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  • Controlling plasma arc torches and related systems and methods
    Patent number: 11826847
    Abstract: In some aspects, methods for preserving a usable life of a plasma arc electrode consumable installed in a plasma arc torch can include measuring a characteristic of an electrical signal being provided to the torch to generate a plasma arc between the torch and a workpiece to be processed; monitoring the characteristic during operation of the torch over a time period; comparing the characteristic to a threshold value; and, responsive to determining that a measured characteristic meets and/or exceeds the threshold value, initiating an arc extinguishing sequence to preserve the life of the electrode.
    Type: Grant
    Filed: January 8, 2020
    Date of Patent: November 28, 2023
    Assignee: Hypertherm, Inc.
    Inventors: Jonathan Ames, Christopher S. Passage, Soumya Mitra, John Peters
  • Arc cutting system, including coolant tubes and other consumables, and related operational methods
    Patent number: 10129969
    Abstract: A method of using a coolant tube in a liquid cooled plasma arc torch is provided. The method includes installing the coolant tube and a first electrode in the plasma arc torch. The method also includes biasing, by a first coolant flow, a biasing surface of the coolant tube against the first electrode, such that the coolant tube translates axially along the longitudinal axis to contact the first electrode. The biasing by the first coolant flow defines a first distance in an axial direction between the O-ring of the coolant tube and a proximal end of the first electrode. The method further includes removing the first electrode from the plasma arc torch and installing a second electrode in the torch. The method includes biasing, by a second coolant flow, the biasing surface of the coolant tube against the second electrode, such that the coolant tube translates axially along the longitudinal axis to contact the second electrode.
    Type: Grant
    Filed: April 11, 2017
    Date of Patent: November 13, 2018
    Assignee: Hypertherm, Inc.
    Inventors: Madhura S. Mitra, Soumya Mitra, Brian J. Currier
  • Nozzle for a plasma arc torch having an angled inner surface to facilitate and control arc ignition
    Patent number: 5164568
    Abstract: A plasma arc torch mounts an electrode and a nozzle, with a mutual spacing, symmetrically about a common longitudinal axis at one end of the torch adjacent a workpiece. The inner surface of the nozzle has an annular, inwardly-directed projection, located opposite the electrode and at a point of closest spacing between the electrode and the nozzle. The projection, or "angle kink", is characterized by a minimum radius of curvature as compared to the radii of curvature of adjacent portions of the nozzle opposite said electrode. The inner surface is adjacent a central exit passage of the nozzle and the angle kink is spaced from the intersection of the exit port and the inner nozzle. In the preferred form the interior nozzle surface is formed by two conical surfaces each having different slopes with respect to the longitudinal axis so as to form the circumferentially extending angle kink at their plane of intersection.
    Type: Grant
    Filed: January 21, 1992
    Date of Patent: November 17, 1992
    Assignee: Hypertherm, Inc.
    Inventor: Nicholas A. Sanders
  • Pilot arc circuit for a contact start plasma torch
    Publication number: 20080083713
    Abstract: A contact start plasma system is provided that includes a passive pilot arc circuit that decreases the size and cost of the system. The plasma arc system includes a torch body, an electrode having a longitudinally disposed axis and mounted in the body, a nozzle having a longitudinally disposed axis, the nozzle axis being disposed substantially collinearly with the electrode axis, a power supply coupled to the electrode, the nozzle and a workpiece, the power supply providing a current for operating the torch in a pilot arc mode and a transferred arc mode, a gas source coupled to the plasma chamber, the gas source providing gas for operating in a pilot arc mode and a transferred arc mode, and a passive pilot arc circuit coupled between the power supply and the nozzle, the passive pilot arc circuit controlling the operation of the torch in the pilot arc mode. Either the electrode or the nozzle can be translatable for blow-forward or blow-back mode of operation.
    Type: Application
    Filed: September 11, 2006
    Publication date: April 10, 2008
    Applicant: Hypertherm, Inc.
    Inventor: Nicholas A. Sanders
  • Consumable cartridge for a plasma arc cutting system
    Patent number: 9981335
    Abstract: A replaceable cartridge for a plasma arc torch 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.
    Type: Grant
    Filed: May 11, 2015
    Date of Patent: May 29, 2018
    Assignee: Hypertherm, Inc.
    Inventors: Nicholas A. Sanders, Peter J. Twarog, E. Michael Shipulski, Yu Zhang
  • Consumable cartridge for a plasma arc cutting system
    Patent number: 10960485
    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.
    Type: Grant
    Filed: May 4, 2018
    Date of Patent: March 30, 2021
    Assignee: Hypertherm, Inc.
    Inventors: Nicholas A. Sanders, Peter J. Twarog, E. Michael Shipulski, Yu Zhang
  • Consumable cartridge for a plasma arc cutting system
    Patent number: 11684994
    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.
