Hypertherm, Inc.

Jesse A Roberts

Stephen Theodore Eickhoff

Zheng Duan

Peter J Twarog

Yu Zhang

Jonathan Philip Mather

Sung Je Kim

Garrett K Quillia

Steven Moody

Shreyansh Patel

Michael Scheller

David Jonathan Cook

David Agan

Eric Streit

E Michael Shipulski

Stephen M Liebold

Brett Andrew Hansen

Michael Hoffa

Junsong Mao

Justin Gullotta

Brian J Currier

David L Bouthillier

Harshawardhan Jogdand

Dennis M Borowy

Michael F Kornprobst

Micah Roberts

Stephen M Dunbar

Qinghua Liu

Brenda Melius

Jing Wu

Dennis Kulakowski

Ashok V Retnaswamy

Richard Pavlik

Faraz Mehdi

Erik Brine

Clayton Gould

Brandon Mason

Jon Mather

Peter John Twarog

Brett A Hansen

A consumable cartridge for a plasma arc torch includes a cartridge frame having a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, the second end including a plurality of discrete retaining features. The consumable cartridge includes an electrically conductive contact element secured to the cartridge frame by the plurality of discrete retaining features and translatable up to a predetermined distance within the cartridge frame along the longitudinal axis at the second end, the contact element having a core, a proximal surface, and a distal surface. The proximal surface is shaped to contact a torch plunger of the plasma arc torch upon installation into the plasma arc torch and the distal surface is shaped to contact an electrode of the plasma arc torch during an operation of the plasma arc torch.

Swirl ring and contact element for a plasma arc torch cartridge

A translatable electrode for use in a cartridge assembly for a contact start plasma arc torch including an electrode body having a longitudinal axis and including a proximal end and a distal end. The proximal end including a spiral groove and a contact surface at a proximal end face shaped to electrically communicate with a cathodic element. The translatable electrode also including at least one emissive insert disposed within the distal end of the electrode body and proximate a distal end face. The translatable electrode including at least one baffle disposed between the proximal and distal end of the electrode body. The translatable electrode also including a gas flow dampening region disposed circumferentially about the distal end and adjacent the distal end face and positioned between the at least one baffle and the distal end face.

Swirl control through electrode geometry

A lead connector is provided for connecting a plasma torch lead of a plasma arc torch to a power supply of a plasma cutting system. The lead connector includes a base portion, a central conduit disposed in the base portion, where the central conduit is configured to carry a gas and a torch current to the plasma arc torch, and multiple pins disposed radially about a center of the central conduit. The pins are located at a radius of between about 0.4 inches and about 0.65 inches from the center of the central conduit on a radial plane of the base portion. The pins include one or more pilot carrying pins and one or more control signal pins located from about 27 degrees to about 64 degrees and from about 120 degrees to about 170 degrees, respectively, about the center of the central conduit on the radial plane.

Connector in a plasma arc torch system

In some aspects, electrodes can include a front portion shaped to matingly engage a nozzle of the plasma cutting system, the front portion having a first end comprising a plasma arc emitter disposed therein; and a rear portion thermally connected to a second end of the front portion, the rear portion shaped to slidingly engage with a complementary swirl ring of the plasma cutting system and including: an annular mating feature extending radially from a proximal end of the rear portion of the electrode to define a first annular width to interface with the swirl ring, the annular mating feature comprising a sealing member configured to form a dynamic seal with the swirl ring to inhibit a flow of a gas from a forward side of the annular mating feature to a rearward side of the annular mating feature.

Cooling plasma cutting system consumables and related systems and methods

A consumable cartridge for a plasma arc torch is provided. The consumable cartridge includes an outer component defining a substantially hollow body, an inner component disposed substantially within the hollow body of the outer component, and a hollow region between the rear portion of the inner component and the outer component. The inner component includes a forward portion configured to axially secure and rotatatably engage the outer component to the inner component and a rear portion substantially suspended within the hollow body of the outer component. The rear portion is axially secured and rotatably engaged with the outer component via the forward portion. The hollow region is configured to receive a torch head to enable mating between the rear portion of the inner component and a cathode of the torch head.

Cost effective cartridge for a plasma arc torch

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 hand-held plasma power tool is provided, which includes a hand-held housing, a plasma delivery tip section at least partially disposed within the housing for delivering a plasma arc to a workpiece, an air compressor disposed within the housing for providing a gas to the plasma delivery tip section, and a power source disposed within the housing for providing a current to at least one of the air compressor or the plasma delivery tip section. The hand-held plasma power tool further comprises a handle section defined by at least a portion of the housing. The handle section is configured to enable an operator to manipulate the plasma power tool by hand while delivering the plasma arc to the workpiece.

Plasma power tool

In some aspects, methods for controlling a pneumatic system in a plasma arc processing system can include: receiving, by a computing device, a command to begin a plasma processing operation; generating a valve command signal for a valve that includes an operational drive voltage of at least about 125% of a continuous duty cycle coil voltage rating of the valve to open the valve; and once open, adjusting the valve command signal to facilitate a steady state operation to: monitor a steady state operational duty cycle of the valve, the steady state operational duty cycle being determined by comparing the continuous duty cycle coil voltage rating of the valve to an actual operational drive voltage supplied to the valve, and control the operational drive voltage supplied to the valve to maintain a steady state operational duty cycle of the valve at less than about 60% during steady state operation.

Controlling gas flows to plasma arc torches and related systems and methods

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.

Supplying pressurized gas to plasma arc torch consumables and related systems and methods

A swirl ring for a plasma arc torch includes a body configured to at least partially surround and slidingly engage an electrode of the plasma arc torch. The body includes a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, and at least one protuberance extending from the second end in a direction of the longitudinal axis. The at least one protuberance is configured to engage a switch of the plasma arc torch for sensing a presence of a swirl ring in the plasma arc torch.

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.

Plasma cutting system with efficient components

A swirl ring component of a contact start plasma arc torch is provided. The swirl ring component includes a hollow body formed of a front portion and a rear portion along a longitudinal axis and defining an exterior surface and an interior surface. The swirl ring component also includes one or more gas passageways extending from the exterior surface to the interior surface in the front portion of the hollow body and a resilient element disposed relative to the interior surface in the rear portion of the hollow body and configured to pass at least a pilot arc current to an electrode body. The swirl ring component further includes a shoulder portion configured to retain the resilient element in the hollow body.

Electrode for a contact start plasma arc torch and contact start plasma arc torch employing such electrodes

Growing community of inventors

Cornish, NH, United States of America

Jesse A Roberts