Welding torch and arc welding system

Description

1 / 28 Welding torch and arc welding system CROSS-REFERENCE TO RELATED REQUESTS

[0001] This request is a partial continuation of Patent Application No. US 18 / 769,633, filed on July 11, 2024, is incorporated herein in its entirety by reference. STATE OF THE ART OF THE INVENTION Field of invention

[0002] The present invention relates to electric arc torches, such as arc welding torches and plasma arc cutting torches. In particular, the present invention relates to such torches that have a built-in actuator that moves a portion of the torch during operation. Description of the Related Technique

[0003] During manual welding, a welding torch can be manipulated by the operator to obtain a desired weld bead, for example, by moving the torch back and forth in a direction generally perpendicular to the torch's direction of travel. The operator can also adjust the torch angle during welding. Inexperienced welders should learn proper weaving techniques or other torch manipulation techniques to create desired welds. Torch weaving can also be performed automatically by a robot arm during a robot welding operation. However, the robot arm may not be able to accelerate the torch as needed to execute a desired weft pattern due to inertia in the system. Similar to welding torches, the orientation of plasma arc cutting torches can be manipulated during Petition 870250080927, dated 09 / 09 / 2025, page 6 / 66 2 / 28 a plasma cutting operation, for example, to achieve a desired bevel angle along a cutting edge. It would be desirable to include an actuator within a welding torch and / or a plasma arc torch to automatically move the distal end of the torch to achieve a desired weave pattern, torch angle, etc. BRIEF SUMMARY OF THE INVENTION

[0004] The following summary presents a simplified overview to provide a basic understanding of some aspects of the devices, systems, and / or methods discussed in this document. This summary is not a comprehensive overview of the devices, systems, and / or methods discussed in this document. It is not intended to identify critical elements or to delineate the scope of such devices, systems, and / or methods. Its sole purpose is to present some concepts in a simplified way as a prelude to the more detailed description that will be presented later.

[0005] According to one aspect of the present invention, a welding torch is provided comprising a torch gun tube, a diffuser located distally to the torch gun tube, a contact tip located distally to the torch gun tube, and a hexapod actuator located near the diffuser and the contact tip. The hexapod actuator comprises a movable platform with six degrees of freedom and having a central opening through the movable platform. The torch gun tube, the diffuser, and the contact tip are moved by said movable platform in said six degrees of freedom. A wire electrode is fed to the contact tip through the central opening of the Petition 870250080927, dated 09 / 09 / 2025, page 7 / 66 3 / 28 mobile platform during the movement of the torch gun tube, diffuser and contact tip along the mobile platform.

[0006] According to another aspect of the present invention, a welding torch is provided comprising a torch gun tube, a diffuser located distally to the torch gun tube, a contact tip located distally to the torch gun tube, and a motion stage located near the diffuser and the contact tip. The motion stage comprises a first linear actuator, a second linear actuator, a third linear actuator, a fourth linear actuator, a fifth linear actuator, a sixth linear actuator, and a mobile platform with six degrees of freedom by the first linear actuator, the second linear actuator, the third linear actuator, the fourth linear actuator, the fifth linear actuator, and the sixth linear actuator. The mobile platform has a central opening through the mobile platform, in which the torch gun tube, the diffuser, and the contact tip are moved by said mobile platform in said six degrees of freedom.A wire electrode is fed to the contact tip through the central opening of the moving platform as the torch gun tube, diffuser, and contact tip move along the moving platform.

[0007] According to another aspect of the present invention, an arc welding system is provided comprising a welding robot that includes a robot base and a robot arm attached to the robot base. A welding torch is attached to the robot arm. The welding torch comprises a diffuser and a contact tip. An actuator Petition 870250080927, dated 09 / 09 / 2025, page 8 / 66 The 4 / 28 hexapod actuator is attached to the welding robot and comprises a mobile platform with six degrees of freedom. The hexapod actuator is located near the diffuser and the contact tip. A welding power supply is configured to provide an electrical power output to the welding torch. A motion controller is operatively connected to the hexapod actuator to control the movements of the mobile platform during a welding operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The foregoing and other aspects of the invention will become apparent to persons skilled in the art to which the invention relates by reading the following description with reference to the accompanying drawings, in which: Figure 1 shows a welding system; Figure 2 shows a welding torch; Figure 3 shows a hexapod actuator; Figure 4 shows six degrees of freedom; Figure 5 shows a robotic arc welding system; Figure 6 shows a welding torch; Figure 7 shows a welding robot and hexapod actuator; Figure 8 shows a plasma arc torch; Figure 9 is an exploded view showing components of the plasma arc torch; Figure 10 shows a plasma cutting table and Figure 11 shows an example controller. DETAILED DESCRIPTION OF THE INVENTION

[0009] The present invention relates to blowtorches of Petition 870250080927, dated 09 / 09 / 2025, page 9 / 66 5 / 28 electric arc torches, such as arc welding torches and plasma arc cutting torches, which have a built-in actuator that moves a portion of the torch during operation. In particular, the actuator is a hexapod actuator that can move a portion of the torch with six degrees of freedom. The present invention will now be described with reference to the drawings, in which similar reference numbers are used to refer to similar elements. It is important to note that the various drawings are not necessarily drawn to scale from one figure to another nor within a given figure and, in particular, that the size of the components is arbitrary to facilitate understanding of the drawings. In the following description, for explanatory purposes, several specific details are presented to provide a complete understanding of the present invention. However, it may become apparent that the present invention can be practiced without these specific details.Furthermore, other embodiments of the invention are possible, and the invention can be practiced and carried out in ways different from those described. The terminology and phraseology used in the description of the invention are used for the purpose of promoting understanding of the invention and should not be considered limiting.