    Type: Grant
    Filed: February 1, 2021
    Date of Patent: June 27, 2023
    Assignee: Hypertherm, Inc.
    Inventors: Nicholas A. Sanders, Peter J. Twarog, E. Michael Shipulski, Yu Zhang
  • Plasma arc torch with vented flow nozzle retainer
    Patent number: 6084199
    Abstract: A flow of ionizable gas is provided to a shielded plasma arc torch which includes an electrode, a translatable nozzle, a nozzle retainer, and a shield. After passing through a heat exchanger to cool the electrode, the gas flow enters an annular chamber where the flow is divided into three subflows. A first subflow enters a plasma chamber formed by the electrode, the nozzle, and a swirl ring to pressurize the plasma chamber and support a plasma arc. The second subflow passes serially through apertures in the nozzle retainer and the shield to shield the plasma arc. The remaining flow is vented to ambient. Accordingly, a single gas flow may be employed to independently support multiple torch operating requirements.
    Type: Grant
    Filed: August 1, 1997
    Date of Patent: July 4, 2000
    Assignee: Hypertherm, Inc.
    Inventors: Jon Lindsay, Stephen T. Eickhoff, Michael W. Vandiver
  • Safety circuit for a blow forward contact start plasma arc torch
    Patent number: 5900169
    Abstract: A safety circuit is utilized in a blow forward contact start plasma arc torch to extinguish the current to the torch upon determination of an unsafe operating condition. The torch includes a torch body, an electrode and a translatable conductive nozzle biased into contact with the electrode. The safety circuit receives a reference signal a signal indicative of the arc voltage and a mode status signal. The torch current is extinguished when the signal indicative of the arc voltage is less than the reference signal and the mode status signal indicates the torch is operating in the transferred arc mode.
    Type: Grant
    Filed: June 6, 1997
    Date of Patent: May 4, 1999
    Assignee: Hypertherm, Inc.
    Inventors: Dennis Borowy, Jon Lindsay
  • Pilot arc circuit for a contact start plasma torch
    Patent number: 7615720
    Abstract: A contact start plasma system is provided that includes a passive pilot arc circuit that decreases the size and cost of the system. The plasma arc system includes a torch body, an electrode having a longitudinally disposed axis and mounted in the body, a nozzle having a longitudinally disposed axis, the nozzle axis being disposed substantially collinearly with the electrode axis, a power supply coupled to the electrode, the nozzle and a workpiece, the power supply providing a current for operating the torch in a pilot arc mode and a transferred arc mode, a gas source coupled to the plasma chamber, the gas source providing gas for operating in a pilot arc mode and a transferred arc mode, and a passive pilot arc circuit coupled between the power supply and the nozzle, the passive pilot arc circuit controlling the operation of the torch in the pilot arc mode. Either the electrode or the nozzle can be translatable for blow-forward or blow-back mode of operation.
    Type: Grant
    Filed: September 11, 2006
    Date of Patent: November 10, 2009
    Assignee: Hypertherm, Inc.
    Inventor: Nicholas A. Sanders
  • High Quality Hole Cutting Using Variable Shield Gas Compositions
    Publication number: 20100155376
    Abstract: A method and apparatus for a plasma torch system having a plasma torch tip configuration that includes a nozzle, an electrode, and a control unit for controlling a composition of the shield gas flow, such that while cutting the contour the shield gas flow comprises a first shield gas composition and while cutting the hole the shield gas flow comprises a second shield gas composition.
    Type: Application
    Filed: December 22, 2008
    Publication date: June 24, 2010
    Applicant: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Guy T. Best
  • Consumable component parts for a plasma torch
    Patent number: 8866038
    Abstract: A component for a plasma arc torch includes a body portion, a tapered surface on the body portion, the tapered surface including a compressible member that provides a disengagement force relative to the body portion, and an axially disposed surface on the body portion for coupling a mating surface on an adjacent structure of the torch. The component can be a nozzle and/or an electrode.
    Type: Grant
    Filed: January 23, 2007
    Date of Patent: October 21, 2014
    Assignee: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Brent R. Bartlett, Aaron D. Brandt, Zheng Duan, Stephen M. Liebold
  • HIGH QUALITY HOLE CUTTING USING VARIABLE SHIELD GAS COMPOSITIONS
    Publication number: 20120018409
    Abstract: A method and apparatus for a plasma torch system having a plasma torch tip configuration that includes a nozzle, an electrode, and a control unit for controlling a composition of the shield gas flow, such that while cutting the contour the shield gas flow comprises a first shield gas composition and while cutting the hole the shield gas flow comprises a second shield gas composition.
