PLASMA TORCH CUTTING SYSTEM

Abstract

A plasma cutting system includes a plasma cutting power supply configured to provide cutting current to a torch. A controllable gas valve regulates at least one of a flow rate and a pressure supplied to the torch. A controller is operatively connected to the power supply to control a current level, and to the gas valve to adjust a valve position. The controller is configured to receive real-time torch position information from a motion control system that controls positioning of the torch. The position information includes torch positions along a first axis and a second axis that is perpendicular to the first axis. The controller is configured to calculate respective derivatives from the torch positions along the first and second axes, and a real-time velocity magnitude of the torch from the respective derivatives, and adjust the current level and the valve position based on the calculated real-time velocity magnitude.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application Ser. No. 62/932,550 filed on Nov. 8, 2019, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to cutting systems that utilize plasma torches, and to controlling cutting current and/or gas flow during a cutting operation.

Description of Related Art

Automated plasma cutting systems have been developed which use computer numerical control (CNC) technology to control the movement and process of a plasma cutting operation, including controlling the movement of the cutting torch. For example, a CNC controller can move a plasma torch in perpendicular X and Y directions along a workpiece placed onto a cutting table to cut a desired shape or part from the workpiece. Workpieces can also be held by a fixture for cutting by a torch mounted to a robot whose movements are controlled by a robot controller. A consistent kerf (e.g., a consistent cut width and bevel angle) is desirable so that the part cut from the workpiece has generally uniform edges and correct dimensions. Cutting speed or torch velocity can affect the kerf, and velocity changes can result in a widening or narrowing of the kerf. For example, faster cutting speeds provide a narrower kerf and slower cutting speeds provide a wider kerf.

BRIEF SUMMARY OF THE INVENTION

The following summary presents a simplified summary in order to provide a basic understanding of some aspects of the devices, systems and/or methods discussed herein. This summary is not an extensive overview of the devices, systems and/or methods discussed herein. It is not intended to identify critical elements or to delineate the scope of such devices, systems and/or methods. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

In accordance with one aspect of the present invention, provided is a plasma cutting system. The system includes a plasma cutting power supply configured to provide a cutting current to a torch to create a plasma arc. A controllable gas valve regulates at least one of a flow rate and a pressure of a plasma gas supplied to the torch. A controller is operatively connected to the plasma cutting power supply to control a current level of the cutting current, and is operatively connected to the controllable gas valve to adjust a valve position of the controllable gas valve. The controller is configured to receive real-time torch position information from a motion control system that controls positioning of the torch. The real-time torch position information includes torch positions along a first axis and torch positions along a second axis that is perpendicular to the first axis. The controller is further configured to calculate respective derivatives from the torch positions along the first axis and the torch positions along the second axis. The controller is further configured to calculate a real-time velocity magnitude of the torch from the respective derivatives, and adjust the current level of the cutting current and the valve position of the controllable gas valve based on the calculated real-time velocity magnitude of the torch.

In accordance with another aspect of the present invention, provided is a plasma cutting system. The system includes a plasma cutting power supply configured to provide a cutting current to a torch to create a plasma arc. A controllable gas valve regulates at least one of a flow rate and a pressure of a plasma gas supplied to the torch. A controller is operatively connected to the plasma cutting power supply to control a current level of the cutting current, and operatively connected to the controllable gas valve to adjust a valve position of the controllable gas valve. The controller is configured to receive real-time torch position information from a motion control system that adjusts velocity of the torch when cutting a corner portion of a part cut from a workpiece. The controller is further configured to calculate first derivatives from the real-time torch position information and determine real-time velocity magnitudes of the torch when the corner portion is cut from the workpiece. The controller is further configured to maintain kerf consistency by adjusting, based on the determined real-time velocity magnitudes of the torch, the current level of the cutting current and the valve position of the controllable gas valve as the corner portion of the part is cut from the workpiece.

