Abstract: Computer numerical control (CNC) machines execute a process automatically unless a condition occurs that triggers one or more alarms that terminate the process. Accordingly, CNC laser cutting post-process inspection is usually non-existent or minimal. However, with CNC laser welding it is more common for a visual inspection or automated inspection to be performed to verify that the process was completed. Similar issues occur when single piece parts are required in addition to which executing an offline inspection requires additional complexity in re-working any piece part. Accordingly, embodiments of the invention provide enterprises and facilities employing CNC laser cutting/welding systems with a means to overcome these limitations. Further, providing intuitive user interfaces allows the user to perform tasks directly through a touch screen interface they are viewing the work piece/piece-parts upon.

Abstract: Computer (or computerized) numerical control (CNC) tools are employed globally. Whilst these may be purchased with an initial set of configurations users must establish any other configurations themselves leading to potentially every CNC tool being configured slightly differently for the same process requirement even before considering new materials, tool elements etc. Accordingly, users and manufacturers would benefit from access to updated process parameters for machine tools that reflect scenarios encountered in manufacturing operations that are new or lead to improved tolerances, yields, reducing process time etc. However, users are not going to employ just any set of parameters given to them as these may damage their CNC tool or tool elements. Embodiments of the invention provide a subscription service providing access to verified settings where the verification is performed by the machine tool manufacturer or machine tool element manufacturer.

Abstract: An engine driven welding machine that includes a frame with lower tubular portions that extend across the ends of the frame. The lower tubular portions make it easier to lift the engine driven welding machine onto an elevated surface, such as the bed of a truck. The frame may include two different lifting portions that extend across the same side or end of the frame at different levels. For example, two tubular portions of the frame may extend generally horizontally across the same side or end of the frame to provide two lifting areas at different levels of the frame.

Abstract: A device finder locates devices connected to a network that do not have a network address assigned to them by sending a broadcast message to all connected devices independent of network address. The broadcast message requests identification information from each device. The devices on the network, including any devices that do not have a network address, send a broadcast message in response that includes device identification information. Once the identification information has been received, a network address can be assigned to the device.

Abstract: A weld data acquisition system collects data from the weld controller according to user selected collection parameters. The weld data acquisition system is able to transmit the data at high frequency to a weld data software utility that provides a user interface.

Abstract: A system and method provides a distributed welding architecture in accordance with the present invention. The system includes a welder operatively coupled to a server and a network interface to enable a network architecture, the network architecture serving a network that communicates with at least one remote system. The remote system includes at least one remote interface to communicate with the network architecture, wherein the remote system accesses at least one HTTP socket to establish web communications with the welder and loads at least one application from the welder. The remote system accesses at least one Welding Application socket via the at least one application to exchange information between the welder and the remote system, wherein the at least one application includes at least one of a weld configuration component, a weld monitoring component, and a weld control component to interact with the distributed welding system.

Abstract: A plasma torch comprises a tubular nozzle having an end wall and an electrode in the nozzle having a nose end facing the end wall. The nose end and end wall provide a plasma gas chamber, and the end wall has a gas chamber outlet opening extending axially therethrough. The gas chamber has an entrance radially outwardly of the outlet opening and the end wall has a plurality of arcuate ribs thereon circumferentially spaced apart about said outlet opening and providing a plurality of arcuate gas directing channels for radially guiding the flow of plasma gas in a swirling flow pattern from the entrance to the outlet opening. The nozzle and nozzle mounting components provide an improved arrangement for cooling the torch tip and producing a gas shield about the plasma jet.

Abstract: A method of gas shielded arc welding steel railroad rails spaced from each other to define a transverse gap, which method comprising the steps of providing an elongated steel barrier plate wedged into said gap at the bottom of the spaced rails and filling gap above said steel barrier plate with a molten steel from an advancing filler metal electrode by a gas shielded electric arc welding process initiated by an arc between the electrode and the barrier plate.

Abstract: Welding apparatus having selectively operable local and remote current setting devices for selecting and controlling the welding current to be applied across an electrode and workpiece at a welding arc includes a control circuit for sensing the connection and disconnection of the remote current setting device thereto and respectively setting a remote and local mode of welding current control.

Abstract: A multi-stage down chopper for arc welding by creating current flow between an electrode and a workpiece, the chopper includes a D.C. input source, a first switching stage, with a first switch device and a first choke, this first stage selectively connects the D.C. input source across the electrode and workpiece at a controlled duty cycle and switching rate and a second switching stage, with a second switch device and a second choke, the second stage also selectively connects the D.C. input source across the electrode and workpiece at the aforesaid controlled duty cycle and switching rate, wherein the chopper is improved by the first and second chokes onto a single core and by providing a minimum current override feedback circuit.

