasma apparatus is provided including a cathode module, an anode module, and at least one inter-electrode insert located between the cathode module and the anode module. The cathode module includes at least one cathode, and a pilot module may be provided adjacent to the cathode module. The pilot module may assist ignition of the plasma apparatus. The inter-electrode insert may have an upstream and a downstream transverse surface. Both the upstream transverse surface and the downstream transverse surface are angled in a downstream direction.

Abstract: A lightweight bevel head attachment for a torch cutting machine includes a horizontal support tray, a rotation assembly mounted under the support tray, a tilt assembly coupled to the rotation assembly for rotation therewith about a vertical axis, a torch holder carried and pivoted by the title assembly, and a rack-and-pinion lift assembly having a mounting plate for attachment to the cutting machine carriage. The tilt assembly includes a pair of link arms housing a pulley system for transmitting pivotal motion at an input shaft to an output shaft on which the torch holder is mounted. The bevel head attachment can provide bevel angles in a range of about ±75 degrees.

Abstract: A plasma apparatus is provided including a cathode module, an anode module, and at least one inter-electrode insert located between the cathode module and the anode module. The cathode module includes at least one cathode, and a pilot module may be provided adjacent to the cathode module. The pilot module may assist ignition of the plasma apparatus. The inter-electrode insert may have an upstream and a downstream transverse surface. Both the upstream transverse surface and the downstream transverse surface are angled in a downstream direction.

Abstract: The invention relates to a device for machining, particularly for cutting, of electrically conductive workpieces using a machining tool (10), which can be displaced back and forth toward and away from a workpiece by means of a drive unit and which comprises an electrically insulated, metallic tool head (12) forming a first capacitance (C1) with the workpiece, and comprising an analysis unit (14) for analyzing a characteristic value dependent on the first capacitance (C1) . The invention provides that a metallic connecting element (18) is attached to the tool head (12), the element being connected to the analysis unit (14) and forming a second capacitance (C2) with the tool head (12).

Abstract: A system and method for producing braces for a cavity die having a predetermined shape are disclosed. The system includes an input file containing information about the shape of the cavity die and a bracing program running on a computer. The bracing program produces an output file based on the input file and brace parameters. The output file includes information about the design of the braces. The computer instructs a brace-making machine to produce the braces based on the information in the output file. The method includes the steps of: a) providing input information about the shape of the cavity die and the brace parameters to the computer; b) processing the input information by the computer to produce an output file containing information about the design of the braces; and c) producing the braces in accordance with the information from the output file.

Abstract: A vortex generator uses a single piece to generate the vortex and hold the electrode. The single piece may be a non-conductive material such as a ceramic. The vortex generator may use threads to hold the electrode. The threads and holes for generating the vortex may be bored into the base material of the vortex generator before the base material is hardened.

Abstract: A device for plasma treating a surface comprises a movable plasma generator and an actuator for moving the plasma generator. The actuator may be configured to move the plasma generator in a first direction along a path and then in a second direction along substantially the same path (e.g. the same path, an ovular path, etc.). For example, the actuator may be configured to reciprocate the plasma generator back and forth along the path. Movement of the plasma generator may be made along a track. To facilitate movement along the track, the plasma generator may include bearings that cooperate with the track. The plasma generator may be configured to move from a first position to a second position through an intermediate position. The plasma generator may then be configured to move back towards the first position by traveling through the intermediate, or substantially the intermediate, position.

Abstract: Disclosed herein is an automatic pulse plasma welding method and apparatus for forming a lap joint between membrane sheets, which applies plasma welding to a lap joint between membrane sheets to improve working efficiency and productivity, and which provides optimal welding conditions to the respective regions of the lap joint between membrane sheets to improve welding quality.

Abstract: A thermal cutting machine and a cutting method using the same are described, which employ a simple, long-life torch hood for effectively shutting off spatter, the torch hood enabling easy supervision of the cut condition of a workpiece and easy replacement of the consumable parts of the torch. In the thermal cutting machine for cutting a metal by a plasma arc or laser beam generated from the torch, a hood liftable by an actuator is disposed so as to surround the torch and a control unit is provided for giving an instruction to the actuator to lower the hood to a torch-shielding position.

Abstract: A cutting system is disclosed for a plasma cutting torch movable by a driver relative to a work piece along a Z-axis. During cutting, the torch provides an arc voltage proportional to a distance between the torch and the work piece. A height control feedback circuit is connected to the torch and includes sensor circuitry providing an electrical signal proportional to the arc voltage and an analog-to-digital converter for converting the proportional signal to a digital signal. A computer and controller, including controls for selecting a desired height of the plasma torch, receive the digital signal, compare the actual height to the desired height, and actuate the driver to move the torch to within a preset limit of the desired height.