In accordance with another aspect of the present invention, provided is a plasma cutting method. The method includes providing a plasma cutting system that includes a plasma cutting power supply configured to provide a cutting current to a torch to create a plasma arc, a controllable gas valve for regulating at least one of a flow rate and a pressure of a plasma gas supplied to the torch, and a controller operatively connected to the plasma cutting power supply to control a current level of the cutting current, and operatively connected to the controllable gas valve to adjust a valve position of the controllable gas valve. The method further includes receiving real-time torch position information from a motion control system that controls positioning of the torch. The real-time torch position information includes torch positions along a first axis and torch positions along a second axis that is perpendicular to the first axis. The method further includes calculating, by the controller, respective derivatives from the torch positions along the first axis and the torch positions along the second axis, and calculating, by the controller, a real-time velocity magnitude of the torch from the respective derivatives. The method further includes adjusting the current level of the cutting current and the valve position of the controllable gas valve based on the calculated real-time velocity magnitude of the torch.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other aspects of the invention will become apparent to those skilled in the art to which the invention relates upon reading the following description with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a plasma cutting table;

FIG. 2 is a schematic representation of an example plasma cutting system;

FIG. 3 is a schematic representation of an example plasma cutting system;

FIG. 4 shows a plasma cutting operation;

FIG. 5 shows a plasma cutting operation;

FIG. 6 shows a plasma cutting operation;

FIG. 7 shows a plasma cutting operation;

FIG. 8 shows a plasma cutting operation;

FIG. 9 is a flow diagram of an example plasma cutting method; and

FIG. 10 shows an example controller.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to plasma cutting systems. The present invention will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. It is to be appreciated that the various drawings are not necessarily drawn to scale from one figure to another nor inside a given figure, and in particular that the size of the components are arbitrarily drawn for facilitating the understanding of the drawings. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It may be evident, however, that the present invention can be practiced without these specific details. Additionally, other embodiments of the invention are possible and the invention is capable of being practiced and carried out in ways other than as described. The terminology and phraseology used in describing the invention is employed for the purpose of promoting an understanding of the invention and should not be taken as limiting.

As used herein, “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. Any disjunctive word or phrase presenting two or more alternative terms, whether in the description of embodiments, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” should be understood to include the possibilities of “A” or “B” or “A and B.”

As used herein, the noun “real time” and the adjective “real-time” refer to instances of both real time and near-real time (e.g., within milliseconds or hundreds of milliseconds, such a up to one second, from actual real time as determined by processing latency, network latency, and/or other communication latency).

FIG. 1 shows an example plasma cutting table 102. The plasma cutting table 102 has a main body 104 upon which a workpiece, such as a metal sheet or plate, is placed. The plasma cutting table 102 includes a gantry 106 that can move back and forth along the length of the cutting table's main body 104 in a first direction (e.g., in a Y direction). The gantry 106 can move on tracks or rails that extend along the sides of the table 102. A plasma cutting torch 108 is attached to a movable torch carriage 110 that is mounted on the gantry 106. The torch carriage 110 can move back and forth along the gantry 106 in a second direction (e.g., in an X direction) that is perpendicular to the first direction. The plasma cutting table 102 can be programmed to make precise cuts in a workpiece through controlled movements of the torch carriage 110 and gantry 106 in the X and Y directions, respectively. In certain embodiments, the torch carriage 110 can move the plasma cutting torch 108 vertically toward and away from the workpiece (e.g., in a Z direction), so that the torch can be moved in three perpendicular directions. In certain embodiments, the torch carriage 110 can also rotate or tilt the torch 108 in a plane perpendicular to the plane of the table (e.g., in the X-Z plane), to make beveled cuts. In further embodiments, the torch carriage 110 can also rotate the torch 108 about the vertical or Z-axis when cutting a part from a workpiece, to maintain an angular orientation of the torch or plasma arc with respect to the kerf cut through the workpiece.

The plasma cutting table 102 can include a water tray 112 located adjacent the workpiece. During a plasma cutting operation, the water tray 112 is filled with water, and the water can be drained to allow the water chamber to be cleaned to remove accumulated dross and slag. The plasma cutting table 102 can also include a user interface 114 for setting various operational parameters of the plasma cutting table and the plasma cutting operation. The user interface 114 can be operatively connected to a motion controller, such as a CNC, and/or operatively connected to a plasma cutting power supply or plasma cutting control system.

