Described herein are examples of weld training systems that show (e.g., transparent and/or translucent) “ghost” images of a welding tool on a display screen of a welding headgear to indicate target positions and/or target orientations of an actual welding tool. In some examples, the weld training systems may additionally “reset” the target tool image to a position closer to the actual welding tool if the target tool image gets too far away. The ability to “reset” the target tool image to a position closer to the actual welding tool may help in minimizing a risk that an operator 106 will overcompensate to try to catch up with the target tool image, which can be detrimental to the weld. Additionally, resetting the target tool image to a position closer the welding tool may allow an operator to better perceive and/or understand differences in orientation and/or other technique parameters.

An apparatus may include a power supply to generate an output current. The apparatus may further include a plasma torch to apply the output current across a gap and a user interface to receive a selection for enabling a pierce current mode. The apparatus may further include a controller to temporarily increase an output current setting at the plasma torch from a first level to a second level, responsive to the selection of pierce current mode.

A method for thermal processing of a workpiece uses a thermal processing machine. The method includes the following steps carried out in an automated manner: setting up the processing machine by producing contact between the processing tool and the workpiece and recording the spatial position of a workpiece surface, positioning the processing tool at a predetermined first and second distance from the workpiece surface and recording the associated signal values of the distance sensor as first and second measured values, and calibrating the distance controller which includes determining a height derivative of the distance sensor signal and an amplification factor for the signal of the distance sensor taking in account the first measured value, the second measured value, the first distance and the second distance; positioning the processing tool at a predetermined working distance from the workpiece surface with the inclusion of the amplification factor; and thermally processing the workpiece.

The present invention features a computer-implemented method of planning a processing path relative to a three-dimensional workpiece for a plasma arc cutting system coupled to a robotic arm. The method includes receiving input data from a user comprising (i) Computer-Aided Design (CAD) data for specifying a desired part to be processed from the three-dimensional workpiece, and (ii) one or more desired parameters for operating the plasma arc cutting system. A plurality of features of the desired part to be formed on the three-dimensional workpiece are identified based on the CAD data. The method also includes dynamically filtering a library of cut charts based on the plurality of features and the desired operating parameters to determine a recommended cut chart for processing the plurality of features. The method further includes generating the processing path based on the recommended cut chart and the plurality of features to be formed.

The present invention features a computer-implemented method of planning a processing path relative to a three-dimensional workpiece for a plasma arc cutting system coupled to a robotic arm. The method includes receiving input data from a user comprising (i) Computer-Aided Design (CAD) data for specifying a desired part to be processed from the three-dimensional workpiece, and (ii) one or more desired parameters for operating the plasma arc cutting system. A plurality of features of the desired part to be formed on the three-dimensional workpiece are identified based on the CAD data. The method also includes dynamically filtering a library of cut charts based on the plurality of features and the desired operating parameters to determine a recommended cut chart for processing the plurality of features. The method further includes generating the processing path based on the recommended cut chart and the plurality of features to be formed.

A method for joining by welding or gluing joining elements to components, with the following steps: preparation of a joining element, which comprises a first joining surface, and preparation of a component, which comprises a second joining surface; preparation of the first or second joining surface; and carrying out the joining process, in which the joining element is joined to the component; wherein the preparatory step comprises at least one of the following cleaning methods for cleaning the first or second joining surface: a TIG arc method, a plasma gas cleaning method, and a snow jet method.

Cutting torch guide structures, systems, and kits include a base structure having a bottom surface and a channel formed in the base structure, a mechanically switched permanent magnet coupled to the base structure and configured to mechanically switch between two magnetic states, and a cutting torch guide structure configured to be releasably received in the channel and magnetically coupled to the base structure by magnetic attraction between a at least one permanent magnet fixed in at least one recess in the channel and a guide structure permanent magnet fixed to the cutting torch guide structure, where the cutting torch guide structure is configured with a first portion that is removable received in the channel of the base structure and a second portion that overhangs the base structure and includes an edge that defines a predefined shape and is configured to be in slidable contact with a cutting torch tip.

Cutting torch guide structures, systems, and kits include a base structure having a bottom surface and a channel formed in the base structure, a mechanically switched permanent magnet coupled to the base structure and configured to mechanically switch between two magnetic states, and a cutting torch guide structure configured to be releasably received in the channel and magnetically coupled to the base structure by magnetic attraction between a at least one permanent magnet fixed in at least one recess in the channel and a guide structure permanent magnet fixed to the cutting torch guide structure, where the cutting torch guide structure is configured with a first portion that is removable received in the channel of the base structure and a second portion that overhangs the base structure and includes an edge that defines a predefined shape and is configured to be in slidable contact with a cutting torch tip.

A system and method for forming a structure with steep walls (walls having an angle greater than 60° with respect to a level plane) through one or more incremental sheet forming operations is provided. The method includes a workpiece with an inner region and an outer region that are separated by a boundary region. The boundary region includes a plurality of openings and a plurality of connecting elements. The openings are cut into the workpiece using a boundary region cutting tool. A forming tool is configured to operate on the inner region after the boundary region cutting operation has been completed. At least one control unit is in communication with the forming tool. The at least one control unit operates the forming tool to form the structure from the inner region.

A portable device for precision plasma and oxy-fuel torch cutting is provided. Versions of an example portable cutting torch tool guide the gun of a cutting torch to make precision linear cuts or curved cuts in a metal workpiece. In an implementation, the device is a gun for a cutting torch, with an integrated rail follower and adjustable vertical and horizontal offsets from a workpiece. The cutting torch tool may use various kinds of rails for stable cuts, with optional movement damping, motorized drive, servos for vertical and horizontal offset, and remote control with user interface.