Abstract: Systems and methods for providing an improved start in a welding process are provided. The system may include a power circuit and a control circuit. The power circuit can generate a welding output power. The control circuit may be in communication with the power circuit to control, during the start of the welding process, at least one welding parameter until the control circuit determines that welding energy output exceeds an energy output threshold.

Abstract: An electrode for a plasma arc torch includes a conductive body and a plurality of emissive inserts. The conductive body includes a proximal end portion, a distal end portion and a cavity extending from the proximal end portion to the distal end portion. The distal end portion defines a distal end face. The plurality of emissive inserts extend through the distal end face. The conductive body further defines a dimple extending into the distal end face and at least partially into the emissive inserts. The dimple is positioned concentrically about a centerline of the conductive body.

Abstract: A method of operating a plasma arc torch is provided that includes directing a first portion of gas into a plasma chamber, directing a second portion of the gas to initiate a pilot arc in the plasma chamber, and redirecting the second portion of the gas to form a shield gas flow rather than venting the second portion to atmosphere. A plasma arc torch for this method includes a start cartridge disposed between an electrode and a tip for initiating the pilot arc. The start cartridge defines at least one redirect gas passageway in fluid communication with a shield gas passageway. The second portion of gas is redirected through the at least one redirect gas passageway and into the shield gas passageway.

Abstract: A modular power supply is provided. The modular power supply includes multiple inverters and a controller. Each inverter is configured to receive an input voltage and provide an output to a load. The controller is configured to provide a synchronization signal to each inverter of the plurality of inverters.

Abstract: A power supply is provided. The power supply in one form includes a rectifier circuit, a capacitor and an RC circuit. The rectifier circuit is configured to receive a three phase AC signal. The rectifier circuit has a positive output connected to a positive node and a negative output connected to a negative node. The capacitor is connected in parallel with the rectifier circuit between the positive node and the negative node. The RC circuit includes a resistor and capacitor connected in electrical series connection where the resistor and capacitor are connected between the positive node and the negative node in parallel with the first capacitor and the rectifier circuit.

Abstract: A device for controlling a plasma arc is provided that includes a plurality of magnetic poles disposed around a distal end portion of a plasma arc torch. A plurality of electrical coils are wound around a proximal end portion of each of the plurality of magnetic poles, and a plurality of lead wires are connected to the plurality of electrical coils. A control system for controlling a current supplied to the plasma arc torch through the lead wires is also provided that changes at least one of a strength of a magnetic field produced by the magnetic poles, a polarity of the magnetic poles, and a movement of a magnetic force between the plurality of magnetic poles, such that a size and location of the plasma arc is controlled.

Abstract: A shield device for a plasma arc torch includes an inner shield member defining an inner auxiliary gas chamber and an outer shield member surrounding the inner shield member. An outer auxiliary gas chamber is defined between the inner shield member and outer shield member. The shield device allows an auxiliary gas flow to be split into a first flow of auxiliary gas through the inner auxiliary gas chamber and a second flow of auxiliary gas through the outer auxiliary gas chamber. The inner shield member and the outer shield member are configured to be mounted to the plasma arc torch as an integral unit.

Abstract: An electrode for a plasma arc torch is provided by the teachings of the present disclosure. In one form, the electrode includes a conductive body, a plurality of deformed emissive inserts, and a dimple. In one form, the plurality of emissive inserts are concentrically nested about the centerline of the conductive body, and the dimple is positioned concentrically about a centerline of the conductive body. The plurality of emissive inserts and the dimple increase the life of the electrode.

Abstract: A shield device for a plasma arc torch includes an inner shield member defining an inner auxiliary gas chamber and an outer shield member surrounding the inner shield member. An outer auxiliary gas chamber is defined between the inner shield member and outer shield member. The shield device allows an auxiliary gas flow to be split into a first flow of auxiliary gas through the inner auxiliary gas chamber and a second flow of auxiliary gas through the outer auxiliary gas chamber. The inner shield member and the outer shield member are configured to be mounted to the plasma arc torch as an integral unit.