FIG. 2 depicts an exemplary embodiment of a plasma cutting system 200. The plasma cutting system 200 can include an integrated plasma cutting control system 116. The plasma cutting control system 116 can include a power supply electronics module 118 which functions as a plasma cutting power supply and is used to generate the cutting current signal that is sent to the torch 108. The power supply electronics module 118 provides the torch 108 with cutting current to create a plasma arc for cutting a part from a workpiece W. All of the power electronics which are used to generate the cutting current signal can be located within the same housing 120 as a main system controller 122. Alternatively, the plasma cutting system 200 can include a separate plasma cutting power supply that is operatively coupled to the control system 116. The main system controller 122 controls various aspects of the cutting operation, such as current and gas flow control of plasma and shielding gas. As shown, the controller 122 communicates with the power generation components of the power supply module 118 internal to the housing 120 to control operations of the power supply module. Further, the controller 122 controls the plasma and shielding gas flow and/or pressure by directly communicating with a gas flow control device 124. The gas flow control device 124 controls the flow of gas from a gas supply 126 and gas line 128 to the torch 108 via a controllable gas valve 130 or valves. The controllable gas valve 130 or valves can regulate plasma and shielding gas pressure and/or flow rate to the torch 108. The main system controller 122 is operatively connected to the plasma cutting power supply to control a current level of the cutting current, and operatively connected to the controllable gas valve 130 to simultaneously adjust a valve position of the controllable gas valve. The operative connections may or may not be direct connections. For example, the controller 122 could provide a positioning signal (e.g., 4-20 mA, 0-10 V, etc.) to the gas flow control device 124 that directly controls the movement of a proportional valve in the gas flow control device, or the controller could communicate positioning information to a further electronic controller in the gas flow control device, and the further electronic controller would control the gas valve accordingly. The main system controller 122 can send positioning signals to the flow control device 124 to control the positions of the valves and, thus, adjust gas pressure/flow rate. The main system controller 122 can simultaneously adjust the cutting amperage applied to the torch 108 by controlling operations of the power supply electronics module 118. The main system controller 122 can adjust the gas pressure/flow rate and current level of the cutting current in concert (e.g., one level based on the other) using, for example, a lookup table, calculation, or other algorithm. In plasma cutting operations that utilize both a plasma and shielding gas, the main system controller 122 can control both gas flows in concert with the current level; however, in plasma cutting operations that utilize only a plasma gas, the main system controller 122 will control just the plasma gas flow.

The main system controller 122 directly communicates with a motion controller 132. The motion controller 132 controls the movements of a gantry 106 along the cutting table 102, the movements of a torch-holding carriage 110 along the gantry, the vertical positioning the torch 108 on the gantry, and possibly rotations of the torch along horizontal and/or vertical axes. Accordingly, the motion controller 132 can control movements of the torch 108 in X, Y, and Z directions, and certain rotations of the torch if desired. With further reference to FIG. 1, the Y direction or axis can extend into and out of the plane of FIG. 2, along the length of the cutting table 102. The X direction or axis can extend along the gantry 106. The Z direction or axis can be substantially vertical, extending toward and away from the cutting table 102. In addition to controlling the movements of the torch-holding carriage 110 along the gantry 106 in the X direction, and the movements of the gantry 106 along the table 102 in the Y direction, the motion controller 132 also controls the height of the torch 108 in the Z direction during operation of the system 200, and the angling of the torch 108 for any desired bevel cutting and rotation of the torch about the Z-axis for cut consistency.

To the extent the cutting table 102 has any automated or motion functions, the main system controller 122 can be coupled to the table to control the table's operations. For example, if the table 102 is a water table or can move the workpiece, the main system controller 122 can control these operations. The plasma cutting control system 116 can have a user interface output device 134 (e.g., a user interface screen), and/or a user interface input device 135 (e.g., a keyboard) to allow the user to input and review various operational parameters and characteristics of the plasma cutting system 200 and the cutting operation.

