Consumables for processing torches

Abstract

Different sets of consumables that can be used with a shield assembly. Each set of consumables includes a nozzle or tip that has an outer surface that forms an annular gap with the shield assembly when the nozzle is inserted into the shield assembly. The dimensions of the annual gap vary with different nozzles.

Description

CONSUMABLES FOR PROCESSING TORCHESCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 615,970, entitled “CONSUMABLES FOR PROCESSING TORCHES,” filed December 29, 2023, Attorney Docket No. 1485.1086P, the entire disclosure of which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure is directed toward components for welding and cutting torches and, in particular, to consumable components for welding and / or cutting torches.BACKGROUND

[0003] Many welding and cutting torches, such as plasma cutting torches, can receive a variety of consumable components, such as tips / nozzles, electrodes, shields, etc. Generally, consumables, such as electrodes, tips / nozzles, shields, etc., have a limited lifespan and only last for a certain amount of cuts or welds before a user must replace them. Thus, consumables with longer lifespans may save time for a user since a user can continue cutting or welding operations without changing consumables. Additionally, consumables with longer lifespans may provide cost savings for users since a user will not need to purchase replacement consumables as frequently. Thus, consumables with improved lifespans are continuously desired.SUMMARY

[0004] Different sets of consumables that can be used with a shield assembly. Each set of consumables includes a nozzle or tip that has an outer surface that forms an annular gap with the shield assembly when the nozzle is inserted into the shield assembly. The dimensions of the annual gap vary with different nozzles.

[0005] According to one example embodiment, a plasma arc torch receives a flow of fluid from a fluid source, and comprises a shield assembly, the shield assembly including a shield, a shield cup, and a shield cup insulator, the shield cup insulator including a plurality of passageways formed therein, and a first set of consumables positionable in the shield assembly, the first set of consumables including a first nozzle, a first electrode, and a first gas distributor, wherein the flowof fluid flows into the first electrode and is separated into a first flow portion and a second flow portion, the first flow portion travels between the first nozzle and the first electrode and forms a plasma gas flow, and the second flow portion travels between the first nozzle and the shield assembly and forms a shield gas flow, the second flow portion traveling through the plurality of passageways of the shield cup insulator.

[0006] In one aspect, the first nozzle has a first nozzle outer surface with a first profile, the plasma arc torch further comprises a second set of consumables that is positionable in the shield assembly, the second set of consumables includes a second nozzle, a second electrode, and a second gas distributor, the second nozzle has a second nozzle outer surface with a second profile that is different than the first profile.

[0007] In another aspect, when the first set of consumables is placed in the shield assembly, a first annular gap is formed between the first nozzle outer surface and the shield assembly, and when the second set of consumables is placed in the shield assembly, a second annular gap is formed between the second nozzle outer surface and the shield assembly, the second annular gap being different from the first annular gap.

[0008] In another aspect, the first annular gap is larger than the second annular gap.

[0009] In another aspect, the second flow portion has a first flow rate through the first annular gap and a second flow rate through the second annular gap, the first flow rate being larger than the second flow rate.

[0010] In another aspect, when the second flow portion is at the first flow rate, the first flow portion is at a third flow rate, and when the second flow portion is at the second flow rate, the first flow portion is at fourth flow rate, the third flow rate being less than the fourth flow rate.

[0011] In another aspect, the first nozzle outer surface has a first outer diameter, the second nozzle outer surface has a second outer diameter, when the first nozzle is inserted into the shield assembly, the first nozzle outer surface is proximate to the shield cup insulator, and when the second nozzle is inserted into the shield assembly, the second nozzle outer surface is proximate to the shield cup insulator, and the second outer diameter is different from the first outer diameter.

[0012] In another aspect, the shield cup has an inner surface, and, when the first nozzle is located inside the shield assembly, the first nozzle outer surface is spaced from the inner surface of the shield cup to form a first gap therebetween for the second flow portion, and when the second nozzle is located inside the shield assembly, the second nozzle outer surface is spaced from the inner surface of the shield cup to form a second gap therebetween for the second flow portion, and the second gap is smaller than the first gap.

[0013] In another aspect, a first pressure drop is created in the second flow portion by a size of the first gap, a second pressure drop is created in the second flow portion by a size of the second gap, and the second pressure drop is higher than the first pressure drop.

[0014] In another aspect, the second pressure drop causes an increased flow of the first flow portion relative to the first pressure drop.

[0015] In another aspect, the first gas distributor has first passageways formed therein, the second flow portion travels through the plurality of passageways of the shield cup insulator, and the first flow portion travels through the first passageways of the first gas distributor.

[0016] In another aspect, the second gas distributor has second passageways formed therein, and the second passageways have similar dimensions to the first passageways.

[0017] In another aspect, the shield cup insulator has a body portion and a radial flange portion, and each of the plurality of passageways is formed through the radial flange portion.

