Abstract: A swirl ring for a plasma arc torch is provided. The swirl ring comprises a hollow body having a distal end and a proximal end and configured to receive at least a portion of an electrode within the hollow body. The swirl ring also comprises a first set of flange segments circumferentially disposed on an interior surface of the hollow body. The first set of flange segments extend radially inward from the interior surface and shaped to retain a first surface of a sealing member. The swirl ring further comprises a second set of flange segments circumferentially disposed on the interior surface of the hollow body. The second set of flange segments extend radially inward from the interior surface and shaped to retain a second surface of the sealing member.

Abstract: A plasma gas swirl ring for a liquid cooled plasma arc torch is provided. The swirl ring comprises a substantially hollow body having a distal end, a proximal end, an interior region defined by an interior surface, and an exterior surface. The interior region of the body is configured to receive an electrode of the plasma arc torch. The swirl ring comprises a first opening disposed within a portion of the proximal end of the body, a second opening disposed about a central portion of the body, and a third opening comprising at least one swirling port disposed within a portion of the distal end of the body. The third opening is configured to provide a swirling flow of the plasma gas about the electrode at the distal end of the body.

Abstract: In some aspects, waterjet cutting pressurization systems can include a water pump: (i) having a pressurization chamber and (ii) having a high-pressure water seal maintaining water pressure within the chamber; and a leak detector in fluid communication with the high-pressure water seal and configured to monitor a leak rate of a fluid from the high-pressure water seal.

Abstract: In some aspects, methods for controlling a pneumatic system in a plasma arc processing system can include: receiving, by a computing device, a command to begin a plasma processing operation; generating a valve command signal for a valve that includes an operational drive voltage of at least about 125% of a continuous duty cycle coil voltage rating of the valve to open the valve; and once open, adjusting the valve command signal to facilitate a steady state operation to: monitor a steady state operational duty cycle of the valve, the steady state operational duty cycle being determined by comparing the continuous duty cycle coil voltage rating of the valve to an actual operational drive voltage supplied to the valve, and control the operational drive voltage supplied to the valve to maintain a steady state operational duty cycle of the valve at less than about 60% during steady state operation.

Abstract: In some aspects, power supplies for liquid cooled plasma cutting systems configured to support plasma arc generation by a torch head connected to the power supply can include: a set of electrical components for plasma arc generation; and a power supply housing containing the set of electrical components, the power supply housing having a front panel and at least two side panels and defining: a set of inlets for allowing a cooling gas to enter the power supply housing to thermally regulate the set of electrical components, at least one inlet of the set of inlets being positioned at a corner of the housing and oriented at a non-zero angle relative to the front panel and to at least one of the two side panels; and a set of vents for allowing at least a portion of the cooling gas to exit the power supply housing.

Abstract: A plasma cutting system includes a plasma torch having a head, and a housing. A power supply is disposed within the housing and is in communication with the plasma torch. The power supply is configured to provide an output current for generating and maintaining a plasma cutting arc by the plasma torch, and includes a control processor in communication with a plurality of autonomous switching circuits via a multi-node communications bus. Each of the autonomous switching circuits includes a microcontroller configured to control the generation of a portion of the output current based on messages received from the control processor, monitor operating parameters of the autonomous switching circuit, and modify a control parameter of the autonomous switching circuit independent of and asynchronous to the other autonomous switching circuits of the plurality of autonomous switching circuits when one or more of the operating parameters exceeds a predetermined threshold.

Abstract: A torch head for a liquid-cooled plasma arc torch is provided. The torch head includes a torch body and a torch insulator, coupled to the torch body, having a substantially non-conductive insulator body. The torch insulator includes (i) a first liquid coolant channel, disposed within the insulator body, configured to conduct a fluid flow from the torch head into a consumable cartridge along a first preexisting flow path, (ii) a first liquid return channel, disposed within the insulator body, configured to return at least a portion of the fluid flow from the cartridge to the torch head along the first preexisting flow path, and (iii) a gas channel, disposed within the insulator body, configured to conduct a first gas flow from the torch head to the cartridge along a second preexisting flow path. The first and second preexisting flow paths are fluidly isolated from each other.

Abstract: A cartridge for an air-cooled plasma arc torch is provided. The cartridge includes a swirl ring having a molded thermoplastic elongated body with a distal end, a proximal end, and a hollow portion configured to receive an electrode. The swirl ring also has a plurality of gas flow openings defined by the distal end of the elongated body and configured to impart a swirling motion to a plasma gas flow for the plasma arc torch. The swirl ring further includes a nozzle retention feature on a surface of the elongated body at the distal end for retaining a nozzle to the elongated body. The cartridge further includes a cap affixed to the proximal end of the elongated body of the swirl ring for substantially closing the proximal end of the elongated body.

Abstract: A connector component (102) is provided for assembly into a material processing torch head. The connector component (102) comprises a generally cylindrical body (104) that includes a proximal end (106) and a distal end (108) defining a longitudinal axis. At least two thread regions (112) are disposed at a radial location on a surface of the body near the proximal end. Each thread region includes at least one thread (114) disposed on the surface of the body. In addition, at least two non-thread regions (116) are oriented longitudinally at a radial location on the surface of the body (104).

