Abstract: Approaches herein provide a system for determining whether one or more consumable parts of a plasma device has been removed or replaced while the plasma device and associated sensors lie dormant or are no longer receiving data, e.g., when the plasma device is power-off. The approaches herein determine whether certain types of data stored in a controller's memory are still valid, for example, for the purposes of determining degradation and/or end-of-life of the consumable parts. In the case that one or more consumable parts has been serviced or replaced, the data stored in the controller memory may no longer be considered valid for the consumable part(s). In one approach, the controller determines a status of a switch or a conformal film in the device following start-up, and determines, based on the position of the switch or the conformal film, whether the consumable part has been removed or replaced.

Abstract: A wire feeder for a welding system has an automatically generated clamping force on welding wire. The wire feeder includes a drivestand having a lower feed roll. An upper feed roll is positionable adjacent to the lower roll, the upper and lower rolls being configured to receive a wire therebetween. A motor includes an output motor shaft, the lower roll being connected to the output motor shaft. A connecting arm is attached to the upper roll, and attached to the drivestand at a first end. An arm is attached to the connecting arm at a second end, and coupled to the motor. The arm and the connecting arm draw the upper roll towards the lower roll in response to a torque applied by the motor, such that the upper and lower rolls generate a clamping force for the wire, the clamping force being proportional to a torque of the motor.

Abstract: Approaches herein provide a system for determining whether one or more consumable parts of a plasma device has been removed or replaced while the plasma device and associated sensors lie dormant or are no longer receiving data, e.g., when the plasma device is power-off. The approaches herein determine whether certain types of data stored in a controller's memory are still valid, for example, for the purposes of determining degradation and/or end-of-life of the consumable parts. In the case that one or more consumable parts has been serviced or replaced, the data stored in the controller memory may no longer be considered valid for the consumable part(s). In one approach, the controller determines a status of a switch or a conformal film in the device following start-up, and determines, based on the position of the switch or the conformal film, whether the consumable part has been removed or replaced.

Abstract: Approaches herein provide a system for determining whether a consumable part of a plasma device has been removed or replaced while the plasma device and associated sensors lie dormant or are no longer receiving data, e.g., when the plasma device is power-off. The approaches herein determine whether certain types of data stored in a controller's memory are still valid, for example, for the purposes of determining degradation and/or end-of-life of the consumable parts. In the case that one or more consumable parts has been serviced or replaced, the data stored in the controller memory may no longer be considered valid for the consumable set. In one approach, the controller determines a status of an indicator in the device following start-up, and determines, based on the status of the indicator, whether the consumable part has been removed or replaced.

Abstract: Embodiments of the present invention are related to an electrode for a plasma arc torch, the electrode comprising a generally tubular outer wall, an end wall, and a protrusion. The end wall is joined to a distal end of the outer wall and supports an emissive element in a generally central region. The protrusion extends from the generally central region of the end wall and is configured to connect with an electrode holder by a releasable connection, wherein the protrusion is configured such that at least one coolant passage forms between the protrusion and the electrode holder when the electrode is connected with the electrode holder. In some embodiments, the releasable connection comprises a threaded connection, wherein the protrusion is threaded to releasably connect to a threaded coolant tube of the electrode holder. In other embodiments, at least one coolant passage is defined by the threaded connection.

Abstract: A system for supplying fluids to a plasma arc torch includes a single-gas power supply for regulating electrical power to the torch and for regulating supply of a first fluid to the torch, a flow regulator for regulating supply of a second fluid to the torch, and a first pressure-actuated valve disposed between the flow regulator and the torch. The valve shuts off supply of the second fluid to the torch when the first valve is closed and allows the second fluid to be supplied when the first valve is open. The first valve is opened by pressure of the first fluid supplied to the torch and closed when the first fluid is not supplied to the torch. A second pressure-actuated valve may be provided in the supply line for the first fluid, which is opened by pressure of the second fluid being supplied to the torch.

Abstract: Embodiments of the present invention are related to an electrode for a plasma arc torch, the electrode comprising a generally tubular outer wall, an end wall, and a protrusion. The end wall is joined to a distal end of the outer wall and supports an emissive element in a generally central region. The protrusion extends from the generally central region of the end wall and is configured to connect with an electrode holder by a releasable connection, wherein the protrusion is configured such that at least one coolant passage forms between the protrusion and the electrode holder when the electrode is connected with the electrode holder. In some embodiments, the releasable connection comprises a threaded connection, wherein the protrusion is threaded to releasably connect to a threaded coolant tube of the electrode holder. In other embodiments, at least one coolant passage is defined by the threaded connection.