    Type: Application
    Filed: September 29, 2011
    Publication date: January 26, 2012
    Applicant: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Guy T. Best
  • Water injection and venting of a plasma arc torch
    Patent number: 11212904
    Abstract: A plasma arc torch system comprising a plasma arc torch is provided. The torch includes an electrode, a nozzle, a vent passage and a shield. The nozzle is spaced from the electrode to define a plasma chamber therebetween. The plasma chamber is configured to receive a plasma gas. The vent passage, disposed in the nozzle body, is configured to divert a portion of the plasma gas exiting the plasma chamber from a nozzle exit orifice. The shield is spaced from the nozzle to define a flow region therebetween. The flow region is configured to (i) receive a liquid and (ii) expel the liquid along with a plasma arc substantially surrounded by the liquid via a shield exit orifice.
    Type: Grant
    Filed: November 6, 2018
    Date of Patent: December 28, 2021
    Assignee: Hypertherm, Inc.
    Inventors: Madhura Mitra, Soumya Mitra, Stephen Liebold
  • Water injection and venting of a plasma arc torch
    Patent number: 10149376
    Abstract: A plasma arc torch system comprising a plasma arc torch is provided. The torch includes an electrode, a nozzle, a vent passage and a shield. The nozzle is spaced from the electrode to define a plasma chamber therebetween. The plasma chamber is configured to receive a plasma gas. The vent passage, disposed in the nozzle body, is configured to divert a portion of the plasma gas exiting the plasma chamber from a nozzle exit orifice. The shield is spaced from the nozzle to define a flow region therebetween. The flow region is configured to (i) receive a liquid and (ii) expel the liquid along with a plasma arc substantially surrounded by the liquid via a shield exit orifice.
    Type: Grant
    Filed: December 11, 2014
    Date of Patent: December 4, 2018
    Assignee: Hypertherm, Inc.
    Inventors: Madhura Mitra, Soumya Mitra, Stephen Liebold
  • High quality hole cutting using variable shield gas compositions
    Patent number: 8354610
    Abstract: A method and apparatus for a plasma torch system having a plasma torch tip configuration that includes a nozzle, an electrode, and a control unit for controlling a composition of the shield gas flow, such that while cutting the contour the shield gas flow comprises a first shield gas composition and while cutting the hole the shield gas flow comprises a second shield gas composition.
    Type: Grant
    Filed: September 29, 2011
    Date of Patent: January 15, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Guy T. Best
  • Composite consumables for a plasma arc torch
    Patent number: 9662747
    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.
    Type: Grant
    Filed: October 14, 2014
    Date of Patent: May 30, 2017
    Assignee: Hypertherm, Inc.
    Inventors: Clifford Glenn Darrow, Carey Chen, Nicholas A. Sanders
  • High quality hole cutting using variable shield gas compositions
    Patent number: 8354609
    Abstract: A method and apparatus for a plasma torch system having a plasma torch tip configuration that includes a nozzle, an electrode, and a control unit for controlling a composition of the shield gas flow, such that while cutting the contour the shield gas flow comprises a first shield gas composition and while cutting the hole the shield gas flow comprises a second shield gas composition.
    Type: Grant
    Filed: December 22, 2008
    Date of Patent: January 15, 2013
    Assignee: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Guy T. Best
  • Blow forward contact start plasma arc torch with distributed nozzle support
    Patent number: 5886315
    Abstract: A translatable nozzle is supported in a contact start plasma arc torch at an aft end by a swirl ring and at a longitudinally spaced forward end by an insulative bearing member of a nozzle retainer. The nozzle is biased into contact with an electrode by a compliant spring element. A pilot arc is formed by first passing current through the electrode and nozzle. Upon pressurization of a plasma chamber formed therebetween, the nozzle is translated forward, compressing the spring element and initiating the pilot arc. The spring element may be maintained integrally with the nozzle to facilitate removal and replacement of the spring element with the consumable nozzle.
    Type: Grant
    Filed: August 1, 1997
    Date of Patent: March 23, 1999
    Assignee: Hypertherm, Inc.
    Inventors: Zhipeng Lu, Jon Lindsay, Stephen T. Eickhoff, Michael F. Kornprobst
  • Consumable component parts for a plasma torch
    Patent number: RE49153
    Abstract: A component for a plasma arc torch includes a body portion, a tapered surface on the body portion, the tapered surface including a compressible member that provides a disengagement force relative to the body portion, and an axially disposed surface on the body portion for coupling a mating surface on an adjacent structure of the torch. The component can be a nozzle and/or an electrode.
    Type: Grant
    Filed: October 2, 2020
    Date of Patent: July 26, 2022
    Assignee: Hypertherm, Inc.
    Inventors: Jon W. Lindsay, Brent R. Bartlett, Aaron D. Brandt, Zheng Duan, Stephen M. Liebold
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