Abstract: A method of manufacturing an electrode for use in a plasma arc torch is provided that includes forming a conductive body to define a proximal end portion, a distal end portion, a distal end face disposed at the distal end portion, a central cavity, and a central protrusion disposed within the central cavity near the distal end portion. A plurality of emissive inserts are inserted through the distal end face and into the central protrusion. The plurality of emissive inserts are pressed into the central protrusion and both a proximal end portion of the central protrusion and the plurality of emissive inserts are deformed such that the plurality of emissive inserts extend radially and outwardly from the distal end portion at an angle relative to the distal end portion.

Abstract: A consumable component for use in a plasma arc torch is provided that includes a body having a distal end face and at least one extension disposed within the distal end face. The extension is configured to maintain a predetermined torch height above a workpiece during drag cutting operations, for either manual or automated plasma cutting operations.

Abstract: A plasma arc torch is provided that includes a torch body and a torch height controller. The torch height controller includes a movable part mounted to the torch body and a fixed part connected to a robotic arm. The movable part and the torch body are biased toward a workpiece and are translational relative to the fixed part.

Abstract: A method of starting a plasma arc torch is provided that includes directing a pre-flow gas and a start shield gas through the plasma arc torch during generation and transfer of a plasma arc, and switching from the pre-flow gas to a plasma gas, and switching from the start shield gas to a primary shield gas after transfer of the plasma arc to a workpiece. A method of stopping a plasma arc torch is also provided that includes directing a plasma gas and a primary shield gas through the plasma arc torch during steady-state operation, and switching from the primary shield gas to a stop shield gas during ramp down of an operating current.

Abstract: A system and method is provided for calculating a power output and coordinating the reduction of voltage and wire speed; if the computed power output does exceed the power supply capacity.

Abstract: A plasma arc torch includes an electrode, a tip, a third element, and a secondary power circuit. The electrode is disposed within the plasma arc torch and adapted for electrical connection to a cathodic side of a power supply. The tip is positioned distally from the electrode and adapted for electrical connection to an anodic side of the power supply during piloting. A plasma chamber is formed between the electrode and the tip. The third element is disposed near a proximal end of the plasma chamber. The secondary power circuit is disposed proximate the plasma arc torch and in electrical communication with the third element. The secondary power circuit is configured to generate a high voltage pulse on the third element using input to secondary power circuit to initiate a first arc to start the plasma arc torch.

Abstract: Systems and methods for providing an improved start in a welding process are provided. The system may include a power circuit and a control circuit. The power circuit can generate a welding output power. The control circuit may be in communication with the power circuit to control, during the start of the welding process, at least one welding parameter until the control circuit determines that welding energy output exceeds an energy output threshold.

Abstract: A system and method for generating a weld are provided. The system receives a selection of a magnitude of a voltage. The system selects a first weld control algorithm when the magnitude of the voltage is in a first range of values. The system may also select a second weld control algorithm when the magnitude of the voltage is in a second range of values. The system may generate welding output power based on the first and second weld control algorithms.

Abstract: A system and method for generating a weld are provided. A power circuit in communication with a control circuit generates welding output voltage. A voltage reducing circuit in communication with the power circuit generates a reduced output voltage relative to the welding output voltage if the system determines that the welding process is idle for the predefined period of time. The welding output voltage is restored from the reduced voltage if the welding process is restarted.

Abstract: Systems and methods for providing an improved start in a welding are provided. The system may include a power circuit and a control circuit: The power circuit may generate welding output power for a welding process. The control circuit may control the start of the welding process, for example, by generating a current pulse.

Abstract: A component for use in a plasma arc torch is provided that includes an orifice that defines a continuously changing cross-sectional size along the length of a surface of the orifice from an inlet portion to an outlet portion. The surface extends along the component and directs a flow of shield gas at a predetermined angle to result in a specific pierce or cut location on a workpiece. In one form, the component is a shield cap. The continuously changing surface may be convergent, divergent, or a combination of convergent and divergent according to the principles of the present disclosure. Additionally, the shield cap may comprise a single, unitary piece or alternately a plurality of pieces or components.