The main system controller 122 and/or any other controller discussed herein (e.g., the motion controller 132) can include an electronic controller having one or more processors. For example, the controller 122 can include one or more of a microprocessor, a microcontroller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), discrete logic circuitry, or the like. The main system controller 122 can further include memory and may store program instructions that cause the controller to provide the functionality ascribed to it herein. The memory may include one or more volatile, non-volatile, magnetic, optical, or electrical media, such as read-only memory (ROM), random access memory (RAM), electrically-erasable programmable ROM (EEPROM), flash memory, or the like. The main system controller 122 can further include one or more analog-to-digital (A/D) converters for processing various analog inputs to the controller, and one or more digital-to-analog (D/A) converters for processing various digital outputs from the controller.

FIG. 3 depicts a further exemplary embodiment of a plasma cutting system 201. The system 201 is similar to the system shown in FIG. 2 except that the gantry table and motion controller are replaced with a robot arm 136 and robot controller 138. The robot controller 138 includes control circuitry 140 for controlling the movements of the robot arm 136. An example robot arm 136 is a 6-axis robot arm. The end effector of the robot arm 136 is the plasma torch 108 and the robot arm manipulates the plasma torch to cut a part from the workpiece W held by a fixture 142. The control circuitry 140 in the robot controller 138 is operatively connected to the main system controller 122 in the plasma cutting control system 116 for bidirectional communications therewith. The robot controller 138 can include a user interface, such as a teach pendant 144, to program the movements of the robot arm 136 and otherwise interact with the robot system and, in certain embodiments, interact with the plasma cutting control system 116. As used herein, the terms “motion controller” and “motion control system” include circuitry for controlling the movements and positioning of a plasma cutting torch, whether on a cutting table or robot arm. Thus, “motion controller” and “motion control system” include the motion controller 132 shown in FIG. 2 and the robot controller 138 shown in FIG. 3, as well as other known motion controllers for plasma cutting operations. For ease of explanation, the motion control system that controls positioning of the torch, and its interaction with the main system controller 122, is discussed below in the context of the motion controller 132 shown in FIG. 2. However, various aspects of the motion control system are equally applicable to the robot controller 138 and other known motion controllers for plasma cutting operations, as will be appreciated by one of ordinary skill in the art.

FIG. 4 schematically shows an example plasma cutting operation. The plasma cutting torch 108 generates a plasma jet or plasma arc 146 that cuts a kerf through the workpiece W. The “kerf” is the width of material removed during plasma cutting. The plasma torch 108 contains passages for the plasma gas and optionally a shielding gas 148. The use of a shielding gas can help constrict the plasma arc 146 and blow away the dross from the workpiece W.

With reference to FIGS. 2 and 3, the motion controller 132 (or robot controller 138) is programmed to move the torch 108 during a cutting operation to cut a part of a desired shape from a workpiece W located on the cutting table 102 or held by a fixture 142. The main system controller 122 is operatively connected to the motion controller 132 (or robot controller 138) to receive torch position feedback information in real time during the cutting operation. The motion controller 132 (or robot controller 138) continuously sends, in real time, present torch position information to the main system controller 122 during cutting. The main system controller 122 knows the current and past positions of the torch 108 and can determine, in real time, the torch velocity and acceleration. The real-time torch position information can include torch positions along at least a first axis, torch positions along a first axis and a second axis that is perpendicular to the first axis, or torch positions along three axes that are perpendicular to each other (e.g., along the X, Y and Z axes). The real-time torch position information could also include a radial distance and an angle or angles (e.g., polar coordinates, cylindrical coordinates, or spherical coordinates).

The main system controller 122 receives the real-time torch position information and samples the torch position information periodically (e.g., every 100 ms) and calculates the torch's real-time velocity magnitude. This is done, for example, by calculating respective first derivatives or rate of change of the torch position along the different axes of movement (e.g., X′, Y′, Z′) and then calculating the magnitude of the velocity. In a Cartesian coordinate system, the magnitude of velocity can be calculated as the square root of the sum of the squared derivatives or √{square root over ((X′²+Y′²+Z′²))}. In certain embodiments, the main system controller 122 only calculates the velocity magnitude of torch movements in a plane parallel to the workpiece W (e.g., in the X-Y plane), and, thus, needs only to calculate the first derivatives of movements in such a plane (e.g., X′ and Y′). If the main system controller 122 only cares about the real-time velocity magnitude of torch 108 movements in a plane parallel to the workpiece W, then the velocity magnitude can be calculated as √{square root over ((X′²+Y′²))}. Information about torch acceleration can be calculated similar to velocity using the second derivatives of the torch position (e.g., X″, Y″, Z″).

