Abstract: A computerized method is provided for automatically determining at least one characteristic of a workpiece for processing by a plasma arc processing system. The method includes electrically connecting the workpiece to the plasma arc processing system that includes a plasma arc torch. A distal tip of the plasma arc torch is configurable to be positioned proximate to the workpiece. The method includes supplying, by the plasma arc processing system, an electrical current with a low amperage to the workpiece, the low amperage current insufficient to cut the workpiece, and monitoring, by the plasma arc processing system, a path of the electrical current relative to the workpiece. The method further includes determining, by the plasma arc processing system, the at least one characteristic of the workpiece based on the electrical current path monitored.

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 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: An adapter for a plasma arc torch comprising a torch body is provided. The adapter includes a body defining a longitudinal axis between a proximal end and a distal end and at least one protruding portion extending from the proximal end of the body. The at least one protruding portion is configured to be inserted into a cavity of the torch body to physically engage a switch inside of the cavity. The engagement of the switch is adapted to indicate installation of a consumable component in the plasma arc torch.

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: An adapter for a plasma arc torch comprising a torch body is provided. The adapter includes a body defining a longitudinal axis between a proximal end and a distal end and at least one protruding portion extending from the proximal end of the body. The at least one protruding portion is configured to be inserted into a cavity of the torch body to physically engage a switch inside of the cavity. The engagement of the switch is adapted to indicate installation of a consumable component in the plasma arc torch.

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: 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: 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 computerized method is provided for automatically determining at least one characteristic of a workpiece for processing by a plasma arc processing system. The method includes electrically connecting the workpiece to the plasma arc processing system that includes a plasma arc torch. A distal tip of the plasma arc torch is configurable to be positioned proximate to the workpiece. The method includes supplying, by the plasma arc processing system, an electrical current with a low amperage to the workpiece, the low amperage current insufficient to cut the workpiece, and monitoring, by the plasma arc processing system, a path of the electrical current relative to the workpiece. The method further includes determining, by the plasma arc processing system, the at least one characteristic of the workpiece based on the electrical current path monitored.

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, 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 adapter for a plasma arc torch comprising a torch body is provided. The adapter includes a body defining a longitudinal axis between a proximal end and a distal end and at least one protruding portion extending from the proximal end of the body. The at least one protruding portion is configured to be inserted into a cavity of the torch body to physically engage a switch inside of the cavity. The engagement of the switch is adapted to indicate installation of a consumable component in the plasma arc torch.

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 method for visually communicating material processing parameters to an operator of a torch system. The method includes receiving data related to a material processing operation from at least one sensor of a torch system and at least one camera disposed on a protective helmet. The method further includes processing the data into information relating to a set of material processing parameters and converting the information into visual data compatible with a display disposed on or within the protective helmet. The method also includes providing the visual data to a region of the display for viewing by an operator of the torch system. The region of the display is within a field of view of the operator in order to visually communicate the information to the operator of the torch system.

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: 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: 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: 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.