Abstract: A translatable electrode for use in a cartridge assembly for a contact start plasma arc torch including an electrode body having a longitudinal axis and including a proximal end and a distal end. The proximal end including a spiral groove and a contact surface at a proximal end face shaped to electrically communicate with a cathodic element. The translatable electrode also including at least one emissive insert disposed within the distal end of the electrode body and proximate a distal end face. The translatable electrode including at least one baffle disposed between the proximal and distal end of the electrode body. The translatable electrode also including a gas flow dampening region disposed circumferentially about the distal end and adjacent the distal end face and positioned between the at least one baffle and the distal end face.

Abstract: In some aspects, material processing head can include a body; an antenna disposed within the body; a first tag, associated with a first consumable component, disposed within a flux communication zone of the body at a first distance from the antenna, the first tag having a first resonant frequency; and a second tag, associated with a second consumable component, disposed within the flux communication zone of the body at a second distance from the antenna, the second tag having a second resonant frequency that is different than the first resonant frequency, where the first and second resonant frequencies are tuned based upon at least one of: i) a difference between the first distance and the second distance; or ii) a characteristic (e.g., shape) of the flux communication zone in which the first tag and/or the second tag is disposed.

Abstract: A method for determining operating parameters to process a workpiece using a manufacturing processing system including a plasma arc gouging torch. The method includes positioning a plasma arc gouging torch at a location relative to a workpiece and determining a start point and an end point for each gouging path based on the location and a gouge profile. The method further includes using the gouging profile to determine first operating parameters for the plasma arc gouging torch for a first gouging path and determining second operating parameters for the plasma arc gouging torch for a second gouging path based on the gouge profile and the first gouging path. The second operating parameters include at least one of a second torch speed or a torch offset. The method also includes using at least one of the first or second operating parameters to process the workpiece with the plasma arc gouging torch.

Abstract: A lead connector is provided for connecting a plasma torch lead of a plasma arc torch to a power supply of a plasma cutting system. The lead connector includes a base portion, a central conduit disposed in the base portion, where the central conduit is configured to carry a gas and a torch current to the plasma arc torch, and multiple pins disposed radially about a center of the central conduit. The pins are located at a radius of between about 0.4 inches and about 0.65 inches from the center of the central conduit on a radial plane of the base portion. The pins include one or more pilot carrying pins and one or more control signal pins located from about 27 degrees to about 64 degrees and from about 120 degrees to about 170 degrees, respectively, about the center of the central conduit on the radial plane.

Abstract: In some aspects, a plasma torch head for a plasma arc torch can include ports disposed within a base portion that are configured to receive fluids and electrical signals from a plasma torch lead via a plasma torch receptacle, the ports being shaped to align the torch head and the plasma torch receptacle during connection and including: a central coolant supply port to convey a liquid coolant to the torch head, the central coolant supply port extending a length to primarily align the plasma torch head with the torch receptacle, the central coolant supply port further including a flat surface shaped to secondarily align the torch head with the torch receptacle upon mating engagement, and an ohmic contact connector defining a tertiary alignment feature; and a connector disposed about the base portion shaped to engage with and couple to the torch receptacle.

Abstract: A seal assembly can include an annular seal having a first end portion and a second end portion. The second end portion can include a first annular face, a first tapered portion, and a radially-inner surface configured to seal an outer surface of a plunger. The seal assembly can include a backup ring having a first end portion having with a second annular face and a second tapered portion, and a second end portion. The seal assembly can include an annular hoop ring positioned between the annular seal and the annular backup ring, the annular hoop ring having a first tapered surface configured to engage the annular seal, and a second tapered surface configured to engage the annular backup ring. An angle between the second tapered surface and the longitudinal axis of the annular hoop ring can be between 50 degrees and 80 degrees.

