A novel plasma generation and containment system includes a first electrode, a second electrode, a power source, and an electromagnet. The first electrode and the second electrode are electrically coupled via a wire to form an open circuit. The voltage is asserted on the open circuit to form a spark between the first electrode and the second electrode to form a closed circuit. Then, a current is asserted on the closed circuit to form a plasma between the first electrode and the second electrode. The electromagnet provides a magnetic field to contain and compress the plasma.

In some aspects, torch receptacles for coupling a plasma arc torch to a torch lead can include: a body having a first end to connect to the torch lead and a second end to connect to a torch body; a set of ports within the first end to fluidly connect to a set of fluid conduits within the torch lead; and a multiway valve within the body and fluidly connected to the set of ports and to a torch gas conduit formed in the second end, the multiway valve being configured to: i) manipulate a flow of fluids between the first end and the second end to select from primary gases entering the set of ports, ii) deliver a selected primary gas to the torch body through the torch gas conduit, and iii) fluidly connect the torch gas conduit to a gas supply manifold of the plasma cutting system.

In some aspects, torch receptacles for coupling a plasma arc torch to a torch lead can include: a body having a first end to connect to the torch lead and a second end to connect to a torch body; a set of ports within the first end to fluidly connect to a set of fluid conduits within the torch lead; and a multiway valve within the body and fluidly connected to the set of ports and to a torch gas conduit formed in the second end, the multiway valve being configured to: i) manipulate a flow of fluids between the first end and the second end to select from primary gases entering the set of ports, ii) deliver a selected primary gas to the torch body through the torch gas conduit, and iii) fluidly connect the torch gas conduit to a gas supply manifold of the plasma cutting system.

A computerized method is provided for automatically determining at least one characteristic of a workpiece for processing by a plasma arc processing system. The method includes electrically connecting the workpiece to the plasma arc processing system that includes a plasma arc torch. A distal tip of the plasma arc torch is configurable to be positioned proximate to the workpiece. The method includes supplying, by the plasma arc processing system, an electrical current with a low amperage to the workpiece, the low amperage current insufficient to cut the workpiece, and monitoring, by the plasma arc processing system, a path of the electrical current relative to the workpiece. The method further includes determining, by the plasma arc processing system, the at least one characteristic of the workpiece based on the electrical current path monitored.

A computerized method is provided for automatically determining at least one characteristic of a workpiece for processing by a plasma arc processing system. The method includes electrically connecting the workpiece to the plasma arc processing system that includes a plasma arc torch. A distal tip of the plasma arc torch is configurable to be positioned proximate to the workpiece. The method includes supplying, by the plasma arc processing system, an electrical current with a low amperage to the workpiece, the low amperage current insufficient to cut the workpiece, and monitoring, by the plasma arc processing system, a path of the electrical current relative to the workpiece. The method further includes determining, by the plasma arc processing system, the at least one characteristic of the workpiece based on the electrical current path monitored.

An electromagnetic component assembly disposed in a power source of a welding or cutting system. The electromagnetic component assembly includes a core and a tubular winding. The tubular winding is placed near or around the core and conducts a current for an electromagnetic operation. The tubular winding includes a passageway for a process fluid, an inlet, at one end of the passageway, that receives the process fluid, and an outlet, at another end of the passageway, that directs the process fluid downstream toward a torch assembly. The passageway enhances cooling of the electromagnetic component assembly as the process fluid travels through the passageway from the inlet to the outlet.

A system for determining an operational state of an atmospheric pressure plasma. The system has a transformer for coupling power into the atmospheric pressure plasma, a current sampling circuit configured to sample at least one current pulse flowing through a primary winding of the transformer, and a programmed microprocessor configured to determine, from a waveform of the current pulse, the operational state of the atmospheric pressure plasma. The operational state is one of: a no plasma state, a plasma origination state indicative of an ignited arc expanding into a plasma by gas flow thereinto, and a plasma maintenance state indicative of the plasma being expanded.

A system for determining an operational state of an atmospheric pressure plasma. The system has a transformer for coupling power into the atmospheric pressure plasma, a current sampling circuit configured to sample at least one current pulse flowing through a primary winding of the transformer, and a programmed microprocessor configured to determine, from a waveform of the current pulse, the operational state of the atmospheric pressure plasma. The operational state is one of: a no plasma state, a plasma origination state indicative of an ignited arc expanding into a plasma by gas flow thereinto, and a plasma maintenance state indicative of the plasma being expanded.

Disclosed are a reverse polarity plasma arc robot additive manufacturing system and an implementation method therefor, the system comprising an industrial robot, an additive manufacturing power source, a wire feeding machine, a machine visual system, an industrial computer, a plasma welding gun, a refrigerating device, a gas device and an auxiliary tool fixture. The industrial robot, the additive manufacturing power source, the wire feeding machine, the refrigerating device, the gas device and the auxiliary tool fixture are all connected to the industrial computer via a CAN bus; the machine visual system is connected to the industrial computer by means of a TCP/IP protocol; the plasma welding gun is connected to the refrigerating device, the additive manufacturing power source, the wire feeding machine, the gas device and the auxiliary tool fixture; and the refrigerating device is further connected to the additive manufacturing power source. The additive manufacturing power source comprises a main-arc power source and a pilot-arc power source, and the main-arc power source and the pilot-arc power source are both connected to the plasma welding gun; and the main-arc power source comprises a main-arc power source main circuit and a main-arc power source control circuit, and the pilot-arc power source comprises a pilot-arc power source main circuit, a pilot-arc power source control circuit and a high-frequency and high-voltage arc ignition circuit. The additive manufacturing power source not only realizes the inverse change of the high-frequency and high-efficiency, but also realizes the integration and digital integration of the pilot-arc power source and the main-arc power source. The main-arc power source and the pilot-arc power source are digitally coordinated by means of a CAN network, and the volume of same is compact, the compatibility is better, the field environment is more adaptable, and the expansion capability is stronger.

Disclosed are a reverse polarity plasma arc robot additive manufacturing system and an implementation method therefor, the system comprising an industrial robot, an additive manufacturing power source, a wire feeding machine, a machine visual system, an industrial computer, a plasma welding gun, a refrigerating device, a gas device and an auxiliary tool fixture. The industrial robot, the additive manufacturing power source, the wire feeding machine, the refrigerating device, the gas device and the auxiliary tool fixture are all connected to the industrial computer via a CAN bus; the machine visual system is connected to the industrial computer by means of a TCP/IP protocol; the plasma welding gun is connected to the refrigerating device, the additive manufacturing power source, the wire feeding machine, the gas device and the auxiliary tool fixture; and the refrigerating device is further connected to the additive manufacturing power source. The additive manufacturing power source comprises a main-arc power source and a pilot-arc power source, and the main-arc power source and the pilot-arc power source are both connected to the plasma welding gun; and the main-arc power source comprises a main-arc power source main circuit and a main-arc power source control circuit, and the pilot-arc power source comprises a pilot-arc power source main circuit, a pilot-arc power source control circuit and a high-frequency and high-voltage arc ignition circuit. The additive manufacturing power source not only realizes the inverse change of the high-frequency and high-efficiency, but also realizes the integration and digital integration of the pilot-arc power source and the main-arc power source. The main-arc power source and the pilot-arc power source are digitally coordinated by means of a CAN network, and the volume of same is compact, the compatibility is better, the field environment is more adaptable, and the expansion capability is stronger.