Hypertherm, Inc.

Brian J Currier

Jon W Lindsay

Stephen M Liebold

Aaron D Brandt

Zheng Duan

John Peters

Richard Eugene Anderson

Casey Thomas Jones

Edward M Shipulski

Zhipeng Lu

Girish R Kamath

Jeremy Beliveau

Peter J Twarog

Charles Marcou Hackett

Soumya Mitra

Kenneth J Woods

Stephen M Dunbar

Madhura Mitra

Brenda Melius

Yutaka Nakano

E Michael Shipulski

Scott A Leonard

Richard W Couch, Jr

David Jonathan Cook

Jesse A Roberts

Brett Andrew Hansen

Garrett K Quillia

David L Bouthillier

Harshawardhan Jogdand

Richard Rox Anderson

Micah Roberts

Ross Angus Smith

Matthew C Harris

Steve Dunbar

Boris Mandadzhiev

Casey Jones

Madhura S Mitra

In some aspects, a plasma torch head for a plasma arc torch can include ports disposed within a base portion that are configured to receive fluids and electrical signals from a plasma torch lead via a plasma torch receptacle, the ports being shaped to align the torch head and the plasma torch receptacle during connection and including: a central coolant supply port to convey a liquid coolant to the torch head, the central coolant supply port extending a length to primarily align the plasma torch head with the torch receptacle, the central coolant supply port further including a flat surface shaped to secondarily align the torch head with the torch receptacle upon mating engagement, and an ohmic contact connector defining a tertiary alignment feature; and a connector disposed about the base portion shaped to engage with and couple to the torch receptacle.

Connecting plasma arc torches and related systems and methods

A connector component configured for coupling a consumable component to a plasma arc torch is provided. The connector component comprises a body having a proximal end and a distal end disposed along and defining a longitudinal axis. The connector component includes at least two engagement regions disposed radially about the longitudinal axis on a surface of the body. Each engagement region includes at least one engagement feature disposed on the surface of the body. The connector component also includes at least two free regions disposed radially about the longitudinal axis on the surface of the body. Each free region is radially located between a pair of the engagement regions and characterized by an absence of the engagement feature.

Thread connection for a torch system

A liquid cooled shield assembly for a plasma arc torch includes an inner cap and a shield. The inner cap includes a substantially hollow body having a proximal end and a distal end that define a longitudinal axis, the distal end including an annular portion about the longitudinal axis. The inner cap also includes a liquid passage defined, at least in part, by an interior surface of the body, the liquid passage including a first set of ports in the annular portion, the first set of ports extending between an interior portion of the body and an exterior portion of the body to convey a liquid therethrough. The shield at least partially surrounds the inner cap and has a liquid impingement region on an interior surface of the shield adjacent to the first set of ports, the liquid impingement region for receiving the cooling liquid.

Plasma arc cutting system, including retaining caps, and other consumables, and related operational methods

A nozzle for a liquid-cooled plasma arc torch is provided. The nozzle includes a thermally conductive body having a distal end, a proximal end, and a longitudinal axis extending therethrough. The nozzle also includes a plasma arc exit orifice at the distal end of the thermally conductive body. The nozzle additionally includes a cooling waist located circumferentially about an exterior surface of the thermally conductive body. The cooling waist includes a liquid inlet slope, a liquid outlet slope and a heat exchange region between the liquid inlet slope and the liquid outlet slope. The heat exchange region extends substantially parallel to the longitudinal axis, and the liquid inlet slope and the liquid outlet slope are oriented generally perpendicular to the longitudinal axis.

Plasma arc cutting system, including nozzles and other consumables, and related operational methods

In some aspects, power supplies for liquid cooled plasma cutting systems configured to support plasma arc generation by a torch head connected to the power supply can include: a set of electrical components for plasma arc generation; and a power supply housing containing the set of electrical components, the power supply housing having a front panel and at least two side panels and defining: a set of inlets for allowing a cooling gas to enter the power supply housing to thermally regulate the set of electrical components, at least one inlet of the set of inlets being positioned at a corner of the housing and oriented at a non-zero angle relative to the front panel and to at least one of the two side panels; and a set of vents for allowing at least a portion of the cooling gas to exit the power supply housing.