Abstract: An operational monitoring system for use with a liquid jet cutting system can include an accelerometer coupled to a cutting head of the liquid jet cutting system. The accelerometer can be configured to generate motion data associated with movement of the cutting head. The system can include a computing device operably connected to the accelerometer and having a memory and a processor. The memory can store a planned data set including expected parameters associated with movement of the cutting head along a planned cut path. In some embodiments, the computing device is configured to receive the motion data from the accelerometer and correlate the motion data to the planned data set.

Abstract: A liquid coolant tube for a plasma arc cutting torch including a hollow elongated inner body shaped to translate within a hollow elongated outer body. The hollow elongated outer body of the liquid coolant tube is shaped to fixedly connect to the plasma arc cutting torch and includes a set of electrode guides. An external surface of the hollow elongated outer body and the set of electrode guides partially define a set of coolant flow channels between the set of electrode guides. The set of electrode guides are shaped to facilitate alignment of an electrode within the plasma arc cutting torch.

Abstract: A consumable cartridge for a plasma arc torch is provided. The consumable cartridge includes an outer component defining a substantially hollow body, an inner component disposed substantially within the hollow body of the outer component, and a hollow region between the rear portion of the inner component and the outer component. The inner component includes a forward portion configured to axially secure and rotatatably engage the outer component to the inner component and a rear portion substantially suspended within the hollow body of the outer component. The rear portion is axially secured and rotatably engaged with the outer component via the forward portion. The hollow region is configured to receive a torch head to enable mating between the rear portion of the inner component and a cathode of the torch head.

Abstract: A nozzle holder for a laser processing head of a laser processing system is provided. The nozzle holder includes a substantially cylindrical hollow body shaped to matingly engage a laser nozzle. The hollow body defines a longitudinal axis extending therethrough and a plurality of apertures dispersing around a circumference of the hollow body. The nozzle holder also includes a plurality of pawls configured to operably engage the laser nozzle within the hollow body by extending through the plurality of apertures of the hollow body. The nozzle holder further includes a sleeve substantially surrounding the hollow body and the plurality of pawls. The sleeve includes a pawl retractor that is movable along the longitudinal axis to physically displace the plurality of pawls axially and radially relative to the longitudinal axis for disengagement of the plurality of pawls from the laser nozzle.

Abstract: A high-pressure cylinder of a liquid jet cutting system can include a first end portion, a second end portion, and a central bore configured to receive a plunger. The first end portion can have a first tapered surface configured to form a seal with a mating surface of a check valve when the high-pressure cylinder is in a first orientation, and a first annular surface configured to bear against a mating surface of a pump when the high-pressure cylinder is in a second orientation rotated 180 degrees end-over-end from the first orientation. The second end portion can have a second annular tapered surface configured to form a seal with the mating surface of the check valve when the high-pressure cylinder is in the second orientation, and a second annular surface configured to bear against the mating surface of the pump when the high-pressure cylinder is in the first orientation.

Abstract: A computerized method is provided for automatically determining at least one characteristic of a workpiece for processing by a plasma arc processing system. The method includes electrically connecting the workpiece to the plasma arc processing system that includes a plasma arc torch. A distal tip of the plasma arc torch is configurable to be positioned proximate to the workpiece. The method includes supplying, by the plasma arc processing system, an electrical current with a low amperage to the workpiece, the low amperage current insufficient to cut the workpiece, and monitoring, by the plasma arc processing system, a path of the electrical current relative to the workpiece. The method further includes determining, by the plasma arc processing system, the at least one characteristic of the workpiece based on the electrical current path monitored.

Abstract: A double nozzle for a laser processing head includes an inner body portion having an interior surface defining a bore for passing a laser beam, a first interface surface near a distal end of the inner body portion, the first interface surface including a plurality of channels, and an exterior surface near a proximal end of the inner body portion and shaped to engage the laser processing head. Each channel includes interior and exterior linear edges in a cross-section that passes though a central longitudinal axis of the double nozzle. The double nozzle also includes an outer body portion connected to the inner body portion. The outer body portion defines a jet surface, which together with the plurality of channels defines a corresponding plurality of auxiliary fluid flow paths about the bore and between the inner body portion and the outer body portion.

