Abstract: A torch head for a liquid-cooled plasma arc torch is provided. The torch head includes a torch body and a torch insulator, coupled to the torch body, having a substantially non-conductive insulator body. The torch insulator includes (i) a first liquid coolant channel, disposed within the insulator body, configured to conduct a fluid flow from the torch head into a consumable cartridge along a first preexisting flow path, (ii) a first liquid return channel, disposed within the insulator body, configured to return at least a portion of the fluid flow from the cartridge to the torch head along the first preexisting flow path, and (iii) a gas channel, disposed within the insulator body, configured to conduct a first gas flow from the torch head to the cartridge along a second preexisting flow path. The first and second preexisting flow paths are fluidly isolated from each other.

Abstract: A consumable cartridge for a liquid-cooled plasma arc torch is provided. The consumable cartridge comprises a cartridge frame including a proximal end having an end surface, a distal end and a body having a central longitudinal axis extending therethrough. The cartridge configured to form a radio-frequency identification (RFID) interface with a torch head. The consumable cartridge also comprises an arc emitter and an arc constrictor affixed to the cartridge frame at the distal end and an RFID mounting feature formed on or in the cartridge frame adjacent to the end face. The RFID mounting feature is non-concentric with the central longitudinal axis of the body. The consumable cartridge further comprises an RFID tag disposed in or on the RFID mounting feature for transmitting information about the cartridge to a reader device in the torch head when the cartridge is connected to the torch head.

Abstract: A consumable cartridge frame for a liquid-cooled plasma arc torch is provided. The consumable cartridge frame includes an insulator body configured to be disposed between a torch head and a cartridge tip. The consumable cartridge also includes a first cooling channel, disposed in the body, configured to conduct a first fluid flow received from the torch head to contact a component of the cartridge tip connected to the cartridge frame. The consumable cartridge further includes a first return channel, disposed in the body, configured to conduct at least a portion of the first fluid flow from the component to the torch head. The first cooling channel and the first return channel are non-concentric in relation to a central longitudinal axis of the body.

Abstract: A nozzle for a plasma arc torch is provided. The nozzle includes a substantially hollow, elongated nozzle body capable of receiving an electrode, the body defining a longitudinal axis, a distal end, and a proximal end. The nozzle also includes a swirl sleeve attachable to an interior surface of the nozzle body, the swirl sleeve configured to impart a swirling motion to a gas introduced to the nozzle. The nozzle additionally includes a nozzle tip connected to the proximal end of the nozzle body, a nozzle shield, and an insulator configured to connect the nozzle tip and the nozzle shield to electrically insulate the nozzle shield and the nozzle tip from one another while transferring thermal energy therebetween.

Abstract: In some aspects, reciprocating engines can include a drive mechanism for generating a rotational motion output from reciprocating piston assembly, where the drive mechanism includes an axially translating y-axis component to reciprocate along a y-axis with the piston assembly; an x-axis component: i) configured to reciprocate substantially perpendicularly to the y-axis, ii) having an internal ring gear, and iii) having an orbital engagement component substantially concentric with the internal ring gear; an output shaft assembly having an output pinion gear engaging tangentially with the internal ring gear; and a stationary engagement component substantially concentric with the output shaft assembly, the stationary engagement component interfacing with the orbital engagement component, the interfacing between the stationary engagement component and the orbital engagement component applying a force to the x-axis component to maintain contact between the internal ring gear and the output pinion gear.

Abstract: A component for a contact start plasma arc torch is provided. The component includes a hollow body defining a channel with a longitudinal axis. The channel is capable of slideably receiving an electrode body along the longitudinal axis. The component includes a contact element disposed in the hollow body and includes a first surface and a second surface. The first surface is adapted to facilitate electrical communication with a power supply and the second surface is adapted to physically contact a surface of the electrode body when the plasma arc torch is operated in a transferred arc mode. In addition, the second surface is characterized by the absence of physical contact with the surface of the electrode body when the torch is operated in a pilot arc mode.

Abstract: A connector component (102) is provided for assembly into a material processing torch head. The connector component (102) comprises a generally cylindrical body (104) that includes a proximal end (106) and a distal end (108) defining a longitudinal axis. At least two thread regions (112) are disposed at a radial location on a surface of the body near the proximal end. Each thread region includes at least one thread (114) disposed on the surface of the body. In addition, at least two non-thread regions (116) are oriented longitudinally at a radial location on the surface of the body (104).

Abstract: In some aspects, a power delivery device configured to couple to a reciprocating element of a reciprocating engine is configured to couple to a power output element via a substantially steady, invariant (e.g., constant) moment arm in order to generate increased torque and power.

Abstract: A plasma arc torch is provided for use in a plasma cutting system. The plasma arc torch includes a torch body for conducting electrical current. The torch body includes a torch tip configured to pass the electrical current to at least one consumable component connected to the tip. The plasma arc torch also includes at least one antenna positioned relative to the torch tip. The antenna is used to wirelessly detect the presence of the at least one consumable component. The plasma arc torch further includes a detection circuit configured to permit passing of the electrical current from the torch tip to the at least one consumable component based on at least the wireless detection.

