Abstract: A method is provided for operating a plasma arc torch system having a power supply and a plasma arc torch. The method includes supplying power to the power supply from a battery. The battery provides at least a portion of the power to generate a plasma arc by the plasma arc torch. The method also includes communicating a first signal, indicating at least one parameter of the battery, between the battery and a control unit of the power supply, generating a second signal, by the control unit, based on the at least one parameter of the battery, and controlling, using the control circuit, operation of the plasma arc torch based on the second signal.

Abstract: An automated method for cutting a plurality of hole features using a plasma arc torch system can be implemented on a computer numerical controller. The automated method can include the steps of: a) cutting a lead-in for a hole feature using a lead-in command speed based on a diameter of that hole feature and b) cutting a perimeter for the hole feature using a perimeter command speed greater than the corresponding lead-in command speed for the hole feature. The automated method can also include the step c) of repeating steps a) and b) for each additional hole feature having a same diameter or a different diameter.

Abstract: In some aspects, lead connector assemblies for plasma arc torches for providing electrical and fluid connections can include male and female connectors. The female connector can include a current conductive member, a sealing member, clearance region, binding region, and a locking ring having a locking flange. The male connector can include a body defining an internal fluid passage, an electrical contact region, a sealing region, a locking trough, and a driving lip. The male connector, when assembled to the female connector, typically has an engaged configuration and a disengaged configuration. In the engaged configuration, the male connector is locked within the female connector, the electrical contact region forms an electrical connection with the current conducting member, the sealing region forms a seal against the sealing member, the locking trough receives the locking flange, and the locking flange is positioned between the driving lip and the binding region.

Abstract: A consumable component of a liquid jet cutting system is provided. The consumable component includes a body defining a conduit for a liquid jet and a signal device located on or within the body for transmitting a signal associated with the consumable component to a reader.

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: In some aspects, nozzles for plasma torches can include a nozzle body having a proximal end and a distal end that define a nozzle body length and a longitudinal axis. The body can include an exit orifice defined by the distal end; a plenum extending from the proximal end to a plenum floor, a distance from the plenum floor to the distal end defining a plenum floor thickness, and a distance from the plenum floor to the proximal end defining a proximal end height; and a bore extending from the plenum floor to the exit orifice that has a bore length and a bore width. The nozzle body has a nozzle width in a direction transverse to the longitudinal axis. The nozzle body length is greater than the width and a ratio of the proximal end height to the plenum floor thickness is less than 2.0.

Abstract: An electrode for a plasma arc cutting torch which minimizes the deposition of high emissivity material on the nozzle, reduces electrode wear, and improves cut quality. The electrode has a body having a first end, a second end in a spaced relationship relative to the first end, and an outer surface extending from the first end to the second end. The body has an end face disposed at the second end. The electrode also includes at least one passage extending from a first opening in the body to a second opening in the end face. A controller can control the electrode gas flow through the passages as a function of a plasma arc torch parameter. Methods for operating the plasma arc cutting torch with the electrode are disclosed.

Abstract: An apparatus and method of graphically indicating the performance of intensifier pumps used in water-jet cutting utilizes output signals from end-of-stroke proximity sensors to establish stroke times for the pump's plungers. The stroke times are then used to present bar graphs for each plunger reflecting the magnitude of the time valve by the height of the bars and performance status by the color of the bars.

Abstract: The invention features, in one aspect, a computerized method for measuring or improving performance of a cutting head of an automated cutting system by evaluating motor control processing of an automated motion control of the cutting head of the automated cutting system. The method includes generating one or more motor outputs for the automated cutting system for any of a cut, a trace, or a motion, the one or more motor outputs corresponding to at least a portion of a set of motor output commands. A characteristic is measured of the one or more motor outputs for the plurality of axes of the automated cutting system. The characteristic is compared with the at least a portion of the set of motor output commands to determine a performance measurement of the automated cutting system.

Abstract: A consumable set is provided that is usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece. The consumable set includes a nozzle having: 1) a nozzle body defining a longitudinal axis extending therethrough, and 2) a nozzle exit orifice, disposed in the nozzle body, for constricting the plasma arc. The nozzle exit orifice defines an exit orifice axis oriented at a non-zero angle relative to the longitudinal axis. The consumable set can also include an alignment surface generally parallel to the exit orifice axis. The alignment surface is dimensioned to align the exit orifice such that the plasma arc impinges orthogonally on the processing surface.

