An automated oxy-fuel thermal processing system including an oxy-fuel torch, an automated machine tool operatively coupled to the torch for moving the torch relative to a work piece, and a circuit including a voltage source or a current electrically connected to the torch and configured to be electrically connected to the work piece. The automated oxy-fuel thermal processing system may further include a processor that is operatively connected to the torch, the automated machine tool, the circuit, and the voltage source or current source, wherein the processor is configured to control the operation of the torch, the automated machine tool and the voltage source or current source, and to monitor a current or voltage in the circuit in a predefined manner.

A cutting torch guide assembly for cutting beveled openings includes a first rod that is hollow. A first sleeve is positioned around and slidably positionable on the first rod. A pin is coupled to and extends perpendicularly from the first sleeve. The pin is configured to couple to a metal substrate to define an axis of a penetration that is to be cut into the metal substrate. A second rod is positioned in and selectively extensible from the first rod. The first sleeve is positionable to select a diameter of the penetration on an opposing side of the metal substrate. The second rod is positionable relative to the first rod to select a thickness of the metal substrate. A ring coupled to the second rod is configured to insert a nozzle of a cutting torch so that the nozzle is positioned to cut a beveled penetration into the substrate.

A cutting torch guide assembly for cutting beveled openings includes a first rod that is hollow. A first sleeve is positioned around and slidably positionable on the first rod. A pin is coupled to and extends perpendicularly from the first sleeve. The pin is configured to couple to a metal substrate to define an axis of a penetration that is to be cut into the metal substrate. A second rod is positioned in and selectively extensible from the first rod. The first sleeve is positionable to select a diameter of the penetration on an opposing side of the metal substrate. The second rod is positionable relative to the first rod to select a thickness of the metal substrate. A ring coupled to the second rod is configured to insert a nozzle of a cutting torch so that the nozzle is positioned to cut a beveled penetration into the substrate.

Embodiments of multipurpose workstations are disclosed having a small, portable housing that defines an interior space, into which a conductive, uneven surface having a plurality of differing heights is disposed. The conductive surface can include a plurality of openings sized and disposed to provide for an air gap within an opening or below the surface. The workstations can further include an upper removable conductive flat metal surface, and a tray disposed below the uneven, conductive surface that collects material that passes through the openings.

Embodiments of multipurpose workstations are disclosed having a small, portable housing that defines an interior space, into which a conductive, uneven surface having a plurality of differing heights is disposed. The conductive surface can include a plurality of openings sized and disposed to provide for an air gap within an opening or below the surface. The workstations can further include an upper removable conductive flat metal surface, and a tray disposed below the uneven, conductive surface that collects material that passes through the openings.

A system (40) for processing a workpiece includes a support surface (88) for supporting a workpiece (44). The system (40) includes a processing tool (92) movable with respect to a processing path. The system (40) includes a sensor carriage (408) movable along a scan axis and having a light source (476, 515, 550, 586) located to emit a light beam at an angle to the scan axis onto a target surface of a workpiece (44), and a camera (484, 522, 558, 594) configured to record location data of the light beam on a target surface of a workpiece (44) as the sensor carriage (408) moves along the scan axis. The system (40) includes a control system for generating a three-dimensional point representation of a workpiece surface from the light beam location data, to control movement of the processing tool (92) based on the three-dimensional point representation of a workpiece (44).

A system (40) for processing a workpiece includes a support surface (88) for supporting a workpiece (44). The system (40) includes a processing tool (92) movable with respect to a processing path. The system (40) includes a sensor carriage (408) movable along a scan axis and having a light source (476, 515, 550, 586) located to emit a light beam at an angle to the scan axis onto a target surface of a workpiece (44), and a camera (484, 522, 558, 594) configured to record location data of the light beam on a target surface of a workpiece (44) as the sensor carriage (408) moves along the scan axis. The system (40) includes a control system for generating a three-dimensional point representation of a workpiece surface from the light beam location data, to control movement of the processing tool (92) based on the three-dimensional point representation of a workpiece (44).

In some aspects, material processing head can include a body; an antenna disposed within the body; a first tag, associated with a first consumable component, disposed within a flux communication zone of the body at a first distance from the antenna, the first tag having a first resonant frequency; and a second tag, associated with a second consumable component, disposed within the flux communication zone of the body at a second distance from the antenna, the second tag having a second resonant frequency that is different than the first resonant frequency, where the first and second resonant frequencies are tuned based upon at least one of: i) a difference between the first distance and the second distance; or ii) a characteristic (e.g., shape) of the flux communication zone in which the first tag and/or the second tag is disposed.

In some aspects, material processing head can include a body; an antenna disposed within the body; a first tag, associated with a first consumable component, disposed within a flux communication zone of the body at a first distance from the antenna, the first tag having a first resonant frequency; and a second tag, associated with a second consumable component, disposed within the flux communication zone of the body at a second distance from the antenna, the second tag having a second resonant frequency that is different than the first resonant frequency, where the first and second resonant frequencies are tuned based upon at least one of: i) a difference between the first distance and the second distance; or ii) a characteristic (e.g., shape) of the flux communication zone in which the first tag and/or the second tag is disposed.

A scrap cutting apparatus including an enclosure comprising two open sides, two closed sides, an open bottom, and a closed top, wherein at least one opening is provided in at least one of closed sides, at least one torch extending through the at least one opening, and a rail system comprising two parallel rails, wherein the enclosure is adapted to move along the rail system. Also, a method of cutting metal scrap including positioning a plurality of pieces of scrap material between the rails of the scrap cutting apparatus described above, moving the enclosure over a first piece of scrap material, making at least one cut in the first piece of scrap material using the at least one torch, moving the enclosure along the rail system and over a second piece of scrap material, and making at least one cut in the second piece of scrap material using the torch.