Abstract: Embodiments of the present invention are related to an electrode for a plasma arc torch, the electrode comprising a generally tubular outer wall, an end wall, and a protrusion. The end wall is joined to a distal end of the outer wall and supports an emissive element in a generally central region. The protrusion extends from the generally central region of the end wall and is configured to connect with an electrode holder by a releasable connection, wherein the protrusion is configured such that at least one coolant passage forms between the protrusion and the electrode holder when the electrode is connected with the electrode holder. In some embodiments, the releasable connection comprises a threaded connection, wherein the protrusion is threaded to releasably connect to a threaded coolant tube of the electrode holder. In other embodiments, at least one coolant passage is defined by the threaded connection.

Abstract: A plasma arc torch is provided that includes a wear stop designed to detect wear of an electrode and prevent the use of the electrode once the electrode has experienced a certain amount of wear. Either the electrode or the nozzle is movable with respect to the main torch body, and the movable component defines a projection. The wear stop is positioned a predetermined distance from a nozzle of the torch, such that prior to experiencing an excessive amount of wear, the electrode is able to contact the nozzle and initiate a pilot arc for starting a torch operation. Once the length of the electrode becomes shorter than a predetermined length due to wear, the projection of the electrode engages the wear stop, and the wear stop prevents the electrode from contacting the nozzle. In this way, an electrode that is excessively worn cannot be used in subsequent torch operations.

Abstract: A system for supplying fluids to a plasma arc torch includes a single-gas power supply for regulating electrical power to the torch and for regulating supply of a first fluid to the torch, a flow regulator for regulating supply of a second fluid to the torch, and a first pressure-actuated valve disposed between the flow regulator and the torch. The valve shuts off supply of the second fluid to the torch when the first valve is closed and allows the second fluid to be supplied when the first valve is open. The first valve is opened by pressure of the first fluid supplied to the torch and closed when the first fluid is not supplied to the torch. A second pressure-actuated valve may be provided in the supply line for the first fluid, which is opened by pressure of the second fluid being supplied to the torch.

Abstract: A plasma arc torch is provided that includes a wear stop designed to detect wear of an electrode and prevent the use of the electrode once the electrode has experienced a certain amount of wear. Either the electrode or the nozzle is movable with respect to the main torch body, and the movable component defines a projection. The wear stop is positioned a predetermined distance from a nozzle of the torch, such that prior to experiencing an excessive amount of wear, the electrode is able to contact the nozzle and initiate a pilot arc for starting a torch operation. Once the length of the electrode becomes shorter than a predetermined length due to wear, the projection of the electrode engages the wear stop, and the wear stop prevents the electrode from contacting the nozzle. In this way, an electrode that is excessively worn cannot be used in subsequent torch operations.

Abstract: A system for supplying fluids to a plasma arc torch includes a single-gas power supply for regulating supply of electrical power to the plasma arc torch and for regulating supply of a first fluid to the plasma arc torch, a flow regulator for regulating supply of a second fluid to the plasma arc torch, and a first pressure-actuated valve disposed between the flow regulator and the plasma arc torch. The pressure-actuated valve shuts off supply of the second fluid to the torch when the first pressure-actuated valve is closed and allows the second fluid to be supplied to the torch when the first pressure-actuated valve is open. The first pressure-actuated valve is structured and arranged to be opened by pressure of the first fluid being supplied to the torch and to be closed when the first fluid is not being supplied to the torch. The system can also include a second pressure-actuated valve in the supply line for the first fluid, which is opened by pressure of the second fluid being supplied to the torch.

Abstract: A plasma arc torch is provided that includes a wear stop designed to detect wear of an electrode and prevent the use of the electrode once the electrode has experienced a certain amount of wear. Either the electrode or the nozzle is movable with respect to the main torch body, and the movable component defines a projection. The wear stop is positioned a predetermined distance from a nozzle of the torch, such that prior to experiencing an excessive amount of wear, the electrode is able to contact the nozzle and initiate a pilot arc for starting a torch operation. Once the length of the electrode becomes shorter than a predetermined length due to wear, the projection of the electrode engages the wear stop, and the wear stop prevents the electrode from contacting the nozzle. In this way, an electrode that is excessively worn cannot be used in subsequent torch operations.

