Abstract: A consumable cartridge for a plasma arc torch includes a cartridge frame having a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, the second end including a plurality of discrete retaining features. The consumable cartridge includes an electrically conductive contact element secured to the cartridge frame by the plurality of discrete retaining features and translatable up to a predetermined distance within the cartridge frame along the longitudinal axis at the second end, the contact element having a core, a proximal surface, and a distal surface. The proximal surface is shaped to contact a torch plunger of the plasma arc torch upon installation into the plasma arc torch and the distal surface is shaped to contact an electrode of the plasma arc torch during an operation of the plasma arc torch.

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: In some aspects, electrodes can include a front portion shaped to matingly engage a nozzle of the plasma cutting system, the front portion having a first end comprising a plasma arc emitter disposed therein; and a rear portion thermally connected to a second end of the front portion, the rear portion shaped to slidingly engage with a complementary swirl ring of the plasma cutting system and including: an annular mating feature extending radially from a proximal end of the rear portion of the electrode to define a first annular width to interface with the swirl ring, the annular mating feature comprising a sealing member configured to form a dynamic seal with the swirl ring to inhibit a flow of a gas from a forward side of the annular mating feature to a rearward side of the annular mating feature.

Abstract: In some aspects, methods for controlling a plasma arc in a plasma torch of a plasma cutting system in a low operating current mode can include: receiving, by a computing device within the plasma power supply, a command to begin a plasma processing operation; generating a pilot arc command to generate a pilot arc within the plasma torch, the generating of the pilot arc command including directing an electrical signal and a gas flow to the plasma torch, the electrical signal being configured to generate the pilot arc at a current having a first arc amperage magnitude; and generating an operational arc command to facilitate a transition from the pilot arc to an operational plasma arc, the generating of the operational arc command including adjusting the current directed to the plasma torch to be a second arc amperage magnitude that is lower than the first arc amperage magnitude.

Abstract: A material processing system includes a power supply in electrical communication with a cutting head. The power supply includes a control processor and a wireless communications control circuit configured to establish a web server for wirelessly communicating with a client device via a first communications interface. The wireless communications control circuit is configured to receive a request from the client device for a first web resource. The wireless communications control circuit is configured to request, via a second communications interface, a set of material processing system parameters from the control processor. The set of material processing system parameters is based on content of the request. The wireless communications control circuit is configured to serve, via the web server over the first communications interface, the first web resource to the client device. The first web resource includes web page formatting information and the set of material processing system parameters.

Abstract: A pressurized fluid jet cutting head is provided. The cutting head includes a body having one or more component parts coupled together, wherein a junction in the cutting head is defined between a first component part having a first engagement surface and a second component part having a second engagement surface, wherein the first and second engagement surfaces abut at the junction. A temperature sensor is positioned in thermal communication with the body and is configured to measure a temperature value of at least one of the first component part, the second component part, and the junction. The temperature value is communicated to a controller for analysis, wherein the controller receives the measured temperature value and communicates operating instructions for the cutting head based on a comparison of the measured temperature value to a predetermined value.

Abstract: In some aspects, methods of disengaging a plasma control circuit within a plasma arc torch of a plasma processing system to place the torch into a safety-locked mode can include providing: a plasma control circuit configured to convey a current from the plasma cutting system through the plasma arc torch to one or more consumables disposed in the torch and an operator interface switch connected to the plasma control circuit and configured to initiate generation of a plasma arc from the plasma arc torch; and activating a switch, separate from the operator interface switch, disposed on the torch and connected to the plasma control circuit to disconnect the plasma control circuit to limit the current, including pilot current, from flowing to the one or more consumables.

Abstract: A computer-implemented method is provided for guiding a robot in a robotic system, by creating a refined path, based on an initial path in a three-dimensional space. The method includes receiving data related to creating the initial path, including a start point and an endpoint, and generating the initial path by interpolating the start point and the endpoint. The method also includes receiving inputs for at least one support point that defines a coordinate in the three-dimensional space for altering the initial path, and adjusting the initial path to generate the refined path by modifying a set of one or more polynomial functions, such that the refined path interpolates the at least one support point between the start point and the endpoint. The method further includes providing the refined path to a second computing module for guiding the robot.

Abstract: A connector component configured for coupling a consumable component to a plasma arc torch is provided. The connector component comprises a body having a proximal end and a distal end disposed along and defining a longitudinal axis. The connector component includes at least two engagement regions disposed radially about the longitudinal axis on a surface of the body. Each engagement region includes at least one engagement feature disposed on the surface of the body. The connector component also includes at least two free regions disposed radially about the longitudinal axis on the surface of the body. Each free region is radially located between a pair of the engagement regions and characterized by an absence of the engagement feature.

Abstract: A hand-held plasma power tool is provided, which includes a hand-held housing, a plasma delivery tip section at least partially disposed within the housing for delivering a plasma arc to a workpiece, an air compressor disposed within the housing for providing a gas to the plasma delivery tip section, and a power source disposed within the housing for providing a current to at least one of the air compressor or the plasma delivery tip section. The hand-held plasma power tool further comprises a handle section defined by at least a portion of the housing. The handle section is configured to enable an operator to manipulate the plasma power tool by hand while delivering the plasma arc to the workpiece.

