A plasma arc cutting system includes a power supply and a plasma torch attachable to the power supply. The plasma torch generates a plasma arc for cutting a workpiece. A reader is associated with the plasma torch. The reader is capable of reading stored data from an identification device located on a cartridge or a consumable component of the plasma arc cutting system. A controller is within the plasma arc cutting system and in communication with the power supply. The controller is capable of automatically establishing operating parameters of the plasma arc cutting system based upon the data stored on the identification device. An override feature allows a user of the plasma arc cutting system to override the automatically established operating parameters of the torch and to input user selected operating parameters.

A circuit for the control and identification of a plasma torch comprising an electronic circuit plate (100) provided with a microcontroller located next to the plasma cut torch (200), controlling and identifying the plasma torch (200) next to the central plate (30) of the device (300) by means of two wires (10) known as “network” which perform the communication between the circuit (100) and the power supply of the device (300) promoting monitoring and control of all the actions of the device, eliminating the need of various wires, solving the problems of frequent stops of the device due to breaking wires and eliminating difficulties to read the power of the plasma torch (200).

A welding-type control system including configurable hardware, a hardware configuration memory device that configures the configurable hardware when loaded with configuration data, a processor, an input portal via which the processor can receive a file with the configuration data, and a memory with instructions that when executed by the processor cause the processor to transfer the configuration data in the file to the memory device. A controlled system including such a welding-type control system includes a welding system, a cladding system or a plasma cutting system.

A plasma computer numerically controlled (CNC) cutting machine is controlled by a computer such as a personal computer capable running an operating system and software programs. In an embodiment, the computer executes a CNC program to control movement of a plasma torch to cut parts from a workpiece while a spectrometer determines an emissions spectra of light emitted as the torch cuts the workpiece. The spectrometer cooperates with software running on a computer to analyze the metal as it is being cut by the CNC cutting machine and determine a composition. In embodiments, the composition is compared to an expected composition and saved in a database with identifying information; in a particular embodiment the database is queried to provide identifying information of metal having similar composition to the workpiece.

A torch assembly for cutting or spraying applications. The torch assembly includes a torch connector that connects to at least one cable that communicates with a power supply. The torch assembly includes a trigger mounted on the torch assembly to start and stop torch operations. The trigger electrically communicates with the power supply via the at least one cable. The torch assembly also includes a remote switch mounted on the torch assembly to allow an operator to remotely adjust an output of the power supply to a desired output level. The remote switch is electrically coupled to the power supply via the at least one cable.

A plasma arc torch is provided for use in a plasma cutting system. The plasma arc torch includes a torch body for conducting electrical current. The torch body includes a torch tip configured to pass the electrical current to at least one consumable component connected to the tip. The plasma arc torch also includes at least one antenna positioned relative to the torch tip. The antenna is used to wirelessly detect the presence of the at least one consumable component. The plasma arc torch further includes a detection circuit configured to permit passing of the electrical current from the torch tip to the at least one consumable component based on at least the wireless detection.

A method for plasma cutting a workpiece comprises providing a plasma cutting system having a plasma current source and a plasma torch, the plasma torch having an electrode and nozzle where the nozzle is a small distance from the electrode at a lower end of the plasma torch, forming a plasma chamber between the nozzle and the electrode. A current is produced with a plasma current source and the current flows through the plasma torch during the plasma cutting process. The current is then brought to pulsation during at least a partial time period during the plasma cutting process, with the pulsation occurring in a targeted or controlled manner with a freely selectable frequency.

A tool (10) for processing a workpiece in a processing machine has a connecting portion (11) which is at the machine side during operation and is preferably standardized, for connecting the tool with a numerically controlled machine tool (30), a plasma duct (44) for conducting a generated plasma, and an outlet portion (13) which is at the workpiece side during operation and is disposed at the end of the duct (44), and which comprises one or a plurality of outlets (22) for supplying the plasma to a workpiece surface.

A material processing system for performing a processing operation includes a processor that receives information from a user relating to a proposed processing operation to be performed by the material processing system. The processor determines, responsive to the information received from the user, two or more configurations of consumable components for performing the proposed processing operation and estimates processing performance capabilities associated with using each configuration of consumable components. An interactive display presents the estimated processing performance capabilities to the user for selection.

A plasma cutting system for measuring or monitoring the voltage between a plasma torch and the material being cut to determine a voltage or voltage signature and comparing that measurement against predetermined values to indicate that an initial pierce of the material is complete, and based on the measurement, moving the torch or the material to a different location for additional cutting. The system further provides a Fix Drawing Tool, which will automatically detect and fix gaps or overlaps in a drawing that are very difficult to find visually. These gaps and overlaps become a problem when trying to make a proper toolpath because a CAM program requires a clean, closed shape. The system also provides a Dynamic Corner Looping system, which automatically adjusts with the feed-rate and accelerations of the toolpath and plasma machine, eliminates unwanted dross, sharpens corners and minimizes material loss. A pendant tethering system is also disclosed for managing control of a CNC machine remotely. Additional disclosed functionality includes a data collection system, a manual hand wheel with 3D simulation and a multiple fabrication head management system.