The main system controller 122 is configured to adjust the current level of the cutting current and the valve position of the controllable gas valve 130 based on the calculated real-time velocity magnitude of the torch 108. Thus, the main system controller 122 can adjust plasma (and optionally shielding) gas pressures and/or flow rates and plasma cutting current level in real time based on the present velocity of the torch 108. As the torch velocity changes, the main system controller 122 will adjust the plasma and shielding gas pressures/flow rates and the cutting current level accordingly. As noted above, the main system controller 122 can adjust the gas pressure/flow rate and current level of the cutting current in concert using, a lookup table, calculation, or other algorithm. The lookup table, calculation, or other algorithm can include torch velocity as a parameter for determining the correct gas pressure/flow rate and cutting current. For example, the lookup table can relate torch velocity to the correct gas parameters and current level. Within the plasma cutting system, it is to be expected that the cutting current will respond more quickly to set point changes than the gas flow, so adjustments to the gas valve position based on torch velocity can slightly lead (in time) changes to the current level.

When cutting a part from a workpiece, a consistent kerf is desirable so that the part has generally uniform edges and correct dimensions. Torch velocity can affect the kerf, and velocity changes can result in a widening or narrowing of the kerf. For example, faster cutting speeds provide a narrower kerf and slower cutting speeds provide a wider kerf. If the cutting current level is kept constant while the torch velocity changes, the kerf can widen and narrow and will be inconsistent. However, adjusting the current level based on torch velocity can help to maintain kerf consistency. For example, increasing the cutting amperage will widen the kerf, and decreasing the cutting amperage will narrow the kerf. Adjustments to the cutting current level can be used to offset changes in torch velocity to maintain kerf consistency. If torch velocity decreases, the cutting current level can also be reduced so that the kerf is not widened due to the slower torch velocity. If torch velocity increases, the cutting current level can also be increased so that the kerf is not narrowed due to the faster torch velocity. The correct plasma and shielding gas pressure/flow rate will depend on the cutting current level, so plasma and shielding gas amounts can also be adjusted based on torch velocity.

It is common for torch velocity to decrease and then increase when cutting corner portions of a part. FIGS. 5-8 show an example plasma cutting operation during which the cutting current level and gas valve position can be adjusted as torch velocity changes, to maintain a consistent kerf. The kerf 150 is shown in solid line in FIGS. 5-8. The remaining uncut portion 152 of the part 154 to be cut from the workpiece W is shown in dashed lines. The part 154 is square and the torch 108 is shown cutting the upper side and upper left corner 156 of the part. Between FIGS. 5 and 6, the torch velocity will decrease as the torch 108 approaches the corner 156, and between FIGS. 7 and 8, the torch velocity will increase as the torch departs from the corner.

From the torch position information received from the motion controller 132, the changes in torch velocity can be recognized by the main system controller 122 in real time. If the cutting current level is kept constant while the corner 156 is cut, the kerf 150 will widen at the corner due to the slower torch velocity. To avoid this, the main system controller 122 can determine the torch velocity magnitude and reduce the current level of the cutting current, and adjust the valve position of the controllable gas valve 130, as the torch 108 approaches the corner 156. As the torch 108 slows down near the corner cut, the current level and gas flow will be reduced by the main system controller 122 to avoid blowing out too much material in the corner 156. This can make the cut edges along the workpiece W more consistent (i.e., keep the kerf 150 consistent). As the torch 108 departs from the corner 156 and speeds up, the main system controller 122 can increase the cutting current level and increase the gas flow to the torch.

The main system controller 122 can also weigh the velocity in certain directions when adjusting gas pressure/flow rate and current level. For example, the main system controller 122 can take into account the velocity in the X and Y directions to a greater degree than velocity in the Z direction. That is, velocity changes in the Z direction can be less impactful on gas flow and current level adjustments than velocity changes in the X and Y directions. The main system controller 122 can also adjust the gas pressure/flow rate and cutting current level based on a calculated real-time velocity magnitude in less than the three axial directions, such as in only one direction or in two directions (e.g, X and Y directions).