Abstract: Embodiments of the present invention are related to an electrode for a plasma arc torch, the electrode comprising a generally tubular outer wall, an end wall, and a protrusion. The end wall is joined to a distal end of the outer wall and supports an emissive element in a generally central region. The protrusion extends from the generally central region of the end wall and is configured to connect with an electrode holder by a releasable connection, wherein the protrusion is configured such that at least one coolant passage forms between the protrusion and the electrode holder when the electrode is connected with the electrode holder. In some embodiments, the releasable connection comprises a threaded connection, wherein the protrusion is threaded to releasably connect to a threaded coolant tube of the electrode holder. In other embodiments, at least one coolant passage is defined by the threaded connection.

Abstract: A system for supplying fluids to a plasma arc torch includes a single-gas power supply for regulating supply of electrical power to the plasma arc torch and for regulating supply of a first fluid to the plasma arc torch, a flow regulator for regulating supply of a second fluid to the plasma arc torch, and a first pressure-actuated valve disposed between the flow regulator and the plasma arc torch. The pressure-actuated valve shuts off supply of the second fluid to the torch when the first pressure-actuated valve is closed and allows the second fluid to be supplied to the torch when the first pressure-actuated valve is open. The first pressure-actuated valve is structured and arranged to be opened by pressure of the first fluid being supplied to the torch and to be closed when the first fluid is not being supplied to the torch. The system can also include a second pressure-actuated valve in the supply line for the first fluid, which is opened by pressure of the second fluid being supplied to the torch.

Abstract: A blow-back plasma arc torch employs a plasma gas and a separately supplied secondary fluid. The secondary fluid serves to internally cool an electrode of the torch and to shield the plasma gas and arc emanating from the primary nozzle of the torch. The secondary fluid can be a gas or liquid water. Secondary fluid or plasma gas is used to actuate a piston to which the electrode is connected so as to move the electrode from a starting position to an operating position. The secondary fluid is supplied to the torch at a greater mass flow rate than the plasma gas.

Abstract: A plasma arc torch is provided that includes a wear stop designed to detect wear of an electrode and prevent the use of the electrode once the electrode has experienced a certain amount of wear. Either the electrode or the nozzle is movable with respect to the main torch body, and the movable component defines a projection. The wear stop is positioned a predetermined distance from a nozzle of the torch, such that prior to experiencing an excessive amount of wear, the electrode is able to contact the nozzle and initiate a pilot arc for starting a torch operation. Once the length of the electrode becomes shorter than a predetermined length due to wear, the projection of the electrode engages the wear stop, and the wear stop prevents the electrode from contacting the nozzle. In this way, an electrode that is excessively worn cannot be used in subsequent torch operations.

Abstract: A plasma arc generation system includes a power module operably engaged with a plasma arc torch head portion and adapted to provide an electrical current for causing an arc at the torch head portion or generating a plasma. A cooling device is operably engaged with the power module so as to direct a fluid thereto for cooling the power module. The cooling device is configured such that the fluid directly contacts the power module to receive heat therefrom generated by the power module. Associated systems and methods are also provided.

Abstract: A plasma torch is provided having a movable member carrying an electrode and movable along a tubular member bore having a nozzle at one end. A piston member engaged with the movable member moves the electrode between inoperable and operable positions within the bore, the movable member being biased outwardly of the one end of the bore. A first sealing member engaged with the piston member allows a fluid flow into the bore to act on the piston member to move the electrode to the operable position when the nozzle/electrode is engaged with the tubular member. A second sealing member, engaged with the bore, engages the piston member when the nozzle/electrode is removed. The fluid flow enters the bore between the sealing members, the second sealing member thus preventing torch operation when the nozzle/electrode is removed by preventing the fluid flow from acting on the piston.

Abstract: A fastening arrangement comprising a thread-forming lobular screw and a member defining a non-tapped pilot hole therein. The screw has a shaft and a head joined to a proximal end of the shaft, the shaft defining a plurality N of lobes circumferentially spaced about a central longitudinal axis of the shaft, a thread being formed on an outer surface of the shaft. The pilot hole comprises a central portion of a diameter intermediate the minor and major diameters of the screw thread, and a plurality N of circumferentially spaced cutouts extending radially out from the central portion. A plurality of longitudinally extending edges parallel to the axis of the screw are defined at junctures between the cutouts and central portion of the pilot hole. The screw thread forms a thread in the member beginning at the longitudinal edges of the pilot hole.