In some aspects, methods for measuring a level of usage of one or more replaceable consumable components within a material processing system can include detecting a type of consumable component in use within a processing device of the material processing system; determining, using a computing system, if the type of consumable component in use is a specific type of consumable component; and determining, using the computing system, a usage ratio of the specific type of consumable component used relative to other types of consumable components used within the processing device during a cumulative time period of use of the material processing system.

In some aspects, methods for measuring a level of usage of one or more replaceable consumable components within a material processing system can include detecting a type of consumable component in use within a processing device of the material processing system; determining, using a computing system, if the type of consumable component in use is a specific type of consumable component; and determining, using the computing system, a usage ratio of the specific type of consumable component used relative to other types of consumable components used within the processing device during a cumulative time period of use of the material processing system.

Method and apparatus for monitoring and diagnosing gun performance is derived that can determine proper gun operation and if not operating properly diagnose potential causes for abhorrent operation. The voltage produced by the gun is sampled in real time and the frequency spectrum produced analyzed using FFT and then reducing the FFT pattern down to a set of numerical values or a signature that can be compared to known signatures for both correct operation and abnormal operation. Using best fit techniques the cause of any abnormal behavior can then be identified. The method can also be used to predict the end of hardware life and aid in production scheduling and spare parts acquisition by providing advanced notice of wear and usage.

A plasma cutting method providing a plasma torch having an electrode disposed within a first nozzle with a first exit section facing an end of the electrode. The first gas source supplies a gas to the first nozzle. A second nozzle is arranged concentrically around the first nozzle and has a second exit section substantially facing the first exit section. A second gas source supplies the gas between the first nozzle and the second nozzle. The electrode is supplied with a current, and the first and second nozzles are supplied with the gas to form a plasma with the gas introduced into the first nozzle. The surrounding pressure around the plasma jet in the second nozzle at the exit of the first nozzle is controlled to be at least superior to the atmospheric pressure and inferior to the pressure in the first exit section.

A plasma cutting method providing a plasma torch having an electrode disposed within a first nozzle with a first exit section facing an end of the electrode. The first gas source supplies a gas to the first nozzle. A second nozzle is arranged concentrically around the first nozzle and has a second exit section substantially facing the first exit section. A second gas source supplies the gas between the first nozzle and the second nozzle. The electrode is supplied with a current, and the first and second nozzles are supplied with the gas to form a plasma with the gas introduced into the first nozzle. The surrounding pressure around the plasma jet in the second nozzle at the exit of the first nozzle is controlled to be at least superior to the atmospheric pressure and inferior to the pressure in the first exit section.

A plasma emitting device includes plasma head configured to generate a plasmarized gas and jet the plasmarized gas so generated from a nozzle thereof, a gas supply device configured to supply a gas to the plasma head while controlling a flow rate of the gas, gas tube connecting the gas supply device with the plasma head to constitute a gas flow path, and pressure detector configured to detect a pressure of the gas supplied from the gas supply deice. Pressures of gases which are supplied to the plasma head are detected for use for various purposes, whereby the practical plasma emitting device is made up. Specifically, for example, a head clogging, which is a clog impeding a gas flow in the plasma head, can be determined without difficulty based on the detected pressure.

A plasma emitting device includes plasma head configured to generate a plasmarized gas and jet the plasmarized gas so generated from a nozzle thereof, a gas supply device configured to supply a gas to the plasma head while controlling a flow rate of the gas, gas tube connecting the gas supply device with the plasma head to constitute a gas flow path, and pressure detector configured to detect a pressure of the gas supplied from the gas supply deice. Pressures of gases which are supplied to the plasma head are detected for use for various purposes, whereby the practical plasma emitting device is made up. Specifically, for example, a head clogging, which is a clog impeding a gas flow in the plasma head, can be determined without difficulty based on the detected pressure.

A torch head for a liquid-cooled plasma arc torch is provided. The torch head includes a torch body and a torch insulator, coupled to the torch body, having a substantially non-conductive insulator body. The torch insulator includes (i) a first liquid coolant channel, disposed within the insulator body, configured to conduct a fluid flow from the torch head into a consumable cartridge along a first preexisting flow path, (ii) a first liquid return channel, disposed within the insulator body, configured to return at least a portion of the fluid flow from the cartridge to the torch head along the first preexisting flow path, and (iii) a gas channel, disposed within the insulator body, configured to conduct a first gas flow from the torch head to the cartridge along a second preexisting flow path. The first and second preexisting flow paths are fluidly isolated from each other.

A torch head for a liquid-cooled plasma arc torch is provided. The torch head includes a torch body and a torch insulator, coupled to the torch body, having a substantially non-conductive insulator body. The torch insulator includes (i) a first liquid coolant channel, disposed within the insulator body, configured to conduct a fluid flow from the torch head into a consumable cartridge along a first preexisting flow path, (ii) a first liquid return channel, disposed within the insulator body, configured to return at least a portion of the fluid flow from the cartridge to the torch head along the first preexisting flow path, and (iii) a gas channel, disposed within the insulator body, configured to conduct a first gas flow from the torch head to the cartridge along a second preexisting flow path. The first and second preexisting flow paths are fluidly isolated from each other.

A method and apparatus for operating a DC plasma torch. The power supply used is at least two times the average operating voltage used, resulting in a more stable operation of the torch. The torch can include two concentric cylinder electrodes, the electrodes can be graphite, and the plasma forming gas can be hydrogen. The power supply provided also has the capability of igniting the torch at a pulse voltage of at least 20 kilovolts.