Abstract: A method for determining operating parameters to process a workpiece using a manufacturing processing system including a plasma arc gouging torch. The method includes positioning a plasma arc gouging torch at a location relative to a workpiece and determining a start point and an end point for each gouging path based on the location and a gouge profile. The method further includes using the gouging profile to determine first operating parameters for the plasma arc gouging torch for a first gouging path and determining second operating parameters for the plasma arc gouging torch for a second gouging path based on the gouge profile and the first gouging path. The second operating parameters include at least one of a second torch speed or a torch offset. The method also includes using at least one of the first or second operating parameters to process the workpiece with the plasma arc gouging torch.

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, a consumable for plasma arc torch that generates a predetermined plenum pressure from a substantially constant preset gas supply pressure from a plasma arc torch power supply, where the substantially constant preset gas supply being used to support plasma generation for a selection of multiple consumable components that each generate a different plasma plenum pressure for carrying out different processes, can include a proximal portion shaped to connect to the plasma arc torch and define a plasma gas inlet region; a distal portion shaped to define a gas outlet; and a pressure-matching stage comprising a pressure wall defining at least one flow path between the gas inlet region and the gas outlet configured to establish sufficient fixed pressure drop of a flow of gas flowing through the pressure-matching stage to reduce a pressure of the flow of gas to the predetermined plenum pressure.

Abstract: A system to prevent a flow of gas and particulates from spreading to atmosphere during a material processing operation includes a slag deflector disposed proximate a torch during the material processing operation. The slag deflector includes a thermally-conductive base portion having an impact surface facing the torch. The impact surface is shaped to prevent the flow of gas and particulates from the material processing operation from spreading in a direction away from the torch, and to redirect the first flow of particulates to a surface configured to inhibit the first flow of particulates from flowing to atmosphere. The slag deflector includes a coolant flow channel configured to thermally-regulate the impact surface of the thermally conductive base portion.

Abstract: A plasma cutting system is provided. The system includes a power source configured to generate a plasma arc, and a plasma arc torch connected to the power source for delivering the plasma arc to a workpiece. The plasma arc torch defines a multi-function fluid flow path for sustaining the plasma arc and cooling the plasma arc torch such that the plasma cutting system has a power-to-gas flow ratio of at least 2 kilowatts per cubic feet per minute (KW/cfm). The power-to-gas flow ratio comprises a ratio of power of the generated plasma arc to a total gas flow supplied to the plasma arc torch.

Abstract: In some aspects, a consumable for plasma arc torch that generates a predetermined plenum pressure from a substantially constant preset gas supply pressure from a plasma arc torch power supply, where the substantially constant preset gas supply being used to support plasma generation for a selection of multiple consumable components that each generate a different plasma plenum pressure for carrying out different processes, can include a proximal portion shaped to connect to the plasma arc torch and define a plasma gas inlet region; a distal portion shaped to define a gas outlet; and a pressure-matching stage comprising a pressure wall defining at least one flow path between the gas inlet region and the gas outlet configured to establish sufficient fixed pressure drop of a flow of gas flowing through the pressure-matching stage to reduce a pressure of the flow of gas to the predetermined plenum pressure.

Abstract: In some aspects, methods for operating a plasma cutting system can include initiating an arc between a set of consumable components disposed in a torch of the plasma cutting system, the set of consumable components including a first consumable component and a second consumable component, detecting an operational characteristic of the arc, and analyzing the operational characteristic to identify at least one consumable component of the set of consumable components.

Abstract: A power supply assembly for a plasma arc torch is provided. The power supply assembly includes an input circuit, an energy storage device, a torch connector and an output circuit. The input circuit is configured to produce a first output signal. The energy storage device is electrically connected to the input circuit for receiving a charge signal therefrom. The energy storage device is capable of producing a second output signal. The torch connector is electrically connected to the input circuit and the energy storage device for receiving the first and second output signals through the output circuit. The torch connector is configured to supply at least one of the first or second output signal to the plasma arc torch to sustain a plasma arc.

Abstract: A plasma cutting system is provided. The system includes a power source configured to generate a plasma arc, and a plasma arc torch connected to the power source for delivering the plasma arc to a workpiece. The plasma arc torch defines a multi-function fluid flow path for sustaining the plasma arc and cooling the plasma arc torch such that the plasma cutting system has a power-to-gas flow ratio of at least 2 kilowatts per cubic feet per minute (KW/cfm). The power-to-gas flow ratio comprises a ratio of power of the generated plasma arc to a total gas flow supplied to the plasma arc torch.

Abstract: In some aspects, methods for operating a plasma cutting system can include initiating an arc between a set of consumable components disposed in a torch of the plasma cutting system, the set of consumable components including a first consumable component and a second consumable component, detecting an operational characteristic of the arc, and analyzing the operational characteristic to identify at least one consumable component of the set of consumable components.

Abstract: A power supply assembly for a plasma arc torch is provided. The power supply assembly includes an input circuit, an energy storage device, a torch connector and an output circuit. The input circuit is configured to produce a first output signal. The energy storage device is electrically connected to the input circuit for receiving a charge signal therefrom. The energy storage device is capable of producing a second output signal. The torch connector is electrically connected to the input circuit and the energy storage device for receiving the first and second output signals through the output circuit. The torch connector is configured to supply at least one of the first or second output signal to the plasma arc torch to sustain a plasma arc.