When cutting of the part 154 is complete, the main system controller 122 turns off the plasma arc and the arc “snaps off”. Abruptly snapping off the arc when the arc is long and the current is high causes wear and tear on the electrode and can reduce consumable life. For example, an excessive amount of hafnium is pulled from the electrode when the arc snaps off abruptly. Deterioration of the nozzle orifice in the torch is also accelerated when the arc abruptly snaps off.

To reduce the wear on the consumables in the torch 108 due to the arc snapping, the plasma cutting system drives the torch toward the workpiece W (e.g., downward or in the Z direction) to shorten the arc length as the current is reduced by the main system controller 122 at the end of a cutting operation. The movement of the torch 108 toward the workpiece W is controlled by the motion controller 132, or can be controlled by the main system controller 122. By moving the torch 108 toward the workpiece W, the arc is kept as short as possible but is maintained as the current approaches 0 amps. The arc then snaps off at a lower current level than it would if the torch 108 had not been driven toward the workpiece W. The lower current level as the arc extinguishes reduces damage to the nozzle orifice and reduces or prevents the hafnium in the electrode from being pulled away, which leads to longer and less variable consumable life. In certain embodiments, the rate of current reduction before the arc snaps off and the motion of the torch 108 toward the workpiece W can be tied to a logarithmic gas curve associated with the venting of the gas from the torch at the end of the plasma cutting operation.

FIG. 9 provides a flow diagram of an example plasma cutting method performed by a plasma cutting system. The plasma cutting system, such as a system described above, is provided in step 170. Real-time torch position information is received from a motion control system that controls positioning of a torch (step 172). The real-time torch position information can include torch positions along a first axis and torch positions along a second axis that is perpendicular to the first axis. A controller of the plasma cutting system calculates respective derivatives from the torch positions along the first axis and the torch positions along the second axis (step 174). The controller calculates a real-time velocity magnitude of the torch from the respective derivatives (step 176). The controller adjusts the current level of the cutting current and the valve position of a controllable gas valve based on the calculated real-time velocity magnitude of the torch (step 178). At the end of a cutting operation, the controller extinguishes the plasma arc by reducing the current level of the cutting current while an arc length of the plasma arc is simultaneously shortened by movement of the torch toward a workpiece (step 180).

FIG. 10 illustrates an embodiment of an example controller, such as the main system controller 122 of the plasma cutting systems 200, 201 discussed above. The controller 122 includes at least one processor 814 which communicates with a number of peripheral devices via bus subsystem 812. These peripheral devices may include a storage subsystem 824, including, for example, a memory subsystem 828 and a file storage subsystem 826, user interface input devices 135, user interface output devices 134, and a network interface subsystem 816. The input and output devices allow user interaction with the controller 122. Network interface subsystem 816 provides an interface to outside networks and is coupled to corresponding interface devices in other computer systems.

User interface input devices 135 may include a keyboard, pointing devices such as a mouse, trackball, touchpad, or graphics tablet, a scanner, a touchscreen incorporated into the display, audio input devices such as voice recognition systems, microphones, and/or other types of input devices. In general, use of the term “input device” is intended to include all possible types of devices and ways to input information into the controller 122 or onto a communication network.

User interface output devices 134 may include a display subsystem, a printer, a fax machine, or non-visual displays such as audio output devices. The display subsystem may include a cathode ray tube (CRT), a flat-panel device such as a liquid crystal display (LCD), a projection device, or some other mechanism for creating a visible image. The display subsystem may also provide non-visual display such as via audio output devices. In general, use of the term “output device” is intended to include all possible types of devices and ways to output information from the controller 122 to the user or to another machine or computer system.

Storage subsystem 824 provides a non-transitory, computer-readable storage medium that stores programming and data constructs that provide the functionality of some or all of the modules described herein. For example, the storage subsystem 824 can include stored relationships that correlate torch velocity to cutting current level, and that correlate torch velocity and/or cutting current level to plasma or shield gas valve positions, pressures, flow rates, etc.