Abstract: A drag cup for a plasma arc torch is mounted on a sleeve member of the torch tip having a conical outer surface portion converging toward the torch nozzle and electrode assembly. The drag cup includes a mounting end, a conical portion extending along the conical portion of the sleeve member, and an end radially spaced from and surrounding the torch nozzle and including an end wall spaced axially outwardly of the end of the nozzle and having an opening therethrough coaxial with the plasma jet outlet orifice in the nozzle. The opening through the end wall of the drag cup is 3 to 6 times the size of the nozzle orifice and is large enough to provide a shielding gas flow about the plasma jet without disturbing the jet and, at the same time is small enough to protect the nozzle against molten metal blow-back through the opening.

Abstract: A circuit for providing D.C. current from a power source having a current regulating input to a plasma system including an electrode and a nozzle with a plasma arc opening exposing the electrode to a juxtapositioned workpiece, which circuit has a first circuit branch for creating a pilot arc across the electrode and nozzle, a second circuit branch for creating an operative plasma arc across the electrode and the workpiece, a current sensor in the second circuit branch for sensing the workpiece current in the second circuit branch, a switch for opening the first circuit branch when the sensed workpiece current exceeds a preselected current to transfer the pilot arc to the operative plasma arc, a system for regulating the current in the first circuit branch until the arc transfer and a circuit for increasing the pilot current supplied from said power source to first circuit branch when sensed workpiece current exceeds a low threshold value.

Abstract: An arc retract circuit for use in a plasma arc system with a torch having an electrode and a nozzle, a power supply for providing a D.C.

Abstract: An inlet guide mechanism for a wire feeder used with an arc welder wherein the guide mechanism comprises: a housing with a wire guiding passageway having an entrance end and an exit end for directing welding wire to the wire feeder, a plurality of closely spaced spherical guide balls and a support structure for rotatably mounting the guide balls in a pattern circumferentially around the entrance end of the wire passageway whereby a wire entering the passageway engages the spherical surface of at least one of the guide balls.

Abstract: A plasma system including a torch having an electrode and nozzle with a plasma arc opening exposing the electrode to a workpiece and an input transformer with a primary winding network and a secondary winding network driven by the primary winding network, a first circuit driven by the secondary winding network for creating a pilot arc across the electrode and nozzle, a second circuit driven by the secondary winding network for creating a plasma arc across the electrode and the workpiece and a switch for selectively shifting between the first circuit and the second circuit is improved in a manner where the secondary winding network comprising a first winding with a first effective number of turns for driving the first circuit and a second winding with a second effective number of turns for driving the second circuit, and the first and second effective number of turns can be different to operate the torch by different windings during the pilot arc mode and the cutting mode.

Abstract: A drum with a cylindrical body having an upper end and a lower end and a circular bottom wall secured across said lower end includes a cylindrical core having an inner cylindrical surface, an upper end and a lower end which is fixedly secured to the bottom wall to define an annular wire receiving space between said core and said body of said drum wherein an improved wire biasing mechanism is provided for applying a downward force against wire in the wire receiving space, by a generally flat pressure ring resting on the wire and an elongated, elastic element connected to a loop element attached to the lower end of said core for pulling the pressure ring downwardly.

Abstract: Apparatus is provided for feeding consumable welding electrode wire from a supply reel to a welding gun and comprises pairs of drive roll and drive gear assemblies associated with a wire guide plate assembly for feeding the wire along a linear path through the apparatus. The drive rolls are removably mounted on corresponding support shaft structures by a split snap ring component. The guide plate assembly comprises a guide plate having a guide slot milled therein and a cover plate overlying the slot to provide a wire guide passageway through the apparatus which is constantly linear and aligned with the wire drive rolls.

Abstract: A plasma arc torch comprises relatively displaceable electrode and nozzle components having first and second positions relative to one another in which the electrode respectively contacts the nozzle and is spaced an operating distance therefrom. Arrangements are disclosed for relatively displacing the electrode and nozzle between the first and second positions thereof with a pre-determined force of engagement therebetween in the first position, and without having to interrupt the flow of arc gas and/or the flow of arc current during such relative displacement. A torch start up safety test procedure is performed by sequentially displacing the electrode and nozzle between the two positions thereof, sensing for appropriate open and closed circuit conditions therebetween, and enabling the creation of a pilot arc only when a pre-determined sequence of circuit conditions is sensed.

Abstract: Welding apparatus having selectively operable local and remote current setting devices for selecting and controlling the welding current to be applied across an electrode and workpiece at a welding station includes a control circuit for sensing the connection and disconnection of the remote current setting device thereto and respectively setting a remote and local mode of welding current control.

Abstract: Methods are disclosed for gas shielded arc welding steel railroad rails spaced from each other to define a transverse gap, one of which methods comprises the steps of providing an elongated steel barrier plate wedged into the gap at the bottom of the spaced rails and filling gap above said steel barrier plate with a molten steel from an advancing filler metal electrode by a gas shielded electric arc welding process initiated by an arc between the electrode and the barrier plate. A second method comprises the continuous sequential laying of weld beads in the gap between rail heads along paths extending in laterally opposite directions for the beads to have first ends extending outwardly of an edge of the head in cantilever relationship thereto and which first ends are vertically thicker than second ends of the beads which are spaced from the first ends in the direction toward the opposite edge of the head.