[0018] In an alternative embodiment of the invention, a plasma arc torch receives a flow of fluid from a fluid source, and comprises a shield assembly, a first set of consumables disposable in the shield assembly, the first set of consumables including a first nozzle, a first electrode, and a first gas distributor, the first nozzle having a first nozzle outer surface, the first nozzle outer surface and the shield assembly defining a first annular gap therebetween, and a second set of consumables disposable in the shield assembly, the second set of consumables including a second nozzle, a second electrode, and a second gas distributor, the second nozzle having a second nozzle outer surface, the second nozzle outer surface and the shield assembly defining a second annular gap therebetween, the second annular gap being smaller than the first annular gap, wherein the flow of fluid is separated into a first flow portion and a second flow portion, when the first set of consumables is in the shield assembly, the first flow portion travels between the first nozzle andthe first electrode and forms a first plasma gas flow, and the second flow portion travels between the first nozzle and the shield assembly and forms a first shield gas flow, and when the second set of consumables is in the shield assembly, the first flow portion travels between the second nozzle and the second electrode and forms a second plasma gas flow, and the second flow portion travels between the second nozzle and the shield assembly and forms a second shield gas flow, the second shield gas flow being less than the first shield gas flow, and the second plasma gas flow being greater than the first plasma gas flow.

[0019] In one aspect, the shield assembly includes a shield, a shield cup, and a shield cup insulator, the shield cup insulator has a body portion and a radial flange portion, the radial flange portion includes passageways formed therein, and both of the first shield gas flow and the second shield gas flow travels through the passageways of the shield cup insulator.

[0020] In another aspect, the first nozzle outer surface has a first outer profile, the second nozzle outer surface has a second outer profile, and the second outer profile is different than the first outer profile.

[0021] In another aspect, a first pressure drop is created in the second flow portion by a size of the first annular gap, a second pressure drop is created in the second flow portion by a size of the second annular gap, and the second pressure drop is higher than the first pressure drop, and the second pressure drop causes an increased flow of the first flow portion relative to the first pressure drop.

[0022] In another aspect, the first set of consumables is for a first current, the second set of consumables is for a second current, the second current being different than the first current.

[0023] In another embodiment, a plasma arc torch receives a flow of fluid from a fluid source, and comprises a shield assembly, a first set of consumables disposable in the shield assembly, the first set of consumables including a first nozzle having a first nozzle outer surface, the first nozzle outer surface and the shield assembly defining a first annular gap therebetween, and a second set of consumables disposable in the shield assembly, the second set of consumables including a second nozzle having a second nozzle outer surface, the second nozzle outer surface and the shield assembly defining a second annular gap therebetween, the second annular gap being smaller than the first annular gap, wherein the flow of fluid is separated into a first flow portion and a secondflow portion, when the first set of consumables is in the shield assembly, the first flow portion travels in the first nozzle and forms a first plasma gas flow, and the second flow portion travels between the first nozzle and the shield assembly and forms a first shield gas flow, the first annular gap creating a first pressure drop in the first shield gas flow, and when the second set of consumables is in the shield assembly, the first flow portion travels in the second nozzle and forms a second plasma gas flow, and the second flow portion travels between the second nozzle and the shield assembly and forms a second shield gas flow, the second annular gap creating a second pressure drop in the second shield gas flow, the second pressure drop being greater than the first pressure drop, and the second pressure drop causes the second plasma gas flow to be greater than the first plasma gas flow.

[0024] In one aspect, the first nozzle outer surface has a first outer profile, the second nozzle outer surface has a second outer profile that is different from the first outer profile, the first set of consumables is for a first current, and the second set of consumables is for a second current different from the first current.

[0025] Other systems, methods, features and advantages will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. All such additional systems, methods, features and advantages are included within this description, are within the scope of the claimed subject matter.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0026] The consumables for a plasma arc torch presented herein may be better understood with reference to the following drawings and description. It should be understood that the elements in the figures are not necessarily to scale and that emphasis has been placed upon illustrating the principles of the consumables. In the figures, like-referenced numerals designate corresponding parts throughout the different views.

[0027] FIG. 1 A illustrates a perspective view of a manual cutting system including a power source and torch assembly with which the consumables presented herein may be utilized, according to an example embodiment of the present disclosure.

[0028] FIG. IB illustrates a perspective of the torch assembly illustrated in FIG. 1.

[0029] FIG. 1C illustrates a perspective view of an automated cutting head with which the consumables presented herein may be utilized, according to an example embodiment of the present disclosure.

[0030] FIG. 2 illustrates a perspective view of a consumable cartridge formed from example embodiments of the consumables presented herein.

[0031] FIG. 3 illustrates an exploded perspective view of the consumable cartridge illustrated in FIG. 2.

[0032] FIG. 4 illustrates a cross-sectional side view of the consumable cartridge illustrated in FIG. 2.

[0033] FIG. 5 illustrates a top perspective view of an electrode, according to an example embodiment.

[0034] FIG. 6 illustrates a bottom perspective view of the electrode illustrated in FIG. 5.

[0035] FIG. 7 illustrates a side view of the electrode illustrated in FIG. 5.

[0036] FIG. 8 illustrates a cross-sectional side view of the electrode illustrated in FIG. 5.

[0037] FIG. 9 illustrates a top perspective view of a distributor, according to an example embodiment.

[0038] FIG. 10 illustrates a bottom perspective view of the distributor illustrated in FIG. 9.

[0039] FIG. 11 illustrates a side view of the distributor illustrated in FIG. 9.

[0040] FIG. 12 illustrates a cross-sectional side view of the distributor illustrated in FIG. 9.