These software modules are generally executed by processor 814 alone or in combination with other processors. Memory 828 used in the storage subsystem 824 can include a number of memories including a main random access memory (RAM) 830 for storage of instructions and data during program execution and a read only memory (ROM) 832 in which fixed instructions are stored. A file storage subsystem 826 can provide persistent storage for program and data files, and may include solid state memory, a hard disk drive, a floppy disk drive along with associated removable media, a CD-ROM drive, an optical drive, flash memory, or removable media cartridges. The modules implementing the functionality of certain embodiments may be stored by file storage subsystem 826 in the storage subsystem 824, or in other machines accessible by the processor(s) 814.

Bus subsystem 812 provides a mechanism for letting the various components and subsystems of the controller 122 communicate with each other as intended. Although bus subsystem 812 is shown schematically as a single bus, alternative embodiments of the bus subsystem may use multiple buses.

The controller 122 can be of varying types including a workstation, server, computing cluster, blade server, server farm, or any other data processing system or computing device. Due to the ever-changing nature of computing devices and networks, the description of the controller 122 depicted in FIG. 10 is intended only as a specific example for purposes of illustrating some embodiments. Many other configurations of the controller 122 are possible having more or fewer components than the controller depicted in FIG. 10.

It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.

Claims

1. A plasma cutting system, comprising:

a plasma cutting power supply configured to provide a cutting current to a torch to create a plasma arc;

a controllable gas valve for regulating at least one of a flow rate and a pressure of a plasma gas supplied to the torch; and

a controller operatively connected to the plasma cutting power supply to control a current level of the cutting current, and operatively connected to the controllable gas valve to adjust a valve position of the controllable gas valve,

wherein the controller is configured to: receive real-time torch position information from a motion control system that controls positioning of the torch, wherein the real-time torch position information includes torch positions along a first axis and torch positions along a second axis that is perpendicular to the first axis, calculate respective derivatives from the torch positions along the first axis and the torch positions along the second axis, calculate a real-time velocity magnitude of the torch from the respective derivatives, and adjust the current level of the cutting current and the valve position of the controllable gas valve based on the calculated real-time velocity magnitude of the torch.

2. The plasma cutting system of claim 1, wherein the current level of the cutting current is reduced based on a reduction in the calculated real-time velocity magnitude of the torch.

3. The plasma cutting system of claim 1, wherein the current level of the cutting current and the flow rate of the plasma gas supplied to the torch are reduced based on a reduction in the calculated real-time velocity magnitude of the torch, and increased based on an increase in the calculated real-time velocity magnitude of the torch.

4. The plasma cutting system of claim 1, wherein the controller maintains kerf consistency by reducing the current level of the cutting current as the torch approaches a corner portion of a part cut from a workpiece.

5. The plasma cutting system of claim 1, wherein the real-time torch position information includes torch positions along a third axis that is perpendicular to the first axis and the second axis, and the controller is configured to calculate the real-time velocity magnitude of the torch from a derivative of the torch positions along the third axis.

6. The plasma cutting system of claim 1, wherein the controller is further configured to extinguish the plasma arc to end a cutting operation by reducing the current level of the cutting current while an arc length of the plasma arc is simultaneously shortened by movement of the torch toward a workpiece.

7. The plasma cutting system of claim 1, wherein the controller reduces the current level of the cutting current and the flow rate of the plasma gas supplied to the torch as the torch approaches a corner portion of a part cut from a workpiece.

8. The plasma cutting system of claim 7, wherein the controller increases the current level of the cutting current and the flow rate of the plasma gas supplied to the torch as the torch departs from the corner portion of the part cut from the workpiece.

