Abstract: A thermal processing system includes a thermal torch for processing a workpiece, a power supply for providing power to the thermal torch, a positioning system for relatively moving the thermal torch and the workpiece, a controller for controlling the thermal processing system, and a deterministic-based communication network, such as, for example, a network which operates using SERCOS. The deterministic-based communications network connects at least the controller, the power supply, and the positioning system of the thermal processing system together.

Abstract: A nozzle for a plasma torch can include a body that has an inner surface, an outer surface, a proximal end, and an exit orifice at a distal end. The nozzle can also include a liner surrounded by the inner surface of the body. The liner can include a proximal end and an exit orifice at a distal end adjacent the exit orifice of the body. The nozzle can include at least one vent passage formed in the body. The vent passage can have an inlet formed in the inner surface of the body and an outlet formed in the outer surface of the body. The vent passage can be disposed between the proximal end of the body and the proximal end of the liner. The plasma arc torch can include a configuration that allows for increased electrode life and nozzle life for a vented high current plasma process.

Abstract: A plasma arc torch that includes a torch body having a nozzle mounted relative to a composite electrode in the body to define a plasma chamber. The torch body includes a plasma flow path for directing a plasma gas to the plasma chamber in which a plasma arc is formed. The nozzle includes a hollow, body portion and a substantially solid, head portion defining an exit orifice. The composite electrode can be made of a metallic material (e.g., silver) with high thermal conductivity in the forward portion electrode body adjacent the emitting surface, and the aft portion of the electrode body is made of a second low cost, metallic material with good thermal and electrical conductivity. This composite electrode configuration produces an electrode with reduced electrode wear or pitting comparable to a silver electrode, for a price comparable to that of a copper electrode.

Abstract: A coolant tube and electrode are adapted to mate with each other to align the tube relative to the electrode during operation of the torch. Improved alignment ensures an adequate flow of coolant along an interior surface of the electrode. In one aspect, an elongated body of the coolant tube has a surface adapted to mate with the electrode. In another aspect, an elongated body of the electrode has a surface adapted to mate with the coolant tube. The surfaces of the tube and electrode may, for example, be flanges, tapered surfaces, contours, or steps.

Abstract: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces.

Abstract: A contact start plasma system is provided that includes a passive pilot arc circuit that decreases the size and cost of the system. The plasma arc system includes a torch body, an electrode having a longitudinally disposed axis and mounted in the body, a nozzle having a longitudinally disposed axis, the nozzle axis being disposed substantially collinearly with the electrode axis, a power supply coupled to the electrode, the nozzle and a workpiece, the power supply providing a current for operating the torch in a pilot arc mode and a transferred arc mode, a gas source coupled to the plasma chamber, the gas source providing gas for operating in a pilot arc mode and a transferred arc mode, and a passive pilot arc circuit coupled between the power supply and the nozzle, the passive pilot arc circuit controlling the operation of the torch in the pilot arc mode. Either the electrode or the nozzle can be translatable for blow-forward or blow-back mode of operation.

Abstract: The invention relates to a nozzle for a plasma arc torch and methods of manufacturing the nozzle. The nozzle includes a nozzle body and a nozzle liner. The nozzle body has a cylindrical portion and the nozzle liner has a cylindrical section in close thermal contact with a majority of an interior surface of a cylindrical portion of the nozzle body.

Abstract: A consumable for a plasma arc torch, such as a nozzle, having a body and a head defining a shoulder portion having a frusto-conical portion and a flared portion. The flared portion increases the cross-sectional thickness to provide a greater heat-conduction path for removal of heat generated by a plasma arc, thereby extending consumable life. The frusto-conical portion provides a sharper, pointier nozzle head to simultaneously increase the operator's visibility of the workpiece. Methods of making and using the consumables are also included.