[0041] FIG. 13 illustrates a top perspective view of a nozzle, according to an example embodiment.

[0042] FIG. 14 illustrates a bottom perspective view of the nozzle illustrated in FIG. 13.

[0043] FIG. 15 illustrates a side view of the nozzle illustrated in FIG. 13.

[0044] FIG. 16 illustrates a cross-sectional side view of the nozzle illustrated in FIG. 13.

[0045] FIG. 17 illustrates a side view of another embodiment of a nozzle, according to the present disclosure.

[0046] FIG. 18 illustrates a cross-sectional side view of the nozzle illustrated in FIG. 17.

[0047] FIG. 19 illustrates a side view of another embodiment of a nozzle, according to the present disclosure.

[0048] FIG. 20 illustrates a cross-sectional side view of the nozzle illustrated in FIG. 19.

[0049] FIG. 21 illustrates a side view of another embodiment of a nozzle, according to the present disclosure.

[0050] FIG. 22 illustrates a cross-sectional side view of the nozzle illustrated in FIG. 21.

[0051] FIG. 23 illustrates a top perspective view of a shield, according to an example embodiment.

[0052] FIG. 24 illustrates a bottom perspective view of the shield illustrated in FIG. 23.

[0053] FIG. 25 illustrates a side view of the shield illustrated in FIG. 23.

[0054] FIG. 26 illustrates a cross-sectional view of the shield illustrated in FIG. 23.

[0055] FIG. 27 illustrates a side view of another embodiment of a shield.

[0056] FIG. 28 illustrates a cross-sectional view of the shield illustrated in FIG. 27.

[0057] FIG. 29 illustrates a side view of another embodiment of a shield.

[0058] FIG. 30 illustrates a cross-sectional view of the shield illustrated in FIG. 29.

[0059] FIG. 31 illustrates a top perspective view of torch head components and a consumable cartridge, according to an example embodiment.

[0060] FIG. 32 illustrates a top perspective view of the components illustrated in FIG. 31, with one of the components being removed.

[0061] FIG. 33 illustrates a top perspective view of several torch head components in an assembled configuration.

[0062] FIG. 34 illustrates an exploded perspective view of the torch head components illustrated in FIG. 33.

[0063] FIG. 35 illustrates another exploded perspective view of the torch head components illustrated in FIG. 33.

[0064] FIG. 36 illustrates a perspective view of one of the torch head components illustrated in FIG. 33.

[0065] FIG. 37 illustrates a bottom view of the torch head component illustrated in FIG. 36.

[0066] FIG. 38 illustrates a horizontal cross-sectional perspective view of the torch head component illustrated in FIG. 36.

[0067] FIG. 39 illustrates another horizontal cross-sectional perspective view of the torch head component illustrated in FIG. 38.

[0068] FIG. 40 illustrates a horizontal cross-sectional perspective view of the torch head components illustrated in FIG. 35.

[0069] FIG. 41 illustrates a vertical cross-sectional perspective view of the torch head components illustrated in FIG. 35.

[0070] FIG. 42 illustrates a perspective view of a camera housing and a spring, according to an example embodiment.

[0071] FIG. 43 illustrates a perspective view of a torch head component and a torch head fitting, according to an example embodiment.

[0072] FIG. 44 illustrates a side perspective view of a shield, a shield cup assembly, and a conductor, according to an example embodiment.

[0073] FIG. 45 illustrates a top perspective view of the shield, the shield cup assembly, and the conductor illustrated in FIG. 44.

[0074] FIG. 46 illustrates a side cross-sectional view of the shield cup members in an assembled configuration.

[0075] FIG. 47 illustrates a side cross-sectional view of the torch head assembly and the consumable cartridge illustrated in FIG. 31.

[0076] FIG. 48 illustrates another side cross-sectional view of the torch head assembly and the consumable cartridge illustrated in FIG. 31 and in FIG. 47.

[0077] FIG. 49 illustrates an exploded perspective view of a sensor probe and a torch head component, according to an example embodiment.

[0078] FIG. 50 illustrates a perspective view of the sensor probe and the torch head component illustrated in FIG. 49.

[0079] FIG. 51 illustrates another perspective view of the sensor probe and the torch head component illustrated in FIG. 49.

[0080] FIG. 52 illustrates a perspective view of another embodiment of a consumable cartridge.

[0081] FIG. 53 illustrates a schematic diagram relating to the consumable cartridge illustrated in FIG. 52.

[0082] FIG. 54 illustrates a perspective view of another embodiment of a consumable cartridge.

[0083] FIG. 55 illustrates a top view of the consumable cartridge illustrated in FIG. 54.

[0084] FIG. 56 illustrates a side view of another embodiment of a sensor probe.

[0085] Like reference numerals have been used to identify like elements throughout this disclosure.DETAILED DESCRIPTION

[0086] Consumables for cutting and / or welding torches are presented herein. To control fluid and or gas flow through a plasma cutting torch, drop in consumable cartridges with different dimensions are used. Specifically, to control plasma gas flow by using a drop in consumable cartridge that acts similar to a needle valve to control fluid flow. Each different consumable cartridge is specifically designed for a particular amperage level, and thus, will have a different physical feature that performs the act of controlling fluid flow. The consumable cartridge, in combination with a shield cup assembly, will allow either more or less fluid flow based on what the amperage requires for optimal flow through the plasma orifice and total flow through the torch.