9. A plasma cutting system, comprising:

a plasma cutting power supply configured to provide a cutting current to a torch to create a plasma arc;

a controllable gas valve for regulating at least one of a flow rate and a pressure of a plasma gas supplied to the torch; and

a controller operatively connected to the plasma cutting power supply to control a current level of the cutting current, and operatively connected to the controllable gas valve to adjust a valve position of the controllable gas valve,

wherein the controller is configured to: receive real-time torch position information from a motion control system that adjusts velocity of the torch when cutting a corner portion of a part cut from a workpiece, calculate first derivatives from the real-time torch position information and determine real-time velocity magnitudes of the torch when the corner portion of the part is cut from the workpiece, and maintain kerf consistency by adjusting, based on the determined real-time velocity magnitudes of the torch, the current level of the cutting current and the valve position of the controllable gas valve as the corner portion of the part is cut from the workpiece.

10. The plasma cutting system of claim 9, wherein the real-time torch position information includes torch positions along a first axis and torch positions along a second axis that is perpendicular to the first axis, and the controller is configured to calculate respective first derivatives from the torch positions along the first axis and the torch positions along the second axis.

11. The plasma cutting system of claim 9, wherein the real-time torch position information includes torch positions along a first axis, torch positions along a second axis that is perpendicular to the first axis, and torch positions along a third axis that is perpendicular to the first axis and the second axis, and the controller is configured to calculate respective first derivatives from the torch positions along the first axis, the torch positions along the second axis, and the torch positions along the third axis.

12. The plasma cutting system of claim 9, wherein the current level of the cutting current and the flow rate of the plasma gas supplied to the torch are reduced based on a reduction in the real-time velocity magnitudes of the torch, and increased based on an increase in the real-time velocity magnitudes of the torch.

13. The plasma cutting system of claim 12, wherein the controller reduces the current level of the cutting current and the flow rate of the plasma gas supplied to the torch as the torch approaches the corner portion of the part cut from the workpiece.

14. The plasma cutting system of claim 13, wherein the controller increases the current level of the cutting current and the flow rate of the plasma gas supplied to the torch as the torch departs from the corner portion of the part cut from the workpiece.

15. A plasma cutting method, comprising the steps of:

providing a plasma cutting system comprising: a plasma cutting power supply configured to provide a cutting current to a torch to create a plasma arc; a controllable gas valve for regulating at least one of a flow rate and a pressure of a plasma gas supplied to the torch; and a controller operatively connected to the plasma cutting power supply to control a current level of the cutting current, and operatively connected to the controllable gas valve to adjust a valve position of the controllable gas valve;

receiving real-time torch position information from a motion control system that controls positioning of the torch, wherein the real-time torch position information includes torch positions along a first axis and torch positions along a second axis that is perpendicular to the first axis;

calculating, by the controller, respective derivatives from the torch positions along the first axis and the torch positions along the second axis;

calculating, by the controller, a real-time velocity magnitude of the torch from the respective derivatives; and

adjusting the current level of the cutting current and the valve position of the controllable gas valve based on the calculated real-time velocity magnitude of the torch.

16. The plasma cutting method of claim 15, wherein the step of adjusting includes reducing the current level of the cutting current and the flow rate of the plasma gas supplied to the torch based on a reduction in the calculated real-time velocity magnitude of the torch, and increasing the current level of the cutting current and the flow rate of the plasma gas supplied to the torch based on an increase in the calculated real-time velocity magnitude of the torch.

17. The plasma cutting method of claim 15, wherein the controller maintains kerf consistency by reducing the current level of the cutting current as the torch approaches a corner portion of a part cut from a workpiece.

18. The plasma cutting method of claim 15, wherein the real-time torch position information includes torch positions along a third axis that is perpendicular to the first axis and the second axis, and the controller calculates the real-time velocity magnitude of the torch from a derivative of the torch positions along the third axis.

19. The plasma cutting method of claim 18, further comprising the step of extinguishing the plasma arc to end a cutting operation by reducing the current level of the cutting current while an arc length of the plasma arc is simultaneously shortened by movement of the torch toward a workpiece.

20. The plasma cutting system of claim 15, wherein the step of adjusting includes reducing the current level of the cutting current and the flow rate of the plasma gas supplied to the torch as the torch approaches a corner portion of a part cut from a workpiece.

21. The plasma cutting system of claim 20, wherein the step of adjusting includes increasing the current level of the cutting current and the flow rate of the plasma gas supplied to the torch as the torch departs from the corner portion of the part cut from the workpiece.