Abstract: A welding machine includes a main transformer having first primary winding, a second primary winding, and a secondary winding; a power board configured to receiving mains power and to convert the mains power to converted power to be input to the main transformer; a switch having an input connected to an output of the power board, a first output connected to the first primary winding of the main transformer, and a second output connected to the second primary winding of the main transformer; and a control board configured to control the switch to be arranged in one of (i) a first configuration in which the converted power is supplied, in series, to a first primary winding of a main transformer switching and a second primary winding of the main transformer, and (ii) a second configuration in which the converted power is supplied, in parallel, to the first primary winding of the main transformer and to the second primary winding of the main transformer.

Abstract: Provided herein is a quick disconnect torch handle for use in a plasma arc system. In one approach, the plasma arc system includes a lead having a first end connected to a power source and a second end connected to a torch handle. The quick disconnect is located at a proximal end of the torch handle, and may include at least one signal connection, a pilot connection, a fluid connection, and a main power connection. The fluid and power connection may be formed by a connection between a main power socket and a conductive conduit. Specifically, the main power socket includes a conductive spring and an O-ring encircling an interior bore thereof. Removal of the conductive conduit from the main power socket causes the fluid connection to break between the O-ring and the conductive conduit, and then the power connection to break between the conductive spring and the conductive conduit.

Abstract: A heat extraction assembly or apparatus includes a cooling cassette and a component coupled to a top surface of the cooling cassette. The cooling cassette may include an inlet, an outlet, and a cooling cavity disposed within the top surface of the cooling cassette. The cooling cavity may be in fluid communication with inlet and the outlet. The component may be coupled to the top surface of the cooling cassette proximate to the cooling cavity such that the component at least partially defines a boundary of the cooling cavity. Coolant flowing through the cooling cassette from the inlet to the outlet may directly contact the component at the cooling cavity in order to provide a cooling effect to regulate a temperature of the component.

Abstract: A flow gauge scale assembly includes a first scale and a second scale. The first scale is configured to be disposed in a first radial position on a generally cylindrical flow tube through which a ball can move to indicate a flow rate of a flow of gas. The second scale is configured to be disposed in a second radial position that will be at least partially optically misaligned from the first scale when the flow gauge scale assembly is installed in the generally cylindrical flow tube.

Abstract: A coradial connector is disclosed. The coradial connector system includes a plug and socket. The plug has a plug housing, a plug process conductor, a plug signal conductor disposed coaxially with the plug process conductor, and a plug insulator disposed coaxially with the plug process conductor, between the plug process conductor and signal conductor. The socket includes a socket housing, a socket process conductor, a socket signal conductor disposed coaxially with the socket process conductor, and a socket insulator disposed coaxially with the socket process conductor, between the socket process conductor and signal conductor.

Abstract: A torch having first and second housing portions may contain multiple adjustment features such as an adjustable length, an adjustable pivot angle of the second housing portion, and an adjustable rotational angle of the second housing portion. The second housing portion may be both slidably and rotationally coupled to the first housing portion. The second housing portion may be configured to slide along a longitudinal axis of the torch to adjust a length of the torch. The second housing portion may be further configured to rotate about the longitudinal axis of the torch to adjust the rotational orientation of the second housing portion with respect to the first housing portion. At least a section of the second housing portion may be configured to pivot about a transverse axis with respect to the first housing portion, the transverse axis being transverse to the longitudinal axis of the torch.

Abstract: An electromagnetic component assembly disposed in a power source of a welding or cutting system. The electromagnetic component assembly includes a core and a tubular winding. The tubular winding is placed near or around the core and conducts a current for an electromagnetic operation. The tubular winding includes a passageway for a process fluid, an inlet, at one end of the passageway, that receives the process fluid, and an outlet, at another end of the passageway, that directs the process fluid downstream toward a torch assembly. The passageway enhances cooling of the electromagnetic component assembly as the process fluid travels through the passageway from the inlet to the outlet.

Abstract: Provided for herein is an apparatus that includes a machine-side connection housing. The machine-side connection housing includes a machine-side connection configured to provide a welding consumable or an electrical connection to a welding/cutting torch head. The apparatus also includes a fume extraction connection housing that includes a fume extraction connection to a fume extraction device. A flexible connection is arranged between the machine-side connection housing and the fume extraction connection housing. A seal that includes a first orifice is arranged between the fume extraction connection and the machine-side connection. Finally, a conduit, configured to connect the machine-side connection to the welding/cutting torch head, is arranged to pass through the first orifice, through the flexible connection and through the fume extraction connection housing to the welding/cutting torch head.