[0087] The disclosed techniques relate to controlling fluid flow with only the drop in consumable cartridge. In a torch that is universally designed, any level of consumable cartridge based on its amperage level could be dropped into or coupled to the torch, thereby resulting in the correct flow for both the plasma orifice and the total flow through the torch. Without changing any portion ofthe torch design, or blocking or shutting off any holes, the disclosed techniques add a level of resistance to control the amount of fluid through the components of the torch by finding the specific geometry required to achieve the desired fluid flows.

[0088] In one implementation, the torch can be used with consumable cartridges that will be useable with amperages from between 130 Amp to 30 Amp at various increments, including lOAmp and / or 20Amp increments. As the torch is universal, the only thing changing from 130 Amp to 30 Amp is the consumable cartridge that is dropped or inserted into the torch. Each consumable cartridge has a plasma hole orifice that remains the same to achieve consistent cut quality, size, and speed. This orifice is one way that gas is being passed through the torch and the cartridge. Another way the gas is being passed through the torch is by a shield cup insulator that has slots cut into it in the shield cup. The shield cup holds and covers the consumable cartridge. The shield cup insulator holes do not change from amperage to amperage because this is part of the universal torch. Therefore, the stream of gas is controlled through the shield cup insulator slots or passages without actually changing the shield cup insulator. One way of controlling the fluid flow is similar to a needle valve. A specific sized diameter shoulder is added to the nozzle of the consumable cartridge that restricts air flow from the shield cup insulator. The restriction functions as a flow restriction or choking feature, which forces more air through the plasma orifice and less through the shield region, which collectively is the total flow.

[0089] When a plasma arc initiates or terminates in an existing steady and distinct air flow and pressure environment, it causes a dramatic flow restriction and pressure drop for a few seconds. After that brief period, the plasma arc has mostly stabilized to reduced output values, depending on where flow and pressure are being measured. Generally, it is desirous for a torch to behave in a steady state condition. In some applications, it is more difficult to cut at a constant speed when a plasma arc, air pressure, and air flow are in a state of change. In addition, being in a transient state for a plasma arc is when there is an increased loss of hafnium from the electrode.

[0090] In another aspect of the disclosed techniques, a shield cup assembly design that covers a large electrical current range in plasma cutting applications includes a retaining cup, a front shield cap, a gas distribution ring and an electrical insulator, which collectively form a shield cup assembly. By using a single shield cup assembly, all disposable consumable modules (DCM) for different amperages can be installed and retained at a designated position for both electrical contactand shield gas flow metering. Using a universal shield cup assembly provides a benefit for customers for easy installation and for reduced handling / operational errors during cutting operations at different amperages.

[0091] In one implementation, DCMs for different amperages have different total lengths due to the sizes of the nozzles. In one implementation, the shield cup assembly works for all amperages from 30 Amp to 130 Amp DCMs. In a plasma cutting operation, the desired DCM is inserted into the torch head, and then the shield cup is secureOd. As the shield cup assembly is threaded up with regular hand torque, the DCM is centered with the cup and the top of the electrode is engaged with the electrical contact band located in the center of torch body. The keying features (such as notch 424 described below) are not long enough to engage before the shield cup is started to be threaded onto the torch. In addition, there is currently not enough friction inside the shield cup to rotate the DCM and make it “find” its mate, especially after the rear of the electrode has engaged the spring or cage in the electrode holder.

[0092] In one implementation, the following parameters are unchanged for all amperages: the internal distance of the nozzle to the shield cap front (SI), the wall gap between the nozzle and the shield cap (S2), and the shield cap orifice diameter (W). To balance or meter the gas flows of plasma and shield gas, the gap between the nozzle outer diameter and the inner diameter of the shield retaining cup (G) is adjusted based on the nozzle orifice diameter (D) with a relationship of: G = (0.5 ~ 0.75) x D. The shield gas metering gap (G) is adjusted by changing the nozzle outer diameter in a DCM. In one example, for a 130 Amp DCM, D =0.069” and G =0.050”. To achieve good cutting quality, the cold plasma flow rate is kept at the range of 150 -190 SCFH and the total cold flow rate through shield cap orifice is 500 -600 SCFH.

[0093] In different implementations, the front shield cap can be attached to the retaining cup with thread jointing or crimping or welding. Also, the shield cup assembly can be modified for plasma gouging and drag cutting applications.

[0094] In one implementation, a microswitch or a switch probe is used to perform a consumable Part in Place (PIP) function. A camera embedded inside of a plasma torch can be used to perform the function of identifying parts of a DCM amperage and / or cutting applications such as standard cutting or gouging. In an alternative implementation, a device that includes a microswitch (orswitch probe) and a miniaturized displacement sensor or a potentiometric distance measurement are combined to identify the cutting amperages and different applications such as plasma gouging. This device is embedded inside torch body as well.