[0010] As used in this document, “at least one”, “one or more”, and “and / or” are open expressions that are both conjunctive and disjunctive in their operation. For example, each of the expressions “at least one of A, B, and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C”, and “A, B, and / or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together. Any disjunctive word or phrase that presents Petition 870250080927, dated 09 / 09 / 2025, p. 10 / 66 6 / 28 The use of two or more alternative terms, whether in the description of embodiments, claims or designs, should be understood as encompassing the possibilities of including one of the terms, any of the terms or both terms. For example, the phrase “A or B” should be understood as including the possibilities of “A” or “B” or “A and B”.

[0011] Although the embodiments of the present invention described herein are discussed in the context of a metal arc welding (GMAW) system, other embodiments of the invention are not limited to this. For example, the embodiments can be used in flux-core arc welding (FCAW), metal-core arc welding (MCAW), gas tungsten arc welding (GTAW), as well as other similar types of welding operations. Furthermore, the embodiments of the present invention can be used in manual, semi-automatic, and robotic welding operations. Embodiments of the present invention can also be used in welding-like metal deposition operations such as additive manufacturing, hardfacing, and cladding. As used herein, the term “welding” is intended to encompass all these technologies, as they all involve the deposition of material to join or construct a workpiece.Therefore, in the interest of efficiency, the term "welding" is used below in the description of illustrative modalities, but it is intended to include all such material deposition operations, regardless of whether or not multiple workpieces are joined.

[0012] Referring now to the drawings, Figure 1 shows an example of welding system 100. Welding system 100 includes welding power supply 102, a Petition 870250080927, dated 09 / 09 / 2025, page 11 / 66 7 / 28 wire feeder 104 and a shielding gas supply 106. The welding power supply 102 includes conductor cables 108, control cable 110, and power supply cables (not shown). Conductor cables 108 include a ground wire and clamp 112 connected to the workpiece W and a conductor cable 114 to provide welding waveforms generated by the welding power supply 102 to the wire feeder 104. The control cable 110 can be configured to connect to the wire feeder 104 to provide communications between the power supply 102 and the wire feeder. Such communications can also be wireless. It is understood that the welding power supply 102, conductor cables 108, and control cable 110 can have any configuration suitable for providing power and welding controls within the welding system 100.Although the wire feeder 104 and the welding power supply 102 are shown as two separate devices interconnected by cabling, the welding power supply and the wire feeder can be integrated into a single welding machine.

[0013] As further illustrated in Figure 1, the gas conduit 116 and regulator 118 are configured to connect the protective gas supply 106 to the wire feeder 104. The protective gas supply 106 may include inert gases, active gases, or a combination of both, including, but not limited to, argon, helium, carbon dioxide, argon and helium, argon, hydrogen, and other gas combinations. The gas supply may be any gas or combination of gases configured to protect a weld from the atmosphere.

[0014] As shown in Figure 1, the feeder Petition 870250080927, dated 09 / 09 / 2025, page 12 / 66 A wire electrode 104 (8 / 28) may include a housing 120, a gearbox 122, a wire spool assembly 124, and a user interface 126. Extending from the gearbox 122 is a hose 128 that is configured to connect to a welding torch 130. The housing 120 may be connected to the user interface 126 and gearbox 122. Additionally, the control cable 110 and the conductor cable 114 extending from the welding power supply 102, and the gas conduit 116 extending from the gas supply 106, are configured to connect to the housing 120, the gearbox 122, and the hose 128. The gearbox 122 includes at least one drive motor and a plurality of rollers that advance and retract a wire electrode drawn from a spool (not shown) mounted on the spool assembly. 124 or extracted from a bulk package, such as a box or drum.Extending between the gearbox 122 and the welding torch 130 is the hose 128. The hose 128 provides a conduit for the welding wire electrode and shielding gas and conducts the welding waveforms to the torch 130. The welding torch 130 may include a manually operable trigger 132 located on a proximal or upstream portion of the torch, to start and stop a welding operation. The hose 128 may conduct a trigger signal from the torch trigger to the wire feeder 104 and to the welding power supply 102 to control the wire electrode feed and the supply of welding waveforms and shielding gas to the torch. It is understood that the hose 128 and the welding torch 130 may have any configuration suitable for supplying welding wire, shielding gas, and controls between them. Petition 870250080927, dated 09 / 09 / 2025, page 13 / 66 The 9 / 28 torch and wire feeder 104. The torch 130 may include a contact tip to conduct the welding waveforms from the wire feeder 104 to the wire electrode and a shielding gas diffuser and nozzle to direct the shielding gas around the arc and toward the weld pool. The torch 130 may also include a hexapod actuator to automatically move the distal portion of the torch with six degrees of freedom during a welding operation. The torch 130 and the hexapod actuator are discussed in more detail below.