Abstract: The invention is generally directed to a nozzle for a plasma torch, the nozzle having a rear portion that defines at least a portion of a plasma chamber and a front portion that includes a first end and a second end. The first end is adjacent the rear portion, and the second end defines a plasma exit portion. One or more fluid passageways are disposed within the front portion and extend from the first end to the second end. The fluid passageways have passageway exit portions that provide one or more discrete jets of a secondary fluid to surround a plasma jet that is ejected from the plasma exit portion. Features of the invention include faster cutting, thicker workpiece piercing capability, reduced noise, improved arc stability, and increased consumable life, all of which improve productivity associated with plasma arc torch workpiece processing.

Abstract: A method for setting up a cutting table for an automated high temperature thermal cutting system can include providing a computer-readable product to, for example, a digital signal processor (e.g., CNC). The computer-readable product can include data for at least one part to be cut from a workpiece (e.g., a part program). A user can be prompted to select values from a menu of mandatory operating parameters (e.g., using a graphical user interface) for a shape of the part to be cut from the workpiece. Mandatory operating parameters can include at least one of an operating current, a gas flow, a thickness of the workpiece, or a material of the workpiece.

Abstract: A shield for a plasma arc torch that pierces and cuts a metallic workpiece producing a splattering of molten metal directed at the torch, the shield protecting consumable components of the plasma arc torch from the splattering molten metal. The shield can include a body, a first surface of the body configured to be contact-cooled by a gas flow, a second surface of the body configured to be contact-cooled by a liquid flow, and a seal assembly configured to be secured to the body and disposed relative to the second surface configured to retain the liquid flow contact-cooling the second surface.

Abstract: A shield for a plasma arc torch that pierces and cuts a metallic workpiece producing a splattering of molten metal directed at the torch, the shield protecting consumable components of the plasma arc torch from the splattering molten metal. The shield can include a body, a first surface of the body configured to be contact-cooled by a gas flow, a second surface of the body configured to be contact-cooled by a liquid flow, and a seal assembly configured to be secured to the body and disposed relative to the second surface configured to retain the liquid flow contact-cooling the second surface.

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: A connector assembly for a thermal cutting system or welding system can include a housing having a locking device. The locking device can cause, upon application of a translational force, engagement of the connector assembly relative to a stationary receiving mechanism and can cause, upon application of a force on a contact member or a rotational moment on the contact member, disengagement of the locking device relative to the stationary receiving mechanism. The connector assembly can include a conduit disposed in the housing, the conduit carrying a gas to the thermal cutting system or welding system. The connector assembly can include a first current carrying member disposed in the housing, the first current carrying member carrying an operating current to the thermal cutting system or welding system and a second current carrying member disposed in the housing, the second current carrying member carrying a second current.

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: The technology features an apparatus and a method for sensing the length of a lead that connects to a power source to a thermal processing system such as a plasma torch system. Components disposed in the thermal processing system enable the length of the lead to be sensed. In addition, the time for contact starting a thermal processing system enables determination of the length of the lead.

Abstract: A nozzle, retaining cap, or shield for a plasma arc torch that includes a surface defining a conductive contact portion for exchanging heat with an adjacent torch component. The adjacent torch component can be a retaining cap, electrode or nozzle. The surface of the nozzle, retaining cap, or shield can also at least partially define a cooling channel having a curvilinear surface. A sealant portion can be positioned between the conductive contact portion and the cooling channel. The sealant portion can form or create a fluid barrier between the cooling channel and the conductive portion.

Abstract: An improved electrode for use in a plasma arc torch. The electrode includes an electrode body, a bore defined by and disposed in the electrode body, and an insert disposed in the bore. The insert and/or the bore of the electrode are configured to improve retention of the insert in the electrode, thereby extending electrode life. The invention also includes a method for forming the electrode. The method includes a step of positioning an insert into a bore of an electrode such that an exterior gap is established that is greater than a second gap.

Abstract: A method for determining a distance between a first piece and a second piece includes measuring, at the first or second piece, a first signal at a first frequency, and measuring, at the first or second piece, a second signal at a second frequency. The second frequency is different from the first frequency. The distance is determined based on the measured first and second signals.

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.