[0095] FIG. 1 A illustrates an example embodiment of a manual cutting system 10 that may utilize the consumable components presented herein. At a high-level, the manual cutting system 10 includes a power supply 12 and a torch assembly 40. The power supply 12 is configured to supply (or at least control the supply of) power and gas to a torch 50 included in the torch assembly 40 via torch lead 42 (also referred to as cable hose 42). For example, the power supply 12 may meter a flow of gas received from a gas supply 20, which the power supply 12 receives via cable hose 22, before or as the power supply 12 supplies gas to the torch 50 via cable hose 42.

[0096] The manual cutting system 10 also includes a working lead assembly 30 with a grounding clamp 32 that is connected to the power supply by a work lead 34 (also referred to as cable hose 34). As illustrated, cable hose 22, cable hose 34, and cable hose 42 may each be any length. Moreover, each end of cable hose 22, cable hose 34, and cable hose 42 may be connected to components of the manual cutting system 10 via any connectors now known or developed hereafter (e.g., via releasable connectors). For example, torch 50 may be connected to a distal end of cable hose 42 via a quick disconnect connector 46 and power supply 12 may be connected to a proximal end of cable hose 42 via a quick disconnect connector 44.

[0097] FIG. IB illustrates the torch assembly 40 of FIG. 1 A independently from the power supply 12. As can be seen, the torch 50 includes a torch body 52 that extends from a first end 56 (e.g., a connection end 56) to a second end 54 (e.g., an operating or operative end 54). The torch body 52 may also include a trigger 58 that allows a user to initiate cutting operations in any manner now known or developed hereafter (e.g., in a 2T or 4T mode). As mentioned above, the connection end 56 of the torch body 52 may be coupled (in any manner now known or developed hereafter) to one end of lead 42 Meanwhile, the operative end 54 of the torch body 52 may receive interchangeable components, such as consumable components that facilitate cutting operations. The consumable stack presented herein, which is depicted installed on torch 50 in FIG. IB, is generally referred to as consumable stack 70 in FIG. IB; however, the depiction shown in FIG. IB is merely representative of a consumable stack that includes the features presented herein.

[0098] FIG. 1C illustrates an example embodiment of an automated cutting head 60 that may utilize the consumable components presented herein. As can be seen, the cutting head 60 includes a body 62 that extends from a first end 63 (e.g., a connection end 63) to a second end 64 (e.g., an operating or operative end 64). The connection end 63 of the body 62 may be coupled (in any manner now known or developed hereafter) to an automation support structure (e.g., a cutting table, robot, gantry, etc.) and conduits 65 extending therefrom may be coupled to like conduits in the automation support structure to connect the automated cutting head 60 to a power supply, a gas supply, a coolant supply, and / or any other components supporting automated cutting operations. Meanwhile, the operative end 64 of the body 62 may receive interchangeable components, including consumable components that facilitate cutting operations. Again, the consumable stack 70 depicted in FIG. 1C is merely representative of a consumable stack that includes the features presented herein (like the stack 70 depicted in FIG. IB).

[0099] For simplicity, FIGS. 1A, IB, and 1C do not illustrate an interior of torch body 52 or body 62. However, it is to be understood that any unillustrated components that are typically included in a torch, such as components that facilitate welding or cutting operations, may (and, in fact, should) be included in a torch configured in accordance with an example embodiment of the present invention. Additionally, none of FIGS. 1A, IB, and 1C, or any other figures, illustrates connections portions of the bodies 52 / 62 in detail; however, it should be understood that the consumables presented herein may be coupled to a torch body 52 / 62 that includes features configured to mate with features of the consumables, examples of which are described in detail below.

[0100] Now turning to FIGS. 2-4, an example embodiment of a consumable cartridge is illustrated. In this embodiment, the consumable cartridge 100 has a proximal end 102 and a distal end 104 opposite the proximal end 102. The proximal end 102 is the end of the consumable cartridge 100 that is connected to a torch head assembly. Referring to FIG. 2, the consumable cartridge 100 has a fluid entryway 106 into which gas flows. The gas flowing into the fluid entryway 106 is later split into a plasma gas flow and a shield gas flow, as described in detail below.

[0101] In FIGS. 2 and 3, the various components of the consumable cartridge 100 are illustrated in assembled and exploded perspective views, respectively. In particular, in thisembodiment, the consumable cartridge 100 includes an electrode 200, a gas distributor or insulator 300, a tip or nozzle 400, and an arc initiator 500. The nozzle 400 is sized to receive both a portion of the gas distributor 300 and a portion of the electrode 200. In addition, the gas distributor 300 is sized to receive a portion of the electrode 200. The arc initiator 500 is inserted into an opening of the gas distributor 300 and extends therethrough. A distal end of the arc initiator 500 is located so that it extends into a plasma gas flow in the consumable cartridge 100.

[0102] Referring to FIG. 4, a cross-sectional side view of the consumable cartridge 100 is illustrated. The fluid or gas flow from a pressurized fluid or gas source (not shown) enters the fluid entryway 106. The fluid or gas flow 1270 exits openings 222 in the electrode 200. As described in greater detail below, the gas flow 1270 is split into two separate flows, which are a plasma gas flow and a shield gas flow. The plasma gas flow 1272 is illustrated by the arrows in FIG. 4, which represent the flow after it has been split. The plasma gas flow 1272 flows through the gas distributor 300 and exits openings 324 in the gas distributor 300. The plasma gas flow 1272 then flows inside of the nozzle 400 to a plasma chamber 108 and then out of nozzle 400 through bore 434.