[0015] Referring now to Figure 2, a schematic view of a portion of a gas-shielded welding torch 130 is shown in position above the workpiece W. The distal end of the torch handle 200 is shown in Figure 2 along with a gun tube or gooseneck 202 extending from the torch handle. The welding torch 130 is supplied with one or more wire electrodes 204 (e.g., steel, aluminum, alloys, composites, core, etc., or other welding wire known to those in the art) from a wire supply reel, drum, etc. by a wire feeder. The wire feeder not only regulates the rate at which the welding wire 204 is fed through the torch 130, but may also control the flow of shielding gas from a gas source to the torch.

[0016] The distal portion of the torch 130 includes a nozzle 206. The nozzle 206 directs the flow of shielding gas towards the workpiece W and the melt bath. The distal portion of the torch additionally includes a shielding gas diffuser 208 and a contact tip 210 inside the nozzle 206. The contact tip 210 extends from the shielding gas diffuser 208 and is attached to the diffuser by means of a threaded connection. Petition 870250080927, dated 09 / 09 / 2025, page 14 / 66 10 / 28 The contact tip 210 has a through hole and inlet and outlet holes for the wire electrode 204. In certain embodiments, the contact tip 210 can accommodate two or more wire electrodes fed simultaneously during a multi-wire deposition operation and may have multiple through holes and inlet and outlet holes for the wire electrodes.

[0017] The torch 130 additionally includes a hexapod actuator 212. The hexapod actuator 212 is located upstream or proximal to the diffuser 208, the contact tip 210, and the nozzle 206 (for example, the hexapod actuator is located between a proximal portion of the welding torch that has the trigger and the distal portion of the welding torch). In Figure 2, the hexapod actuator 212 is located along the gun tube or gooseneck 202. However, the hexapod actuator 212 may be located in other locations along the torch 130, such as between the gooseneck 202 and the handle 200 or between the gooseneck and the diffuser 208, for example.

[0018] The hexapod actuator 212 is a miniature motion stage housed in the torch 130. The hexapod actuator 212, when activated during a welding operation, automatically moves the distal portion of the torch 130. The hexapod actuator 212 orients the nozzle 206, the diffuser 208, the contact tip 210, and the wire electrode 204 in relation to the workpiece W.

[0019] As the operator moves the welding torch 130 along a displacement path along the workpiece W, the orientation of the distal portion of the welding torch may change (e.g., due to error of Petition 870250080927, dated 09 / 09 / 2025, page 15 / 66 11 / 28 operator). For example, the “working angle” and / or the “travel angle” of the distal portion of the welding torch may deviate from the appropriate ranges. The hexapod actuator 212 can automatically move or adjust the distal portion of the welding torch 130 during the welding operation so that an appropriate orientation of the distal portion of the torch is maintained, thus improving weld quality and weld repeatability. The hexapod actuator 212 can also move the distal portion of the welding torch 130 to achieve various known weft welding patterns (e.g., circular, zigzag, triangular, figure 8, and similar). An inexperienced welder may not know how to correctly perform weft welding or create certain weft patterns.However, the hexapod actuator 212 or a motion controller for the hexapod actuator can be programmed to automatically weave the distal portion of the torch 130 in a desired pattern at a programmed weaving frequency, length, and width. This allows a welder to move the welding torch 130 along the travel path without manually interlacing the torch, while the hexapod actuator 212 automatically executes or implements the interlacing welding pattern along the weld joint.

[0020] Feedback on the torch's position or orientation to control the operation of the hexapod actuator 12 may be provided by one or more sensors in the torch 130. For example, the torch 130 may include an inertial measurement unit (IMU) 214 that generates torch position signals, such as acceleration and angular velocity and / or gyroscopic signals, during welding operation. The position signals of the Petition 870250080927, dated 09 / 09 / 2025, p. 16 / 66 12 / 28 torches can be transformed to provide linear velocity and linear and angular position. The torch position signals from the IMU 214 can be monitored as feedback directly by the hexapod actuator 212, or the torch position signals can be monitored by a motion controller for the hexapod actuator. The operations of the hexapod actuator 212 and the movements of the distal end of the welding torch 130 during the welding operation can be controlled based on the feedback from the IMU 214, for example, to achieve a desired working angle or torch displacement angle and / or to implement a desired weld pattern or bead. The construction and application of inertial measurement units are well known in the art and need not be discussed in detail in this document.The IMU 214 can be located distally to the hexapod actuator 212, as shown, so as to be moved by the hexapod actuator, or the IMU can be located near or upstream of the hexapod actuator. In certain embodiments, the torch 130 may include multiple IMUs located at various locations along the torch, as desired (e.g., upstream and downstream of the hexapod actuator 212).