Abstract: A nozzle for use in a plasma arc torch is provided. The nozzle includes an aft portion comprising a conductive first material with a first density. The aft portion defines a proximal end and a distal end. The nozzle includes a substantially hollow forward portion including 1) a tip section comprising a conductive second material with a second density, and 2) a rear section configured to couple the forward portion to the proximal end of the aft portion. The second density is at least two times greater than the first density. The nozzle further includes a plasma exit orifice disposed in the tip section of the forward portion.

Abstract: An electrode is provided for use in a plasma arc torch. The electrode includes a body having a forward portion, a middle portion and an aft portion. The forward portion includes an electrode tip comprising a conductive first material, wherein the electrode tip includes: 1) a pilot contact region for initiating a pilot arc across the nozzle and 2) an emitter. The middle portion comprises a second material and defines a proximal end for mating with the forward portion and a distal end for mating with the aft portion. The material density of the second material is at least half of the material density of the first material. The electrode also includes an electrically conductive path extending from the forward portion to the aft portion of the body.

Abstract: An apparatus and method for extending a plasma arc torch is disclosed. The apparatus includes a plasma torch adapter for relocating a mounting location of plasma torch consumables with respect to a plasma arc torch. The adapter is configured to be mounted between a plasma arc torch and the plasma torch consumables. The adapter is connectable to a consumable interface of the torch and includes a generally longitudinal body having a first end and a second end. The adapter includes a first connector at the first end of the body that is adapted to mate with the consumable interface. The adapter further includes a second connector at the second end of the body for mating with a set of plasma torch consumables, such that a second mounting location for consumables is established in a spaced relationship relative to the first connector, the mounting location adjacent the second connector.

Abstract: A thermal processing torch can include a torch housing having a head portion pivotally coupled relative to a body portion with a joint portion. The torch also can include a pivotal connector simultaneously pivoting about a common axis with the joint portion of the torch housing. The pivotal connector can include an electrically conductive wall conducting an electrical current between the body portion of the torch housing and the head portion of the torch housing. The pivotal connector can also include a passage provide a processing gas between the body portion of the torch housing and the head portion of the torch housing.

Abstract: An improved electrode for use in a plasma arc torch. The electrode includes an electrode body, a cavity in a front face at a first end of the electrode body, and an insert disposed in the cavity. The first end of the electrode body is formed of high purity copper containing at least 99.81% copper. The insert has a first end and a second end and is formed of a high emissivity material. A diameter of the first end of the insert is less than a diameter of a second end of the insert. An electrode is compressed to retain the insert using radial compression. The invention also includes a method for forming the electrode, and a method of operation of an electrode in a plasma torch.

Abstract: A method is provided for configuring two thermal processing systems. The method includes providing a first consumable for use in a first thermal processing torch and a second consumable for use in a second thermal processing torch. The first and second consumables have substantially identical physical characteristics. The first and second torches are mounted in a first thermal process system and a second thermal processing system, respectively. The method also includes sensing, by the first thermal processing system, first data stored in a first signal device associated with the first consumable and sensing, by the second thermal processing system, second data stored in a second signal device associated with the second consumable.

Abstract: A consumable component for a thermal processing torch is provided. The consumable component includes a consumable component body and a signal device located on or within the consumable component body for transmitting a signal associated with the consumable component. The signal can be independent of a detectable physical characteristic of the consumable component.

Abstract: In some aspects, a replaceable consumable component for performing a cutting or welding operation can include a body and a readable data storage device coupled to the body or integrated within the body, wherein the data storage device contains an operation instruction for a cutting or welding device.

Abstract: Transformer flux is monitored to determine if an onset of flux saturation is detected. If flux saturation is not detected, the transformer drive signal is received to a switch that maintains the polarity of the transformer flux. If flux saturation is detected, the transformer drive signal is received by a switch that reverses the polarity of the transformer signal and the transformer flux. This reversal of flux polarity can occur multiple times, during the carrier cycle of the drive signal, without compromising the dynamics of the transformer main control loop or requiring the drive signal to be regenerated.