[0103] Turning to FIGS. 5-8, various views of an example embodiment of an electrode are illustrated. Referring to FIG. 5, the electrode 200 includes a proximal end 210 and a proximal portion 212 adjacent to the proximal end 210 The proximal end 210 has an opening 213 formed therein, that is the fluid entryway 106 discussed relative to FIG. 2. The proximal portion 212 includes a wall that has an inner wall surface 214 that defines a channel 216 that extends inside of the electrode 200. The opening 213 is at the entrance to the channel 216, and is sized to receive the gas flow 1270. The electrode includes several openings that are formed through the wall to fluidically couple the channel 216 with the outside of the electrode 200.

[0104] The electrode 200 includes a distal end 230 and a distal portion 232 adjacent to the distal end 230. Both the distal end 230 and the distal portion 232 are located inside of the nozzle 400, as described below. As shown in FIG. 6, the distal end 230 has a bore 234 in which an emissive insert (not shown) is placed. The bore 234, and thus, the emissive insert, are located at the plasma chamber 108.

[0105] Turning to FIGS. 7 and 8, a side perspective view and a side cross-sectional view of the electrode are illustrated, respectively. As shown, the electrode 200 includes a middle portion 236 that has an outer surface and an outer diameter that is larger than the outer diameter of the proximal portion 212. The electrode 200 includes a shoulder 240 that is located distal to the middle portion 236. The shoulder 240 has several different surfaces that collectively form a contoured outer surface. In particular, the shoulder 240 includes a step 242 that leads to a cylindrical outer surface 246 that defines a portion with an outer diameter that is larger than the outer diameter of the middle portion 236. As shown in FIG. 8, step 242 includes a recess formed in its distal surface that forms a groove 244.

[0106] The shoulder 240 includes another step 248, which defines an outer diameter that is larger than the outer diameter of surface 246. Step 248 leads to an angled surface 250 that is tapered or angled outwardly toward a ridge 252. The angled surface 250 is tapered outwardly as it is closer to the distal end 230 of the electrode 200. The ridge 252 defines the largest outer diameter of the electrode 200. In other words, the outer diameter of the ridge 252 is larger than the outer diameter of step 248. On the distal side of ridge 252 is another angled or tapered surface 254 that is angled inwardly as it approaches in the direction of the distal end 230. Adjacent to angled surface 254 is another angled surface 256 that has a slightly different angle than angled surface 254. As shown in FIG. 7, angled surface 256 leads to distal portion 232. As shown in FIG. 8, the distal end 230 includes a bore 234 formed therein, as described above. An emissive insert (not shown) can be disposed in the bore 234.

[0107] Also shown in the cross-sectional view of FIG. 8 are the features of the proximal portion 212 of the electrode 200. The inner wall surface 214 that defines the channel 216 is shown. The channel 216 has a proximal end 218, which is at the opening 213 formed in the proximal end 210. The channel 216 has a distal end 220 that is opposite to its proximal end 218. In this embodiment, the channel 216 extends through the length of the proximal portion 212. Slightly upstream toward the proximal end 218 from the distal end 220 are several openings 222, which were discussed briefly above. In one implementation, four openings 222 are formed through the wall of the electrode 200, each of which is located 90 degrees away from an adjacent opening 222 around the perimeter of the electrode 200. The openings 222 permit the flow of gas therethrough. In alternative implementations, the quantity of openings formed through the wall of the electrodecan vary. For example, in different embodiments, the quantity can be three or six or a different amount.

[0108] Turning to FIGS. 9-12, several different views of an example embodiment of a gas distributor or insulator are illustrated. Initially referring to FIGS. 9-11, the gas distributor 300 has an upstream or proximal end 310 and a downstream or distal end 320. The gas distributor 300 has an upstream section 312 that is adjacent to the proximal end 310, and a downstream section 322 that is adjacent to the distal end 320. The gas distributor 300 has an outer surface 330 that has several notches 332 formed therein. In this embodiment, the outer surface 330 has three notches 332 formed therein.

[0109] Referring to FIG. 9, the gas distributor 300 has an inwardly oriented radial flange 340. Formed in the flange 340 is a through hole 370 into which an arc initiator 500 can be inserted. In this embodiment, the through hole 370 extends parallel to a longitudinal axis of the gas distributor 300. The through hole 370 extends from the proximal end 310 of the gas distributor 300 (see FIG. 10) to the distal end 320 of the gas distributor 300 (see FIG. 11).

[0110] Referring back to FIG. 9, the gas distributor 300 has several openings 360 formed in an inner wall surface. Referring to FIG. 11, the distal end 320 of the gas distributor 300 has several openings 324 formed therein. In this implementation, the quantity of openings 360 and the quantity of openings 324 are the same.

[0111] Turning to the cross-sectional view in FIG. 12, the various features of the gas distributor 300 are illustrated. The through hole 370 for the arc initiator 500 is shown extending from the proximal end 310 to the distal end 320. In addition, the passageways 362 between openings 360 inside the gas distributor 300 and openings 324 in the distal end 320 are shown. Gas flow entering openings 360 after it has exited the electrode 200 travels through the passageways 362 and exits openings 324 on its way to the plasma chamber 108.