[0021] A motion controller 134 for the hexapod actuator is shown schematically in Figure 1. The motion controller 134 may be supplied within the welding power supply 102 or may be a separate, independent device. The motion controller 134 may communicate bidirectionally with the welding power supply 102 to provide, for example, information about the torch position during welding. The information of Petition 870250080927, dated 09 / 09 / 2025, page 17 / 66 13 / 28 torch positions can be used by the welding power supply 102 to provide real-time feedback to the welder during the welding operation. This feedback can include audible or visual alerts to adjust the torch angle or travel speed, for example. Audible and / or visual alerts can be provided by means of a welding helmet with suitable speakers, indicator lights or an interface, for example. Tactile feedback can also be provided to the welder by means of the torch 130, for example.

[0022] The motion controller 134 is operatively connected to the hexapod actuator 212 to control its movements during welding operation based on torch position feedback from the IMU 214. For example, the control and power cabling for the hexapod actuator 212 can be included in the torch hose 128 and the connections between the wire feeder 104 and the power supply 102 to connect the motion controller 134 to the hexapod actuator and the IMU 214. The motion controller can be programmed to adjust or control the position of the distal end of the torch 130 during welding and execute a desired weld pattern or weld bead pattern (e.g., “stacked dimes”). In an exemplary embodiment, the motion controller 134 adjusts the orientation of the hexapod actuator 212 by means of voltage or current level signals supplied to the six separate linear actuators. in the hexapod actuator.A desired motion control or weft pattern can be selected via a user interface on the welding power supply 102 or wire feeder 104 or on a control. Petition 870250080927, dated 09 / 09 / 2025, page 18 / 66 14 / 28 portable, for example, or be selected via a drawing file (e.g., CAD file) for the workpiece or by other form of path planning.

[0023] In certain embodiments, the welding system 100 can utilize machine learning techniques involving artificial intelligence (AI) and / or neural networks to train the motion controller 134 to perform “good” welds (i.e., acceptable weld bead patterns). The motion controller 134 can be trained based on torch motion data captured during manual welding by experienced welders to create training models. For example, the torch movements of experienced welders can be stored in memory to establish the various weld patterns executed by the motion controller 134 and the hexapod actuator 212. Models (e.g., motion models) can be created and stored using the data collected from experienced operators / welders, and the models can alter the welding process behavior and torch movement to provide repeatable welding.The motion controller 134 can replicate the torch movements of an experienced welder by controlling the operation of the various linear actuators in the hexapod actuator 212. The stored torch movements can be further refined over time as the motion controller 134 is trained by additional motion data captured during subsequent welding operations, whether performed manually or automatically by the hexapod actuator 212.

[0024] An exemplary hexapod actuator 212 that can be installed on a welding torch or torch. Petition 870250080927, dated 09 / 09 / 2025, page 19 / 66 15 / 28 plasma cutting is shown in Figure 3. A hexapod actuator is also known as a Stewart platform. The construction of hexapod actuators / Stewart platforms is well known and does not need to be discussed in detail in this document. The hexapod actuator 212 has six linear actuators 216 which can be formed by small electric linear motors. The linear actuators 216 extend between a proximal base portion of the hexapod actuator 212 and a mobile platform 218. Each linear actuator 216 has a leg that extends and retracts to control the spatial orientation of the mobile platform 218. The mobile platform 218 is movable by the linear actuators 216 with six degrees of freedom. The distal portion of the welding torch is fixed to the mobile platform 218 and can be moved by the mobile platform in the six degrees of freedom during a welding operation to maintain the torch orientation, perform weft welding, etc.The six linear actuators 216 are operable separately or controlled separately by the hexapod motion controller to move the mobile platform 218 in six degrees of freedom. The six degrees of freedom in which the platform 218 can move are shown in Figure 4. The six degrees of freedom include movement along a first linear geometric axis 220 (e.g., X-axis), movement along a second linear geometric axis 222 (e.g., Y-axis) that is perpendicular to the first linear geometric axis, and movement along a third linear geometric axis 224 (e.g., Z-axis) that is perpendicular to both the first and second linear geometric axes. The six degrees of freedom additionally include respective rotations around each of the first. Petition 870250080927, dated 09 / 09 / 2025, page 20 / 66 16 / 28 linear geometric axis 220, the second linear geometric axis 222 and the third linear geometric axis 224. The respective rotations can be considered rotations of rotation 226, inclination 228 and yaw 228.

[0025] Referring to Figures 2 and 3, the moving platform 218 of the hexapod actuator 212 has a central opening 230. The wire electrode 204 is fed to the contact tip 210 in the welding torch 130 through the central opening 230 of the moving platform during the movement of the distal portion of the welding torch by the moving platform. Although not shown in Figures 2 and 3, the torch 130 may include a coating for the wire electrode. The coating may pass through the center of the hexapod actuator 212 and the wire electrode may be fed through the coating. The wire feed rate (WFS) of the wire electrode through the torch 130 is controlled by the welding power supply 102. In certain embodiments, the WFS may be adjusted based on the movements of the moving platform 218 during welding.

