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: A method and system utilizing multi-sensor analysis and data point correlation is provided for predictive monitoring and maintenance of a pressurized fluid cutting system. In a disclosed aspect, multiple sensed characteristics of system operation are correlated to determine a particular failure mode. Identification of the failure mode through active sensor data analysis and correlation facilitates predictive maintenance, minimizes system downtime, and optimizes system output.

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, contact members to connect plasma torch leads to plasma cutting systems can include: a base portion; a set of ports within the base portion that include: a coolant supply port to convey a liquid coolant from the cutting system to a plasma arc torch connected to the contact member by the torch lead, a coolant return port: i) to convey return liquid coolant from the torch to the cutting system, and ii) to convey an operational current from the cutting system to the torch, at least one gas supply port to convey processing gases to the torch, and an ohmic contact connector; and a connector to couple the base portion to the cutting system and connect each of the ports and electrical connectors to respective complementary connections of the cutting system upon coupling to the cutting system.

Abstract: In some aspects, torch receptacles for coupling a plasma arc torch to a torch lead can include: a body having a first end to connect to the torch lead and a second end to connect to a torch body; a set of ports within the first end to fluidly connect to a set of fluid conduits within the torch lead; and a multiway valve within the body and fluidly connected to the set of ports and to a torch gas conduit formed in the second end, the multiway valve being configured to: i) manipulate a flow of fluids between the first end and the second end to select from primary gases entering the set of ports, ii) deliver a selected primary gas to the torch body through the torch gas conduit, and iii) fluidly connect the torch gas conduit to a gas supply manifold of the plasma cutting system.

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: In some aspects, autonomous motion devices configured to operably connect to a plasma torch of a plasma cutting system can include: a body to support a power supply of the plasma cutting system and move relative to a workpiece; a torch holder connected to the body and configured to position a plasma arc torch tip of the plasma torch relative to a region of the workpiece to be processed; a drive system to translate the body supporting the power supply and torch autonomously relative to a surface of the workpiece during a plasma processing operation; and a processor in communication with the drive system and configured to communicate with the power supply, the processor being configured to control the translation of the body relative to the workpiece in accordance with the plasma processing operation.

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: 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.