[0112] Inside the gas distributor 300 are an inner wall surface 342 of the radial flange 340 and an inner wall surface 350 below the radial flange 340. The inner diameter defined by inner wall surface 350 is larger than the inner diameter defined by inner wall surface 342. At the end of inner wall surface 350 is a ledge 352 that extends inwardly to another inner wall surface 354 that has a smaller inner diameter than inner wall surface 342. Openings 360 are formed in both theinner wall surface 350 and the ledge 352. Each of the openings 360 is formed at an angle relative to a longitudinal axis of the gas distributor 300 so that the passageways 362 have radial curved orientations around the inside of the gas distributor 300.

[0113] Turning to FIGS. 13-16, an example embodiment of a nozzle or tip is illustrated in several different views. The embodiment of the nozzle 400 illustrated in FIGS. 13-16 is exemplary of a nozzle that can be used in a plasma arc torch for a 30 Amp operation. As illustrated, in this embodiment, the nozzle 400 has a proximal end 410 with a proximal portion 412 (see FIG. 15) located adjacent thereto. The nozzle 400 has a distal end 430 that is located opposite to proximal end 410. The distal end 430 has a distal portion 432 located adjacent thereto.

[0114] As shown in FIGS. 14-16, the proximal portion 412 includes a radial flange 420 that extends outwardly. The radial flange 420 may be referred to alternatively as an upper cylindrical portion. The radial flange 420 has an outer surface 422 in which a notch 424 is formed. The radial flange 420 has a lower surface 426 (see FIG. 16) as well. At the opposite end, the distal end 430 has a bore 434 formed therein through which plasma gas flows from the plasma chamber 108.

[0115] The inner and outer profiles of this embodiment of the nozzle 400 are illustrated in FIGS. 15 and 16. As shown, the widest portion of the nozzle 400 is defined by the outer surface 422 of the radial flange 420. Below the radial flange 420, the nozzle 400 has an outer surface 414 that has several different sections with varying outer diameters and configurations, and a convergent section 416 that is angled or tapered toward the distal end 430.

[0116] Referring to FIG. 15, the outer surface 414 of the nozzle 400 has a profile that includes several different surfaces or surface portions. In this embodiment, between the radial flange 420 and the convergent section 416, the outer surface 414 includes an angled surface 426A, a cylindrical surface 426B, an angled surface 426C, a cylindrical surface 426D, a convex curved surface 426E, an angled surface 426F, a concave curved surface 426G, and a cylindrical surface 426H. Each of those cylindrical surfaces has a different constant outer diameter, and the alternating angled, convex curved, and concave curved surfaces collectively transition the outer profile of the nozzle 400 from the radial flange 420 to the distal end 430.

[0117] Turning to FIG. 16, the inside of the nozzle 400 is an inner surface 450 that defines a cavity 460 of the nozzle 400 that receives a portion of the electrode 200, and also includes several different sections with varying inner diameters and configurations. The inner surface 450 has a ledge 452. As the inner surface 450 progresses toward the distal end 430, each of section of the inner surface 450 has a smaller inner diameter than the prior section. The inner surface 450 is configured to be similarly shaped to the outer profile of the distal portion 232 of the electrode 200, with a gap formed therebetween for the flow of a plasma gas therein.

[0118] In this embodiment, the bore 434 has an inner tapered bore portion 434C, a central bore portion 434B with a cylindrical profile, and an outer bore portion 434A that has an inner diameter that is larger than the inner diameter of the central bore portion 434B. The outer bore portion 434A terminates in an orifice 438 at the outer end thereof.

[0119] The relative lengths of each of the portions of bore 434 are shown in FIG. 16 as well. Central bore portion 434B is the longest part of the bore 434 with a length dimension “b”. The outer bore portion 434A has a length dimension “a”, which is slightly greater than the length dimension “c” of inner bore portion 434C.

[0120] In FIGS. 17-22, several exemplary embodiments of nozzles are illustrated. The nozzles in FIGS. 17-22, along with the nozzles in FIGS. 13-16, vary in dimensions in two different ways. One way is the orifice or bore diameter and the inlet and outlet dimensions. The other way is the outer surface beneath the upper cylindrical portion, which varies based on the amperage. In one nozzle, the upper cylindrical portion has an outer diameter of 0.842 inches. The outer diameter of the outer surface beneath the upper cylindrical portion can vary for different nozzles.

[0121] FIGS. 17-18 illustrate an exemplary embodiment of a nozzle that can be used in a plasma arc torch for a 50 Amp operation. FIGS. 19-20 illustrate an exemplary embodiment of a nozzle that can be used in a plasma arc torch for a 70 Amp operation. FIG. 21-22 illustrate an exemplary embodiment of a nozzle that can be used in a plasma arc torch for a 90 Amp operation. Each of the nozzles in FIGS. 17-22 (and in FIGS. 13-16) has an outer profile that is slightly different dimension-wise relative to the outer profiles of the other nozzles. As discussed in greater detail below, when the nozzle is inserted into a shield assembly, the outer profile of the inserted nozzle defines an annular gap between the nozzle outer profile and the inner surface of the shieldassembly. The annular gap is the space through which a shield gas flow travels. Due to the differences in the outer profiles, the sizes of the annular gaps between the nozzles and the shield assembly will vary. When the size of the annular gap decreases from one nozzle to the other nozzle, the pressure drop for the shield gas flow increases and the flow of the shield gas decreases, which will increase the flow of the plasma gas. This aspect is discussed in greater detail below.