[0026] The welding torch that has the hexapod actuator can be attached to a robot arm. For example, the proximal portion of the welding torch can be attached to the robot arm, and the distal portion of the welding torch, which has the contact tip, diffuser, and nozzle, can be manipulated by the hexapod actuator to allow the welding robot to perform weft welding more easily. A welding robot has a lot of inertia when moving and may not be able to adjust the position of the welding torch quickly (for example, when performing weft welding), or maintain sufficient stability or achieve a desired dynamic response. The hexapod actuator can adjust the position of the distal portion of the torch. Petition 870250080927, dated 09 / 09 / 2025, page 21 / 66 17 / 28 welding much faster than a robot arm. Applying a welding torch with a hexapod actuator in a robotic welding system can eliminate robot inertia problems and increase the reliability and predictability of the system when performing robotic weft welding.

[0027] Figure 5 shows an exemplary robotic welding system 300. The system includes a mobile mechanical assembly that supports a tool. The mobile mechanical assembly can be a robot arm 302, such as a six-axis articulated industrial robot arm as shown, or other types of mobile mechanical assemblies, such as an orbital tube welder. An arm end tool or end effector is connected to the robot arm 302. Exemplary arm end tools include welding torches 130 and plasma cutting torches. For ease of explanation, aspects of the system 300 will be discussed in the context of an electric arc welding system employing a welding torch 130. However, it is important to emphasize that such aspects are also applicable to other types of systems and tools, such as plasma cutters and the like.

[0028] The torch 130 includes a consumable wire electrode 204, through which an arc 308 is generated between the torch and a workpiece W to perform a welding operation on the workpiece. The robot 302 controls the movements of the torch 130 during welding based on control instructions from a computer-based robot controller 312. The robot controller 312 may include a processor, memory, a user interface 314, and may additionally include additional components necessary for Petition 870250080927, dated 09 / 09 / 2025, page 22 / 66 18 / 28 control the movements of robot 302. The robot controller 312, similar to the hexapod actuator motion controller in the torch, can store programmed instructions that, when executed by the processor, cause the robot controller to perform a desired welding operation. The motion controller for the hexapod actuator is not shown in Figure 5. However, the motion controller for the hexapod actuator can be a standalone device or be incorporated into the welding power supply 102 or the robot controller 312. For example, the robot controller 312 can be programmed to control the movement of the robot arm 302 and the hexapod actuator simultaneously during a welding or cutting operation.

[0029] The robot controller 312 includes a handheld control pendulum or teaching pendulum 316 operatively connected to the robot controller. The control pendulum 316 includes a user interface 318 with a display and various user inputs. Using the control pendulum 316, an operator can program or adjust various operations to be performed by the robot 312 and, in certain modes, by the hexapod actuator. The operator can also view on a display of the user interface 318 information about the robot 302 and information about the operation that the robot performs on the workpiece W using the torch 130 and the hexapod actuator (for example, view a selected weft pattern to be performed by the hexapod actuator and the associated weft parameters).

[0030] The 300 robotic welding system additionally includes a 102 welding power supply. The 102 welding power supply provides an output of Petition 870250080927, dated 09 / 09 / 2025, page 23 / 66 19 / 28 electrical power for torch 130 to generate arc 308. Power supply 102 converts input power (e.g., electrical power) into a suitable arc waveform (e.g., a welding waveform) to perform an operation on the workpiece W. Power supply 102 may include electronic circuits (e.g., PWM inverters, switches, etc.) to generate a desired arc waveform. Power supply 102 may additionally include a processor, memory, and a user interface 322 to adjust various parameters of the operation performed on the workpiece W (e.g., voltage, current, wire feed speed, AC balance, etc.).

[0031] Figure 6 shows an embodiment of an exemplary welding torch 600 having a hexapod actuator 602. The welding torch 600 can be configured for mounting as an arm end tool on a robot arm. The hexapod actuator 602 is located near the torch gun tube or gooseneck 202 and near the diffuser and contact tip, which are surrounded by the torch nozzle and are not shown. The torch includes a base portion 604 that is attached to the mobile platform 218 of the hexapod actuator 602. When the welding torch 600 is mounted on a robot arm, the hexapod actuator is located between the robot arm and the most distal portions of the torch (e.g., the base portion 604, the torch gooseneck 202, the nozzle, the diffuser, the contact tip, etc.).A cable from the welding torch 606 extends through the center of the hexapod actuator 602 and into the base portion 604 of the welding torch 600 and terminates at the base portion. Petition 870250080927, dated 09 / 09 / 2025, p. 24 / 66 20 / 28 A wire electrode is fed to the contact tip of the welding torch 600 via the welding torch cable 606. The hexapod actuator 602 may include a printed circuit board, such as a motion and control printed circuit board, which is enclosed in a metal housing 608 for protection. The metal housing 608 is located near or upstream of the mobile platform 218, and the six linear actuators of the hexapod actuator 602 are located between the metal housing and the mobile platform. For example, the six linear actuators extend from the metal housing 608 to the mobile platform 218. The six linear actuators may be connected to the metal housing 608 and the mobile platform 218 by means of universal joints, for example. The metal housing 608 may include a central opening through which the welding torch cable extends or passes, similar to the mobile platform 218.

