Abstract: A method and apparatus for a gas-cooled plasma arc torch. Components of the torch can include an electrode, nozzle and a shield, each of which can be gas-cooled. The nozzle can be disposed relative to the electrode and can include a generally hollow conductive body and a cooling gas flow channel defined by at least one fin disposed about an exterior surface of the body, the body providing a thermal conductive path that transfers heat between the nozzle to the cooling gas flow channel during operation of the torch. The shield can be disposed relative to the nozzle and can include a generally hollow conductive body and a cooling gas flow channel defined by at least one fin disposed about an exterior surface of the body, the body providing a thermal conductive path that transfers heat between the shield to the cooling gas flow channel during operation of the torch.

Abstract: A nozzle or retaining cap 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 or retaining cap 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: A method and apparatus for controlling a gas supply to a plasma arc torch uses a proportional control solenoid valve positioned adjacent the torch to manipulate the gas flow to the torch, thereby extending electrode life during arc transfer and shutdown. Swirl ring design can be simplified and gas supply and distribution systems become less complicated. The invention also allows manipulation of shield gas flow to reduce divot formation when making interior cuts. The system can be controlled with a digital signal processor utilizing a feedback loop from a sensor.

Abstract: A method and apparatus for controlling a gas supply to a plasma arc torch uses a proportional control solenoid valve positioned adjacent the torch to manipulate the gas flow to the torch, thereby extending electrode life during arc transfer and shutdown. Swirl ring design can be simplified and gas supply and distribution systems become less complicated. The invention also allows manipulation of shield gas flow to reduce divot formation when making interior cuts. The system can be controlled with a digital signal processor utilizing a feedback loop from a sensor.

Abstract: Described are computer-based methods and apparatuses for automated self test for a thermal processing system. A signal to execute the automated self test is received. The automated self test is executed. The execution includes executing one or more self test instructions for the one or more subsystems of the system. Data can be received from sensors associated with the subsystems. The data can be analyzed to determine the results of the automated self test for the thermal processing system.

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: 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 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.

Abstract: A method and apparatus is featured for providing linear control of a regulated electrical property (e.g., current or voltage) in a switch mode power supply of a thermal processing system that includes an inductive element and at least one switching element. The method and apparatus feature structure, or steps, for generating a nonlinear model that predict values for a regulated electrical property of the inductive element based on a given duty cycle of the at least one switching element and structure, or steps, for generating a nonlinear model that determines a duty cycle for the at least one switching element based on the nonlinear predictive model for the regulated electrical property, the nonlinear model determining the duty cycle such that a linear relationship results between the regulated electrical property and a selected value.

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: An improved torch providing high visibility of the work zone to the operator, an increased viewing angle, and a reduced obstruction angle. The high visibility torch includes consumables adapted to maintain torch and consumables performance while reducing visual obstruction to the user, by coordinating, balancing, and optimizing design requirements and stack up tolerances. The invention also includes a related low-profile safety switch that promotes workpiece visibility and minimizes view obstruction.

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 system and method is featured for controlling a process parameter of a thermal processing system by estimating an arc voltage between a plasma arc torch tip and a metallic workpiece and controlling the process parameter based on the estimated arc voltage. Particular embodiments include adjusting the height of a plasma torch based on the estimated arc voltage. A system and method is also featured for estimating an arc voltage in a thermal processing system in which a switch mode power supply provides an arc current to generate a plasma arc between a plasma arc torch tip and a metallic workpiece.

Abstract: An improved cooling system for a power supply of a welding or plasma cutting system. The cooling systems includes a heat sink with a panel forming a plurality of enclosed channels. The cooling system also includes a passage defined by walls, and a passage in a heat sink between an inlet port and outlet port. The channels and passages extend from a central portion of the power supply to an end, and a majority of the airflow passing through the power supply is directed through the channels and passages. The method includes step of directing a majority of the airflow through the cooling system via the channels or passages.

Abstract: An improved system for cooling a power supply of a welding or plasma cutting system, and an improved configuration of a power supply. The system cools achieves the improvement in configuration and cooling by mounting electrical components to a circuit board and then to a heat sink. Electrical components are also mounted to a common panel that improves the circulation of air. A central panel supporting the power supply heat sink and components allows a smaller and more compact design while maintaining proper temperatures. Electromagnet cooling is improved by modifying electromagnetic cores to conduct heat to the heat sink, and by the use of thermally conducting polymers.

Abstract: An improved cooling system for a power supply of a welding or plasma cutting system. The cooling systems includes sections that are divided. One section contains electrical components and remains relatively clean, and does not receive an airflow from a fan. Another section does not contain electrical components and channels a majority of the airflow into and out of the power supply. The section channeling the majority of the airflow shields the section with the electrical components from a majority of the airflow. The method includes step of forming and disposing the structure of the cooling system.

Abstract: A method and apparatus for controlling a gas supply to a plasma arc torch uses a proportional control solenoid valve positioned adjacent the torch to manipulate the gas flow to the torch, thereby extending electrode life during arc transfer and shutdown. Swirl ring design can be simplified and gas supply and distribution systems become less complicated. The invention also allows manipulation of shield gas flow to reduce divot formation when making interior cuts. The system can be controlled with a digital signal processor utilizing a feedback loop from a sensor.

Abstract: An electrode for a contact start plasma arc torch includes an elongated electrode body formed of an electrically conductive material. The electrode body is movable relative to the torch. A resilient element is used for passing substantially all of a pilot arc current between a power supply, a power connection in electrical communication with the power supply, and the electrode body during pilot arc operation of the plasma arc torch. The electrode and torch can include a contact element having a first surface in electrical communication with the power contact and a second surface for physical contact and electrical communication with a corresponding contact surface of the electrode body for passing substantially all of a transferred arc current between the power supply and the electrode body during transferred arc mode.

Abstract: An electrode for a contact start plasma arc torch includes an elongated electrode body formed of an electrically conductive material that defines a longitudinal axis and a distal end for housing an emissive element. The electrode includes a second end positioned adjacent the electrode body. The second end defines an extensive portion having a first length along a first direction and a second length along a second direction. The second length is greater than the first length. A component for use with the electrode includes a hollow body element having an interior surface with one or more of a contour, step, or flange that defines a shaped opening capable of slideably receiving a complementary-shaped portion of an electrode body.

Abstract: A method for monitoring the processing of a workpiece includes directing an incident laser beam onto the workpiece and measuring a signal emitted from the workpiece. At least two signals are generated by a detector based upon the emitted signal. A workpiece processing quality is determined based upon the ratio of the two output signals and a magnitude of one of the two outputs.