Abstract: A double nozzle for a laser processing head includes an inner body portion having an interior surface defining a first bore, and an exterior surface, the bore aligned with a central longitudinal axis of the body. The double nozzle includes an outer body portion having an interior surface defining a second bore that is substantially aligned to the longitudinal axis. The outer body portion is matingly engaged with a region of the exterior surface of the inner body portion. The region between the exterior surface of the inner body portion and the interior surface of the outer body portion defines at least six coaxial fluid flow paths through an interior annular flow volume of the double nozzle. Each fluid flow path is defined at least in part by a corresponding feature formed in at least one of the inner body portion or the outer body portion.

Abstract: In some aspects, methods for preserving a usable life of a plasma arc electrode consumable installed in a plasma arc torch can include measuring a characteristic of an electrical signal being provided to the torch to generate a plasma arc between the torch and a workpiece to be processed; monitoring the characteristic during operation of the torch over a time period; comparing the characteristic to a threshold value; and, responsive to determining that a measured characteristic meets and/or exceeds the threshold value, initiating an arc extinguishing sequence to preserve the life of the electrode.

Abstract: A coolant tube for a plasma arc torch is provided. The coolant tube includes an elongated coolant tube body including a distal portion configured to engage an electrode and a proximal portion configured to engage a body of the plasma arc torch. The coolant tube also includes a first electrically conductive element coupled to the distal portion of the elongated coolant tube body. The first electrically conductive element is configured to physically contact an electrode. The coolant tube further includes a second electrically conductive element coupled to the proximal portion of the elongated coolant tube body. The second electrically conductive element is configured to physically contact the body of the plasma arc torch. The elongated coolant tube body defines a current path and a fluid path between the body of the plasma arc torch and the electrode.

Abstract: A liquid-cooled consumable cartridge for a plasma arc torch is provided. The cartridge includes (i) an electrode, (ii) a swirl ring with a first outer retaining feature and a second outer retaining feature on an exterior surface, where the electrode is secured to the swirl ring, and (iii) a nozzle with an inner retaining feature on an interior surface, where the inner retaining feature of the nozzle is mated with the first outer retaining feature of the swirl ring. The cartridge also includes a cartridge frame with an inner retaining feature on an interior surface and an outer retaining feature on an exterior surface. The inner retaining feature of the cartridge frame is mated with the second outer retaining feature of the swirl ring. The cartridge further includes a shield with an inner retaining feature on an interior surface mated with the outer retaining feature of the cartridge frame.

Abstract: The invention features a double nozzle for a laser processing head and related methods for cutting a workpiece. The double nozzle includes an inner body portion having an interior surface defining a first bore, a first exterior circumferential surface disposed toward a distal end of the inner body portion, and a second exterior circumferential surface disposed toward a proximal end of the inner body portion. The second exterior circumferential surface is shaped to mate and align with the laser processing head. The double nozzle also includes an outer body portion having an interior surface defining a second bore. The outer body portion matingly engages with the first exterior circumferential surface of the inner body portion and is isolated from direct alignment contact with the laser processing head. The inner body portion and the outer body portion are aligned to define a coaxial fluid flow path therethrough.

Abstract: A consumable cartridge for a liquid-cooled plasma arc torch is provided. The consumable cartridge comprises a cartridge frame including a proximal end having an end surface, a distal end and a body having a central longitudinal axis extending therethrough. The cartridge configured to form a radio-frequency identification (RFID) interface with a torch head. The consumable cartridge also comprises an arc emitter and an arc constrictor affixed to the cartridge frame at the distal end and an RFID mounting feature formed on or in the cartridge frame adjacent to the end face. The RFID mounting feature is non-concentric with the central longitudinal axis of the body. The consumable cartridge further comprises an RFID tag disposed in or on the RFID mounting feature for transmitting information about the cartridge to a reader device in the torch head when the cartridge is connected to the torch head.

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: An electrode for a plasma arc torch includes a generally cylindrical elongated body formed of an electrically conductive material. The elongated body includes a proximal end that connects to a power supply and a distal end that receives an emissive element. The electrode can include a flange that is disposed about a surface relative to the distal end of the elongated body, extends radially from the surface of the elongated body, and is utilized to establish a uniform gas flow distribution of a plasma gas flow about the distal end of the elongated body. The electrode can include a contact element that is in electrical communication with the proximal end of the electrode. The contact element includes seating portion that has an outer width that is greater than the outermost diameter of the electrode body and is configured to position the contact element within the plasma arc torch.

Abstract: The invention features methods and apparatuses for thermally regulating a laser processing head. A thermal regulation device includes a body shaped to matingly engage a laser processing nozzle and to define a fluid flow boundary of a liquid flow passage between the body and an exterior surface of the laser processing nozzle when the thermal regulation device is affixed to the laser processing nozzle. The thermal regulation device also includes an inlet formed in a first end of the body and configured to provide liquid to the liquid flow passage, the liquid remaining external to an exterior surface of the laser processing nozzle. The thermal regulation device also includes an outlet formed in a second end of the body opposite the first end. The outlet is configured to exhaust liquid from the liquid flow passage.

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: The invention features an inner cap for a liquid-cooled plasma arc torch. The inner cap includes a body having a longitudinal axis, a first end, and a second end. The first end includes an annular portion disposed proximate a torch tip. A liquid passage is formed within the body, is shaped to convey a liquid therethrough, and has a first set of ports formed in the annular portion. A gas passage is formed within the body, is shaped to convey a gas therethrough, and includes a second set of ports formed in the annular portion. The annular portion is configured such that subsets of ports in the first set of ports direct the liquid in a radial direction with respect to the longitudinal axis and alternate, in a rotational direction about the longitudinal axis, with subsets of ports in the second set of ports.