[0032] A welding torch or plasma cutting torch are examples of arm end tools or end effectors that may include a hexapod actuator located between the operating portion or “business end” of the tool and the robot arm. Any known arm end tool or end effector may include or be mounted on a hexapod actuator located between the tool and the robot arm if additional high-speed movements with six degrees of freedom are desired.

[0033] Referring to Figure 7, the welding robot 610 itself can be mounted on a hexapod actuator 612 that moves the entire robot during a welding operation. The welding robot 610 includes a robot base 614 and a robot arm. Petition 870250080927, dated 09 / 09 / 2025, page 25 / 66 21 / 28 302 connected to the base. The robot arm 302 can rotate on the robot base 614, as known in the art. The robot base 614 is mounted and fixed to the mobile platform of the hexapod actuator 610. Being able to move the entire robot 610 can provide certain advantages. For example, if the robotic system is located in a non-stationary area, such as on the deck of a ship, having the ability to move the robot 610 can improve the repeatability of welding, cutting, and additive manufacturing operations. Having the ability to tilt, roll, and yaw the entire robot 610 allows for additional solutions to trajectory planning problems without incurring singularity issues. The hexapod actuator 612 and the robot 610 can be mounted on the end of a crane or boom, and the hexapod actuator can be used to compensate for wind and reflected motion resulting from the robot's movement.Wind and reflected motion can cause the crane arm to move because it is not rigid and becomes less stable as the actuation radius increases. The 612 hexapod actuator can compensate for this movement by applying the inverse of the resonant motion to minimize positional error in the end effector. For example, if the wind blows the crane arm out of position, the 612 hexapod actuator can quickly compensate due to its high dynamic response and inherent stability.

[0034] Figures 8 and 9 show an example of a plasma arc or plasma cutting torch 400 having a hexapod actuator similar to the welding torch discussed above. The hexapod actuator is located between a proximal portion of the plasma arc torch 400 and a distal portion of the plasma arc torch which includes elements such as a Petition 870250080927, dated 09 / 09 / 2025, p. 26 / 66 The 22 / 28 electrode, a swirl ring, and a nozzle. The hexapod actuator can automatically adjust the orientation of the distal portion of the 400 plasma arc torch during a plasma cutting operation to, for example, maintain a consistent bevel angle along a cutting edge of a workpiece and / or maintain a consistent torch angle relative to the workpiece.

[0035] The plasma arc torch 400 may be a liquid-cooled torch having a handle portion 402 located along the proximal portion of the torch. The handle portion 402 may be fixed to an automated cutting device, such as a computer numerical control (CNC) plasma cutting table or a robot arm, for example. Distally to the handle portion 402 is a torch body 404. The torch body 404 may be made of a metallic material and forms the greater part of the outer portion of the torch 400. In an exemplary embodiment, the torch body 404 is made of brass. However, the torch body may be made of various metals and alloys, as would be expected of someone of ordinary skill in the art. Attached to the body of the torch 404 is an external retaining cap 406 which secures a protective cap 408 to the torch 400.

[0036] Figure 9 is an exploded view of the plasma arc torch. The plasma arc torch includes the hexapod actuator 212 located between the proximal portion of the torch and the distal portion of the torch. In certain embodiments, the plasma arc torch includes a quick-disconnect mechanism to detach the distal portion of the torch from a base portion, and the hexapod actuator 212 may be located in the quick-disconnect mechanism. The plasma arc torch also includes Petition 870250080927, dated 09 / 09 / 2025, p. 27 / 66 23 / 28 a IMU 214, which may be located distally to the moving platform of the hexapod actuator 212. The hexapod actuator 212 automatically adjusts the orientation of the distal portion of the plasma arc torch during a plasma cutting operation by adjusting the spatial orientation of the moving platform. Figure 9 shows various torch components and consumables found in the distal portion of the torch and displayed along a geometric axis 409 of the torch. The torch body 404, the outer retaining cap 406, and the protective cap 408 are shown in Figure 9. Extending from the torch body 404 is a nozzle body 410 or anode and a cooling tube 412. The cooling tube 412 is attached to a cathode inside the torch, as is the electrode 414. The torch additionally includes a swirl ring 416 and a nozzle 418. The swirl ring 416 and the nozzle 418 are held in place by an inner retaining cap 420 which is screwed onto the nozzle body 410.Electrode 414, swirl ring 416, nozzle 418, inner retaining cap 420, protective cap 408, and outer retaining cap 406 can be considered consumables for torch 400.

[0037] Figure 10 shows an exemplary plasma cutting table 502 having a plasma arc torch 400. The plasma cutting table 502 has a main body 504 on which a workpiece, such as a sheet or plate of metal, is placed. The plasma cutting table 502 includes a gantry 506 that can move forward and backward along the length of the main body 504 of the cutting table in a first direction (e.g., in a Y direction). The gantry 506 can move on tracks or rails that extend along the sides of the table 502. The proximal portion of the torch Petition 870250080927, dated 09 / 09 / 2025, page 28 / 66 A 24 / 28 plasma arc torch (400) is attached to a mobile torch carriage. 510, which is mounted on gantry 506. The torch carriage 510 can move forward and backward along gantry 506 in a second direction (e.g., in an X direction) that is perpendicular to the first direction. The plasma cutting table 502 can be programmed to make precise cuts in a workpiece by means of controlled movements of the torch carriage 510 and gantry 506 in the X and Y directions, respectively. In certain embodiments, the torch carriage 510 can move the plasma arc torch 400 vertically toward the workpiece and away from it (e.g., in the Z direction), so that the torch can be moved in three perpendicular directions. In certain embodiments, the torch carriage 510 can also rotate or tilt the torch 400 in a plane perpendicular to the table plane (e.g., in the plane). XZ), to make bevel cuts. In additional embodiments, the torch carriage 510 can also rotate the torch 400 around the vertical or Z geometric axis when cutting a portion of a workpiece, to maintain an angular orientation of the torch or plasma arc relative to the cut through the workpiece.