Abstract: The invention features a replaceable cartridge for a plasma arc torch. The cartridge includes a cartridge body having a first section and a second section. The first and second sections are joined at an interface to form a substantially hollow chamber. The interface provides a coupling force that secures the first and second sections together. The cartridge also includes an arc constricting member located in the second section; an electrode included within the substantially hollow chamber; and a contact start spring element affixed to the electrode. The spring element imparts a separating force that biases the electrode toward at least one of the first section or the second section of the body. The separating force has a magnitude that is less than a magnitude of the coupling force.

Abstract: The invention features a frame for a plasma arc torch cartridge. The frame includes a thermally conductive frame body having a longitudinal axis, a first end configured to connect to a first consumable component, and a second end configured to mate with a second consumable component. The frame body surrounds at least a portion of the second consumable component. The frame also includes a set of flow passages formed within the frame body. The set of flow passages fluidly connects an internal surface of the frame body and an external surface of the frame body. The set of flow holes is configured to impart a fluid flow pattern about the second consumable component.

Abstract: A nozzle for a plasma arc torch is provided. The nozzle includes a substantially hollow, elongated nozzle body capable of receiving an electrode, the body defining a longitudinal axis, a distal end, and a proximal end. The nozzle also includes a swirl sleeve attachable to an interior surface of the nozzle body, the swirl sleeve configured to impart a swirling motion to a gas introduced to the nozzle. The nozzle additionally includes a nozzle tip connected to the proximal end of the nozzle body, a nozzle shield, and an insulator configured to connect the nozzle tip and the nozzle shield to electrically insulate the nozzle shield and the nozzle tip from one another while transferring thermal energy therebetween.

Abstract: A nozzle for a plasma arc cutting torch includes a substantially hollow, elongated body capable of receiving an electrode. The nozzle body defines a longitudinal axis and has a length along the axis from a first end of the nozzle body to a second end of the nozzle body. The nozzle also includes a plasma exit orifice disposed at the first end of the body. The first end of the nozzle body has a width and a ratio of the length of the nozzle body to the width of the nozzle body is greater than about 3.

Abstract: An electrode is provided for use in a plasma arc torch. The electrode includes a body having an elongated forward portion and a ring-shaped aft portion. The forward portion is configured to provide an electrically conductive path from the distal end to the proximal end. The forward portion comprises a first conductive material. The ring-shaped aft portion, defining a hollow center, is configured to substantially surround a portion of the forward portion when the forward portion is located inside of the hollow center. The aft portion includes a pneumatic reaction region for receiving a biasing flow of a pressurized gas. The aft portion comprises a second material. In some embodiments, the first conductive material is the same as the second material.

Abstract: In some aspects, a power delivery device configured to couple to a reciprocating element of a reciprocating engine is configured to couple to a power output element via a substantially steady, invariant (e.g., constant) moment arm in order to generate increased torque and power.

Abstract: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces. The plasma arc torch can include a wearable portable assembly which includes the replaceable or rechargeable power and gas source. A plasma delivery device receives current from the power source in the assembly and gas from the gas source in the assembly to generate a plasma arc.

Abstract: An electrode is provided for use in a plasma arc torch. The electrode includes a body having a forward portion, a middle portion and an aft portion. The forward portion includes an electrode tip comprising a conductive first material, wherein the electrode tip includes: 1) a pilot contact region for initiating a pilot arc across the nozzle and 2) an emitter. The middle portion comprises a second material and defines a proximal end for mating with the forward portion and a distal end for mating with the aft portion. The material density of the second material is at least half of the material density of the first material. The electrode also includes an electrically conductive path extending from the forward portion to the aft portion of the body.

Abstract: A nozzle for use in a plasma arc torch is provided. The nozzle includes an aft portion comprising a conductive first material with a first density. The aft portion defines a proximal end and a distal end. The nozzle includes a substantially hollow forward portion including 1) a tip section comprising a conductive second material with a second density, and 2) a rear section configured to couple the forward portion to the proximal end of the aft portion. The second density is at least two times greater than the first density. The nozzle further includes a plasma exit orifice disposed in the tip section of the forward portion.

Abstract: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces. The plasma arc torch can include a wearable portable assembly which includes the replaceable or rechargeable power and gas source. A plasma delivery device receives current from the power source in the assembly and gas from the gas source in the assembly to generate a plasma arc.

Abstract: A component for a contact start plasma arc torch is provided. The component includes a hollow body defining a channel with a longitudinal axis. The channel is capable of slideably receiving an electrode body along the longitudinal axis. The component includes a contact element disposed in the hollow body and includes a first surface and a second surface. The first surface is adapted to facilitate electrical communication with a power supply and the second surface is adapted to physically contact a surface of the electrode body when the plasma arc torch is operated in a transferred arc mode. In addition, the second surface is characterized by the absence of physical contact with the surface of the electrode body when the torch is operated in a pilot arc mode.