Abstract: A plasma processing method is used to process a linear portion of an object to be processed by generating a linear plasma by supplying an electric power to an electrode provided at a plasma source or the object to be processed while supplying gas to the plasma source arranged in the neighborhood of the object to be processed and making activated particles generated by the plasma act on the object to be processed. The method includes detecting an inclination of the plasma source along a direction of an x-axis when the x-axis is taken in a linear direction of the linear portion of the object to be processed, and processing the linear portion of the object to be processed by the generated linear plasma by moving the plasma source along the x-axis direction while maintaining relative positions of the plasma source and the object to be processed so that the detected inclination of the plasma source becomes approximately zero.

Abstract: Process for the surface treatment of an object made of an electrically conductive material, with an atmospheric plasma, including the generation of plasma jets by plasma generators, the application of the plasma jets to a surface of the object to be treated, and the relative displacement of the object relative to the plasma generators. At least one of the plasma jets is a cathodic jet and at least one of the plasma jets is an anodic jet. The anodic jet is applied to a treatment zone on the surface to be treated in the proximity of the cathodic jet.

Abstract: The invention is directed to an arrangement for generating a chemically active jet (active gas jet) by a plasma generated by electric discharge in a process gas. It is the object of the invention to find a novel possibility for generating a chemically active jet by a plasma generated by electric discharge in which high chemical activity develops at increased process gas velocity of the active gas jet on the surface to be treated and is electrically neutral already at the output of the arrangement, so that it does not pose a threat to the operating personnel, the environment and the treated surface. This object is met in that the discharge chamber has a conically narrowed end for increasing the velocity of the active gas jet, and a limiting channel for preventing propagation of the discharge zone into the free space for the surface to be treated is arranged following the narrowed end of the discharge chamber.

Abstract: Not only damage to a nozzle caused by spatter generated during piercing is prevented but also the deterioration of the nozzle owing to a pilot arc is restrained, whereby the service life of the nozzle is significantly increased. To this end, the plasma torch is positioned at an initial level which is the distance between the plasma torch and a steel plate when generating a plasma arc to start piercing operation and which has been set equal to a cutting level which is the distance between the plasma torch and the steel plate when carrying out cutting operation. After generation of the plasma arc, the plasma torch is immediately raised to a piercing level which is more distant from the steel plate W than the initial level and piercing operation is performed at the piercing level. After completion of the piercing operation, the plasma torch is lowered to the cutting level to start cutting operation. Just after transfer from a pilot arc into a main arc, a pilot current is cut off by turning a transistor off.

Abstract: A thermal working tool (1) is movable along a workpiece surface (7) and includes a torch head (2) which has exchangeably mounted thereon cutting or welding tools (3; 4; 5) extending between the torch head (2) and the workpiece surface (7). A distance control for setting a predetermined working distance (A) between the working tool (1) and the workpiece surface (7) is carried out by a magnetic system, an alternating magnetic field being produced in a sensor body with ferromagnetic properties above the workpiece surface (7). The torch head (2) and at least one of the cutting or welding tools (3; 4; 5) contain ferromagnetic material and form at least part of the sensor body (2; 3; 4; 5). The magnetic field produced is sensed by two measuring coils, and is used for controlling the working distance (A).

Abstract: An arc electrode structure, for producing carbon nanostructures, which includes a first electrode and two or more second electrodes disposed within a chamber is provided. The electrodes are connected to a voltage potential to produce an arc-plasma region. The first electrode has a sloped surface with a plurality of holes therein for holding catalyst. The first electrode's sloped surface, and the positioning of the plurality of second electrodes allows control of the direction and region of arc-plasma. Further, the first electrode has a central bore which may be either a blind bore, or a through bore. The blind bore collects unwanted deposits that slide off of the sloped surface of the first electrode. The throughbore either allows soot and carbon nanostructures to be removed from the chamber, or allows organic vapor to be introduced into the chamber.

Abstract: Three adjustable electrodes (33a-33c) within a chamber (40) form a thermal plasma generating system (30). The electrodes (33a-33c) are positioned with a narrow gap at one portion and a wide gap at another portion to form a cone shape. The gap between the electrodes is adjusted to accommodate for wear on the electrodes (33a-33c). An electric arc is initiated at the narrowest point between two electrodes which moves over the length of the electrodes because of a magnetic field created by the arc and the forward motion of the injected stream. At the end of the electrodes, the arc is extinguished and another arc is initiated. The continuous are moving along the electrodes ionizes a working stream that is tangentially injected from three pneumatic rings (35a-35c) which provide improved mixing of the working stream for high quality thermal plasma. The thermal plasma exits through a narrow orifice (42).