[0038] The plasma cutting table 502 may include a water tray 512 located adjacent to the workpiece. During a plasma cutting operation, the water tray 512 is filled with water, and the water can be drained to allow the water chamber to be cleaned to remove accumulated debris and slag. The plasma cutting table 502 may also include a user interface 514 for setting various operating parameters of the plasma cutting table and the plasma cutting operation. The user interface 514 may Petition 870250080927, dated 09 / 09 / 2025, page 29 / 66 25 / 28 can be operatively connected to a motion controller, such as a CNC, for the 592 plasma cutting table and / or operatively connected to a plasma cutting power supply or to the motion controller for the hexapod actuator.

[0039] Figure 11 illustrates an embodiment of an exemplary controller 800 or control subsystem that could be included in the hexapod motion controller, the robot controller, the teaching pendulum for the robot controller, and / or the welding power supply. The controller 800 includes at least one processor 814 that communicates with various peripheral devices via the bus subsystem 812. These peripheral devices may include a storage subsystem 824, including, for example, a memory subsystem 828 and a file storage subsystem 826, user interface input devices 822, user interface output devices 820, and a network interface subsystem 816. The input and output devices allow user interaction with the controller 800.The 816 network interface subsystem provides an interface to external networks and is coupled to corresponding interface devices in other computer systems.

[0040] User interface input devices 822 may include a keyboard, pointing devices such as a mouse, trackball, touchpad or digitizing tablet, a scanner, a touch screen embedded in the display, audio input devices such as voice recognition systems, microphones and / or other types of input devices. In general, the use of the term “input device” is intended to include all possible types of devices and ways of entering information into the Petition 870250080927, dated 09 / 09 / 2025, page 30 / 66 26 / 28 controller 800 or on a communication network.

[0041] User interface output devices 820 may include a display subsystem, a printer, a fax machine, or non-visual displays such as audio output devices. The display subsystem may include a cathode ray tube (CRT), a flat panel display such as a liquid crystal display (LCD), a projection device, or some other mechanism for creating a visible image. The display subsystem may also provide non-visual display, such as through audio output devices. In general, the use of the term “output device” is intended to include all possible types of devices and ways of sending information from the 800 controller to the user or to another machine or computer system.

[0042] Storage subsystem 824 provides a non-transient, computer-readable storage medium that stores programs and data structures that provide the functionality of some or all of the modules described in this document. For example, storage subsystem 824 may include a CAD model of a part to be welded or cut.

[0043] These software modules are generally executed by the 814 processor alone or in combination with other processors. The 828 memory used in the storage subsystem may include a number of memories including a main random access memory (RAM) 830 for storing instructions and data during program execution and a read-only memory (ROM) 832 in which fixed instructions are stored. A file storage subsystem 826 may provide storage Petition 870250080927, dated 09 / 09 / 2025, page 31 / 66 27 / 28 persistent for program files and data and may include solid-state memory, a hard disk drive, a floppy disk drive along with associated removable media, a CD-ROM drive, an optical drive, flash memory, or removable media cartridges. Modules implementing the functionality of certain modes may be stored by the 826 file storage subsystem in the 824 storage subsystem or on other machines accessible by the 814 processor(s).

[0044] The 812 bus subsystem provides a mechanism to allow various components and subsystems of the 800 controller to communicate with each other as intended. Although the 812 bus subsystem is shown schematically as a single bus, alternative embodiments of the bus subsystem may use multiple buses.

[0045] The 800 controller can be of different types, including a workstation, server, computing cluster, blade server, server farm, or any other data processing system or computing device. Due to the constantly changing nature of computing devices and networks, the description of the 800 controller shown in Figure 11 is intended to be only a specific example for illustrative purposes of some embodiments. Many other configurations of the 800 controller are possible, having more or fewer components than the controller shown in Figure 11. It should be clear that this disclosure is made by way of example and that various changes can be made by adding, modifying, or removing details without departing from the original. Petition 870250080927, dated 09 / 09 / 2025, page 32 / 66 28 / 28 of the fair scope of the teachings contained in this revelation. Therefore, the invention is not limited to specific details of this revelation, except to the extent that the following claims are necessarily limited. Petition 870250080927, dated 09 / 09 / 2025, page 33 / 66

Claims

1 / 6 CLAIMS 1. WELDING TORCH characterized by comprising: a torch gun tube; a diffuser located distally to the torch gun tube; a contact tip located distally to the torch gun tube and a hexapod actuator located near the diffuser and the contact tip, wherein the hexapod actuator comprises a movable platform with six degrees of freedom and having a central opening through the movable platform, wherein the torch gun tube, the diffuser and the contact tip are moved by said movable platform in said six degrees of freedom and wherein a wire electrode is fed to the contact tip through the central opening of the movable platform during the movement of the torch gun tube, the diffuser and the contact tip by the movable platform.