Cooling plasma cutting systems and related systems and methods

The invention features an inner cap for a liquid-cooled plasma arc torch. The inner cap includes a body having a longitudinal axis, a first end, and a second end. The first end includes an annular portion disposed proximate a torch tip. A liquid passage is formed within the body, is shaped to convey a liquid therethrough, and has a first set of ports formed in the annular portion. A gas passage is formed within the body, is shaped to convey a gas therethrough, and includes a second set of ports formed in the annular portion. The annular portion is configured such that subsets of ports in the first set of ports direct the liquid in a radial direction with respect to the longitudinal axis and alternate, in a rotational direction about the longitudinal axis, with subsets of ports in the second set of ports.

In some aspects, nozzles for a plasma arc torch can include a first body having a first end, a second end, and a longitudinal axis; and a second body disposed about a portion of the first body to complement the first body, the second body defining a set of channels formed on an internal surface shaped to form a set of liquid flow passages between the first body and the second body, the second body at least partially defining at least one inlet and at least one outlet to the set of liquid flow passages.

Cooling plasma torch nozzles and related systems and methods

A plasma cutting system is provided. The system includes a torch tip having a proximal end and a distal end defining a longitudinal axis extending therethrough. The torch tip includes a plasma plenum and a plasma arc exit orifice located at the distal end of the torch tip. The system includes a lead having a distal end configured for connection to the proximal end of the torch tip. The system also includes an atmospheric vent port disposed between the plasma arc exit orifice and the distal end of the lead. The system further includes a conduit fluidly connecting the plasma plenum and the atmospheric vent port.

Systems and methods for plasma gas venting in a plasma arc torch

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. The biasing by the second coolant flow defines a second distance in an axial direction between the O-ring of the coolant tube and a proximal end of the second electrode. A difference between the first distance and the second distance is at least about 0.25 inches.

Arc cutting system, including coolant tubes and other consumables, and related operational methods

A plasma arc cutting system includes a power supply comprising a multi-pulse transformer and a plurality of semiconductor switches directly connected to a bank of capacitors, and a thermal regulation system connected to the power supply and configured to cool the multi-pulse transformer. The thermal regulation system includes a cold plate in direct contact with the semiconductor switches; a fluid conduit disposed within the cold plate; and a pump connected to the conduit and configured to direct a coolant fluid through the conduit. The power supply has at least one of the following operating requirements: (i) a weight to power ratio of approximately 22.4 pounds per kilowatt; (ii) a volume to power ratio of approximately 1366 cubic inches per kilowatt; (iii) an average semiconductor device case temperature of approximately 100 degrees Centigrade during a cutting operation; (iv) a maximum transformer temperature of about 133 degrees Centigrade during a cutting operation.

Plasma torch power circuit and cooling system

Power supply

In some aspects, a retaining cap for a plasma arc torch can include a shell having an exterior surface that defines, at least in part, a first liquid coolant channel, a liner circumferentially disposed within the shell and having an interior surface that defines, at least in part, a second liquid coolant channel, and a gas flow channel defined at least in part by and located between the shell and the liner.

Apparatus and method for a liquid cooled shield for improved piercing performance

A shield for a plasma arc torch that pierces and cuts a metallic workpiece producing a splattering of molten metal directed at the torch, the shield protecting consumable components of the plasma arc torch from the splattering molten metal. The shield can include a body, a first surface of the body configured to be contact-cooled by a gas flow, a second surface of the body configured to be contact-cooled by a liquid flow, and a seal assembly configured to be secured to the body and disposed relative to the second surface configured to retain the liquid flow contact-cooling the second surface.

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Newport, NH, United States of America

Brian J Currier