Abstract: Consumables for cutting torches include consumables that define a parallel plasma channel and/or a steep, elongated plasma chamber. Additionally, the consumables may define smooth, rounded edges between different geometries of the plasma channel (e.g., at transitions between straight and angles sections) and/or between the plasma channel and the plasma chamber. That is, the consumables may provide a plasma channel that does not converge, diverge, or define any corners and/or a plasma channel that transitions to the plasma chamber without defining any corners.

Abstract: Recognizing interchangeable torch components, such as consumables, for welding and cutting torches includes determining that one or more interchangeable torch components installed in an operative end of a torch are genuine. Operational parameters for the one or more interchangeable torch components can also be determined. When the one or more interchangeable torch components are determined to be genuine, an indicator assembly can be activated to provide a first indication. When the operational parameters are implemented at a power supply connected to the torch, the indicator assembly can be activated to provide a second indication.

Abstract: Consumables for cutting torches include a distributor, an electrode, and a nozzle. The distributor defines a plurality of ports that extend from an internal cavity of the distributor to an exterior surface of the distributor. The electrode is disposed within and irremovably, fixedly coupled to the distributor. The nozzle defines at least one set of passageways that direct gas into a gap defined between the electrode and the nozzle, the nozzle being irremovably, fixedly coupled to the distributor.

Abstract: A welding apparatus is configured to obtain values of one or more real-time operating parameters associated with the welding apparatus. Using the values of the one or more operating conditions, the welding apparatus is configured to determine a dynamic duty cycle of the welding apparatus, given the present/current operating conditions of the welding apparatus.

Abstract: A power supply includes a casing; an AC-to-DC converter; an inverter electrically coupled to the AC-to-DC converter; a transformer having a primary side and a secondary side, wherein the inverter is electrically coupled to the primary side of the transformer; an output rectifier electrically coupled to the secondary side of the transformer; a fan, disposed in the casing and configured to remove heat from the casing generated by the AC-to-DC converter, the inverter and the output rectifier; and a fan controller configured to control when the fan is operational, wherein the fan controller is configured to execute a state machine that is configured to change states based at least on a dynamically adjustable counter.

Abstract: A push-pull welding torch is disclosed. The welding torch includes a torch body and a unitary block disposed in the torch body. The unitary block includes an inlet channel, an outlet channel, and a gas channel fluidly connected to the inlet channel and the outlet channel. The inlet and outlet channels may receive a weld filler material. A quick release tensioner assembly is disclosed for a welding torch that may include a swing arm configured to mount to a drive block assembly via a pivot, a lever disposed between the swing arm and block assembly when the quick release tensioner assembly is mounted to the drive block assembly, a fastener disposed through the swing arm and lever, and a resilient member disposed between the fastener and swing arm. The fastener may be configured to engage the drive block when the quick release assembly is mounted to the drive block.

Abstract: Apparatus and methods associated with operating a plasma torch are disclosed. According to some implementations, the apparatus and methods involve the delivery of a process gas to a shuttle valve at first and second pressures for the purpose of altering an axial position of a valve element located inside the shuttle valve. The shuttle valve is configured such that at different axial positions of the valve element the flow of process gas into the plasma torch is altered.

Abstract: A plasma torch that includes an electrode having an exterior surface and a tip having an interior surface spaced apart from and facing the exterior surface of the electrode. A process gas flow channel located being located between the exterior surface of the electrode and the interior surface of the tip. A thermoelectric cooler having a cold plate and a hot plate is disposed between the exterior surface of the electrode and the interior surface of the tip with the cold plate being thermally connected to the exterior surface of the electrode. According to some implementations, electrical power is deliverable to the thermoelectric cooler only up electrical power being supplied to the electrode.

Abstract: A method of assembling an electrode by securing together an emitter of the electrode inside an emitter holder while at the same time securing together the emitter holder inside a distal end of a tubular body of the electrode. According to one implementation the securing together includes simultaneously applying a proximally directed force to the emitter and a distally directed force to the emitter holder to cause a bulging of the emitter inside the emitter holder and a bulging of the emitter holder inside the distal end of the tubular body.

Abstract: A torch for performing TIG welding is disclosed. The torch includes an electrode for a TIG/GTAW welding operation with an inert gas and an active gas. In accordance with at least one embodiment of the present invention, the torch includes a torch body having a first fluid channel and a second fluid channel, an electrode assembly disposed in the torch body, a nozzle concentric with the electrode and a shield cap concentric with the nozzle. An angle between a longitudinal axis of the electrode assembly and an outer surface of at least one of the electrode holder and the electrode is about nine degrees.