2. Welding torch, according to claim 1, characterized in that the movable platform is located close to the torch gun tube.

3. WELDING TORCH, according to claim 1, characterized by a base portion of the welding torch being fixed to the mobile platform.

4. WELDING TORCH, according to claim 3, characterized by a welding torch cable extending through the central opening of the movable platform and into the base portion of the welding torch.

5. WELDING TORCH, as per Petition 870250074374, dated 08 / 22 / 2025, page 34 / 54 2 / 6 claim 4, characterized by the hexapod actuator including a printed circuit board embedded in a metal housing located near the mobile platform, the metal housing having an additional central opening through which the welding torch cable extends.

6. WELDING TORCH, according to claim 5, characterized in that the hexagonal actuator includes six separately operable linear actuators to move the mobile platform in said six degrees of freedom, wherein the six linear actuators are located between the metal housing and the mobile platform.

7. WELDING TORCH, according to claim 1, characterized by further comprising an inertial measuring unit that generates a torch position signal during a welding operation.

8. WELDING TORCH characterized by comprising: a torch gun tube; a diffuser located distally to the torch gun tube; a contact tip located distally to the torch gun tube and a motion stage located near the diffuser and the contact tip, the motion stage comprising: a first linear actuator; a second linear actuator; a third linear actuator; a fourth linear actuator; a fifth linear actuator; Petition 870250074374, dated 08 / 22 / 2025, page.35 / 54 3 / 6 a sixth linear actuator; and a mobile platform having six degrees of freedom by the first linear actuator, by the second linear actuator, by the third linear actuator, by the fourth linear actuator, by the fifth linear actuator and by the sixth linear actuator and having a central opening through the mobile platform, wherein the torch gun tube, the diffuser and the contact tip are moved by said mobile platform in said six degrees of freedom and wherein a wire electrode is fed to the contact tip through the central opening of the mobile platform during the movement of the torch gun tube, the diffuser and the contact tip by the mobile platform.

9. WELDING TORCH, according to claim 8, characterized in that the six degrees of freedom include: movement along a first linear geometric axis, movement along a second linear geometric axis perpendicular to the first linear geometric axis, movement along a third linear geometric axis perpendicular to the first linear geometric axis and to the second linear geometric axis, and respective rotations around each of the first linear geometric axis, the second linear geometric axis and the third linear geometric axis.

10. Welding torch, according to claim 8, characterized in that the movable platform is located close to the torch gun tube.

11. Welding torch, according to Petition 870250074374, dated 08 / 22 / 2025, page 36 / 54 4 / 6 claim 8, characterized by a base portion of the welding torch being fixed to the mobile platform.

12. WELDING TORCH, according to claim 11, characterized in that a welding torch cable extends through the central opening of the movable platform and into the base portion of the welding torch.

13. WELDING TORCH, according to claim 12, characterized by further comprising a printed circuit board embedded in a metal housing located near the mobile platform, wherein the metal housing has an additional central opening through which the welding torch cable extends, and wherein the first linear actuator, the second linear actuator, the third linear actuator, the fourth linear actuator, the fifth linear actuator and the sixth linear actuator are located between the metal housing and the mobile platform.

14. WELDING TORCH, according to claim 8, characterized by further comprising an inertial measuring unit that generates a torch position signal during a welding operation.

15. ARC WELDING SYSTEM characterized by comprising: a welding robot that includes a robot base and a robot arm fixed to the robot base; a welding torch fixed to the robot arm, the welding torch comprising a diffuser and a contact tip; a hexapod actuator fixed to the welding robot and comprising a mobile platform with six degrees of freedom, the hexapod actuator being located near the diffuser and the contact tip; a welding power supply configured to provide an electrical power output to the welding torch; and a motion controller operatively connected to the hexapod actuator to control the movements of the mobile platform during a welding operation.

16. ARC WELDING SYSTEM, according to claim 15, characterized in that the robot base is fixed to the mobile platform.

17. ARC WELDING SYSTEM, according to claim 15, characterized by the welding torch including a torch gun tube and the hexapod actuator being located between the robot arm and the torch gun tube.

18. ARC WELDING SYSTEM, according to claim 15, characterized in that the mobile platform has a central opening and a welding torch cable extending through the central opening.

19. ARC WELDING SYSTEM, according to claim 18, characterized in that the hexapod actuator includes a printed circuit board embedded in a metal housing located near the mobile platform, wherein the metal housing has an additional central opening through which the welding torch cable extends.

20. ARC WELDING SYSTEM, according to claim 19, characterized in that the hexapod actuator includes six separately operable linear actuators for moving the mobile platform in said six degrees of freedom, wherein the six linear actuators are located between the metal housing and the mobile platform.

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