Abstract: A wire bonding apparatus including a capillary, which allows a tip end of a bonding wire to protrude from the bottom, and a discharge electrode, which generates a spark between the electrode and the tip end of the wire by an electrical discharge; and auxiliary electrodes being disposed so as to surround the area between the tip end of the wire and the tip end of the discharge electrode. The end portion of the spark on the wire side is guided onto the axial line of the portion of the wire that protrudes from the capillary by the electric fields from the auxiliary electrodes, and the end portion of the spark on the discharge electrode side is guided onto the axial line of the discharge electrode. Dissociated ions are adsorbed on the auxiliary electrodes, preventing the discharge electrode from being contaminated.

Abstract: The invention features a centralized control architecture for a closely-coupled plasma arc system, in which the “intelligence” of the system is integrated into a single controller. The closely-coupled plasma arc system includes a power source, an automatic process controller and a torch-height controller, where each of these components individually has a closed-loop dynamic relationship with the controller.

Abstract: A plasma processing system includes an automated electrode retention mechanism (130) for providing automated engagement of a source electrode (152) with a drive electrode (154). In addition, an automated electrode handling system (320) is provided that has the ability to remove a source electrode (152) from the electrode retention mechanism and replace it with a second source electrode (152′) that is stored in a staging area (340) outside the plasma processing system vacuum chamber. The system may operate automatically under program control of a computer system (200) coupled thereto.

Abstract: A thermal spraying system includes thermal spray material, an electrical energy thermal spraying device atomizing and spraying the thermal spray material, a power supply supplying electrical power to the spraying device, a sensor monitoring a power characteristic of the supplied electrical power, and a feed rate control module adjusting a feed rate of the thermal spray material based on the monitored power characteristic.

Abstract: A plasma arc torch is provided that comprises a set of torch consumable components secured to a torch head, wherein a supply of cooling fluid flows coaxially through the torch to cool torch components and a supply of plasma gas and secondary gas flows through the torch to generate and stabilize a plasma stream for operations such as cutting workpieces. The torch consumable components, in part, comprise an electrode and a tip that include a variety of configurations for improved cooling, electrical contact, and attachment to adjacent torch components. Further, a consumables cartridge is provided for ease of use and replacement of the torch consumable components. Additionally, methods of operating the plasma arc torch at relatively high current levels are also provided by the present invention.

Abstract: A method of removing organic impurities from a surface of a substrate that is used for feeding or processing web material, wherein a jet of an atmospheric plasma is directed onto the surface of the substrate.

Abstract: A plasma processing system includes an automated electrode retention mechanism (130) for providing automated engagement of a source electrode (152) with a drive electrode (154). In addition, an automated electrode handling system (320) is provided that has the ability to remove a source electrode (152) from the electrode retention mechanism and replace it with a second source electrode (152′) that is stored in a staging area (340) outside the plasma processing system vacuum chamber. The system may operate automatically under program control of a computer system (200) coupled thereto.

Abstract: The invention relates to plasma torch (1) comprising at least two electrodes (7, 8) separated by an insulating cylindrical case (6) delimiting an inner volume, said torch wherein the electrodes (7, 8) are separated by a sufficiently small distance (D) for an igniting arc to appear between the electrodes (7, 8) when a serviceable voltage supplied by a generator (19) is applied between them.

Abstract: A dual mode plasma arc torch is provided that preferably comprises a start cartridge disposed between an electrode and a tip. In one form, the start cartridge comprises an initiator that is in electrical contact with the electrode and that is resiliently biased into contact with the tip, such that when the plasma arc torch is in a contact start mode, the initiator is movable against the resilient bias to separate from the tip and establish a pilot arc between the initiator and the tip. Further, when the plasma arc torch is in a high frequency start mode, the start cartridge spaces the tip from the electrode such that a pilot arc is established between the electrode and the tip. In other forms, a contact start torch is provided that is operable under high frequency, and conversely, a high frequency start torch is provided that is operable under low voltage.

Abstract: The invention features a centralized control architecture for a closely-coupled plasma arc system, in which the “intelligence” of the system is integrated into a single controller. The closely-coupled plasma arc system includes a power source, an automatic process controller and a torch-height controller, where each of these components individually has a closed-loop dynamic relationship with the controller.