Abstract: In some aspects, methods for preserving a usable life of a plasma arc electrode consumable installed in a plasma arc torch can include measuring a characteristic of an electrical signal being provided to the torch to generate a plasma arc between the torch and a workpiece to be processed; monitoring the characteristic during operation of the torch over a time period; comparing the characteristic to a threshold value; and, responsive to determining that a measured characteristic meets and/or exceeds the threshold value, initiating an arc extinguishing sequence to preserve the life of the electrode.

Abstract: In some aspects, material processing head can include a body; an antenna disposed within the body; a first tag, associated with a first consumable component, disposed within a flux communication zone of the body at a first distance from the antenna, the first tag having a first resonant frequency; and a second tag, associated with a second consumable component, disposed within the flux communication zone of the body at a second distance from the antenna, the second tag having a second resonant frequency that is different than the first resonant frequency, where the first and second resonant frequencies are tuned based upon at least one of: i) a difference between the first distance and the second distance; or ii) a characteristic (e.g., shape) of the flux communication zone in which the first tag and/or the second tag is disposed.

Abstract: A cartridge for an air-cooled plasma arc torch is provided. The cartridge includes a swirl ring having a molded thermoplastic elongated body with a distal end, a proximal end, and a hollow portion configured to receive an electrode. The swirl ring also has a plurality of gas flow openings defined by the distal end of the elongated body and configured to impart a swirling motion to a plasma gas flow for the plasma arc torch. The swirl ring further includes a nozzle retention feature on a surface of the elongated body at the distal end for retaining a nozzle to the elongated body. The cartridge further includes a cap affixed to the proximal end of the elongated body of the swirl ring for substantially closing the proximal end of the elongated body.

Abstract: A check valve assembly for use with a liquid jet cutting system can include a check valve body a high-pressure fluid inlet on one end and a high-pressure fluid outlet on the other end along a central axis of the check valve body. The check valve body can have a first metallic seal surface on an outer surface of the check valve shaped to engage an endcap of the liquid jet cutting system to form a first seal. The assembly can include an annular low-pressure fluid chamber surrounding a portion of the check valve body and defined at least in part by an annular gasket, the check valve body, the first seal, and the endcap. The check valve body can include a low-pressure fluid channel, and a check valve positioned between the low-pressure fluid channel and a high-pressure fluid chamber.

Abstract: The invention features methods and apparatuses for altering a cutting operation during operation of the pressurized liquid jet cutting system. A pressurized liquid jet cutting system includes a pressurized fluid jet cutting head having a plurality of components. The cutting head further includes a sensor configured to sense an operating condition. The sensor transmits a value of the operating condition to a computing device, which alters a subsequent cutting operation. Further, the fluid jet cutting head is configured to work with a data storage mechanism and a reader, such that the data storage mechanism in contact with a body of the fluid jet cutting head is configured to communicate information to a reader of the pressurized liquid jet cutting system. The information is usable to determine a condition of replacement (e.g.

Abstract: The invention features a replaceable cartridge for a plasma arc torch. The cartridge includes a cartridge body having a first section and a second section. The first and second sections are joined at an interface to form a substantially hollow chamber. The interface provides a coupling force that secures the first and second sections together. The cartridge also includes an arc constricting member located in the second section; an electrode included within the substantially hollow chamber; and a contact start spring element affixed to the electrode. The spring element imparts a separating force that biases the electrode toward at least one of the first section or the second section of the body. The separating force has a magnitude that is less than a magnitude of the coupling force.

Abstract: An adapter for a plasma arc torch comprising a torch body is provided. The adapter includes a body defining a longitudinal axis between a proximal end and a distal end and at least one protruding portion extending from the proximal end of the body. The at least one protruding portion is configured to be inserted into a cavity of the torch body to physically engage a switch inside of the cavity. The engagement of the switch is adapted to indicate installation of a consumable component in the plasma arc torch.