Abstract: In some aspects, methods for limiting damage to a plasma arc torch body resulting from a consumable failure within the torch can include determining a specified conductivity parameter set point of a current to be provided to the plasma arc torch for a material processing operation; measuring a detected conductivity parameter of plasma arc current being provided to the plasma torch to perform the material processing operation; comparing the specified conductivity parameter set point to the detected conductivity parameter of plasma arc current and calculating an error term signal; and based on a determination that the error term signal exceeds a threshold amount, initiating a plasma arc shut down sequence to extinguish the plasma arc to limit damage to the plasma arc torch body.

Abstract: A system and method for processing parts from a workpiece is provided. The method may include identifying characteristics of a workpiece to be processed, nesting, by a computer controller, a first nest pattern of a local first part to be cut out of the workpiece, identifying, by a computer controller, an unused portion of the workpiece not occupied by the first nest pattern, querying, by a computer controller, a remote database to identify a remote second part to be cut, wherein the second part comprises material characteristics corresponding to the characteristics of the workpiece and is nestable in the unused portion of the workpiece, and nesting the local first part and the remote second part on the workpiece.

Abstract: In some aspects, computer-implemented methods for selecting a robotic tool path for a manufacturing processing system to execute a material processing sequence in three-dimensional space can include: providing to a computer-readable product including robotic system data of a robotic tool handling system and workpiece data relating to a processing path of a tool along the workpiece; generating a plurality of possible robotic tool paths to be performed to move the tool along the processing path; identifying one or more obstacles, or an absence of obstacles, associated with the robotic tool paths; comparing robotic tool paths based on a predetermined robotic parameter to be controlled as the tool moves from the start point to the end point; and based on the identified obstacles, determining feasible tool paths, between the start point and the end point that avoid the obstacles, that can be obtained by adjusting the predetermined robotic parameter.

Abstract: In some aspects, methods of initiating a plasma arc of a plasma arc torch to pierce a workpiece and detecting plasma piercing through the workpiece to begin a cutting sequence can include calculating a pulse width modulation characteristic of an electrical signal associated with a plasma arc between an electrode of a plasma arc torch and a workpiece to be processed; monitoring the characteristic during operation of the torch over a time period of a workpiece piercing sequence; comparing the characteristic to a threshold value; and responsive to determining that a calculated characteristic meets and/or exceeds the threshold value, ending the workpiece piercing sequence and beginning the cutting sequence and causing the plasma arc torch to move relative to the workpiece to form a cut.

Abstract: A consumable set for a plasma arc torch is provided. The consumable set comprises a consumable tip including a plurality of consumable components, at least one of which includes an asymmetric feature asymmetrically disposed in the consumable tip relative to a longitudinal axis. The consumable set also includes a mounting element for coupling the consumable tip to a torch body. The mounting element is configured to axially secure the consumable tip relative to the torch body while permitting independent rotation of the consumable tip relative to the longitudinal axis during assembly. The mounting element is also configured to both axially and radially fix the consumable tip with respect to the torch body such that the asymmetric feature is locked at the specific radial orientation relative to the longitudinal axis after securement.

Abstract: A liquid cooled shield assembly for a plasma arc torch includes an inner cap and a shield. The inner cap includes a substantially hollow body having a proximal end and a distal end that define a longitudinal axis, the distal end including an annular portion about the longitudinal axis. The inner cap also includes a liquid passage defined, at least in part, by an interior surface of the body, the liquid passage including a first set of ports in the annular portion, the first set of ports extending between an interior portion of the body and an exterior portion of the body to convey a liquid therethrough. The shield at least partially surrounds the inner cap and has a liquid impingement region on an interior surface of the shield adjacent to the first set of ports, the liquid impingement region for receiving the cooling liquid.

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: In some aspects, methods for providing a uniform shield gas flow for an air-cooled plasma arc torch can include supplying a shield gas to a shield gas flow channel defined by an exterior surface of a nozzle and an interior surface of a shield; flowing the shield gas along the shield gas flow channel; reversing the flow of the shield gas along the shield gas flow channel using a recombination region, the recombination region comprising at least one flow reversing member; and flowing the shield gas from the mixing region to an exit orifice of the shield, thereby producing a substantially uniform shield gas flow at the exit orifice.

Abstract: A nozzle for a liquid-cooled plasma arc torch is provided. The nozzle includes a thermally conductive body having a distal end, a proximal end, and a longitudinal axis extending therethrough. The nozzle also includes a plasma arc exit orifice at the distal end of the thermally conductive body. The nozzle additionally includes a cooling waist located circumferentially about an exterior surface of the thermally conductive body. The cooling waist includes a liquid inlet slope, a liquid outlet slope and a heat exchange region between the liquid inlet slope and the liquid outlet slope. The heat exchange region extends substantially parallel to the longitudinal axis, and the liquid inlet slope and the liquid outlet slope are oriented generally perpendicular to the longitudinal axis.

Abstract: An automatically adjustable abrasive recycling system is provided. The abrasive recycling system includes one or more sensors configured to sense at least one characteristic of the abrasive recycling system, and slurry supply mechanism that operates, at least in part, based upon the sensed characteristic to control the operation of the abrasive recycling system. The abrasive recycling system further includes a substantially vertically arranged configuration of component parts. Methodology corresponding to the automatic operation of the abrasive recycling system is also provided.