[0122] Initially turning to FIGS. 17 and 18, a side view and a cross-sectional side view of nozzle 400’ are illustrated. The outer surface of the nozzle 400’ has a profile with several different surfaces or surface portions, similar to those of nozzle 400. In this embodiment, between the radial flange 420’ and the convergent section, the outer surface includes an angled surface 426A’, a cylindrical surface 426B’, an angled surface 426C’, a cylindrical surface 426D’, an angled surface 426F’, and a cylindrical surface 426H’. Each of those cylindrical surfaces has a different constant outer diameter, and the alternating angled surfaces collectively transition the outer profile of the nozzle 400’ from the radial flange 420’ to the distal end.

[0123] In FIG. 18, the inside of the nozzle 400’ is an inner surface that defines a cavity of the nozzle 400’ that receives a portion of the electrode, and also includes several different sections with varying inner diameters and configurations. As the inner surface progresses toward the distal end 430’, each of section of the inner surface has a smaller inner diameter than the prior section. The inner surface is configured to be similarly shaped to the outer profile of the distal portion 232 of the electrode 200, with a gap formed therebetween for the flow of a plasma gas therein.

[0124] Nozzle 400’ includes a distal portion 432’ and a bore 434’ formed in the distal end 430’ . In this embodiment, the bore 434’ has a central bore portion 434B’ with a cylindrical profile, and an outer bore portion 434A’ that has an inner diameter that is larger than the inner diameter of the central bore portion 434B’. The outer bore portion 434A’ terminates in an orifice 438’ at the outer end thereof. The relative lengths of each of the portions of bore 434’ are shown in FIG. 18 as well. Central bore portion 434B’ is the longest part of the bore 434’ with a length dimension b’ . The outer bore portion 434A’ has a length dimension a’, which is shorter than length dimension b’ of central bore portion 434B’.

[0125] Turning to FIGS. 19 and 20, a side view and a cross-sectional side view of nozzle 400” are illustrated. The outer surface of the nozzle 400” has a profile with several differentsurfaces or surface portions, similar to those of nozzle 400 and nozzle 400’. In this embodiment, between the radial flange 420” and the convergent section, the outer surface includes an angled surface 426A”, a cylindrical surface 426B”, an angled surface 426C”, a cylindrical surface 426D”, an angled surface 426F”, and a cylindrical surface 426H”. Each of those cylindrical surfaces has a different constant outer diameter, and the alternating angled surfaces collectively transition the outer profde of the nozzle 400” from the radial flange 420” to the distal end 430”.

[0126] In FIG. 20, the inside of the nozzle 400” is an inner surface that defines a cavity of the nozzle 400” that receives a portion of the electrode, and also includes several different sections with varying inner diameters and configurations. As the inner surface progresses toward the distal end 430”, each of section of the inner surface has a smaller inner diameter than the prior section. The inner surface is configured to be similarly shaped to the outer profile of the distal portion 232 of the electrode 200, with a gap formed therebetween for the flow of a plasma gas therein.

[0127] Nozzle 400” includes a distal portion 432” and a bore 434” formed in the distal end 430”. In this embodiment, the bore 434” has a central bore portion 434B” with a cylindrical profile, and an outer bore portion 434A” that has an inner diameter that is larger than the inner diameter of the central bore portion 434B”. The outer bore portion 434A” terminates in an orifice 438” at the outer end thereof. The relative lengths of each of the portions of bore 434” are shown in FIG. 20 as well. Central bore portion 434B” is the longest part of the bore 434” with a length dimension b”. The outer bore portion 434A” has a length dimension a”, which is shorter than length dimension b” of central bore portion 434B”.

[0128] As compared to nozzle 400’ illustrated in FIGS. 17 and 18, the thickness of the distal end of nozzle 400” along a longitudinal axis of the nozzle 400” is greater than the thickness of the distal end of nozzle 400’ along a longitudinal axis of nozzle 400’ . As a result, the length of bore 434” is greater than the length of bore 434’, and the length b” of central bore portion 434B” is greater than the length b’ of central bore portion 434B’.

[0129] Turning to FIGS. 21 and 22, a side view and a cross-sectional side view of nozzle 400’” are illustrated. This nozzle 400’” can be used for a 90 Amp application. The same nozzle 400’” can be used in a 110 Amp application, with only a slight modification to the orifice dimeter. The outer surface of the nozzle 400’” has a profile with several different surfaces or surfaceportions, similar to those of nozzle 400, nozzle 400’, and nozzle 400”. In this embodiment, between the radial flange 420”’ and the convergent section, the outer surface includes an angled surface 426A’”, a cylindrical surface 426B’”, an angled surface 426C’”, a cylindrical surface 426D’”, an angled surface 426F’”, and a cylindrical surface 426H’”. Each of those cylindrical surfaces has a different constant outer diameter, and the alternating angled surfaces collectively transition the outer profile of the nozzle 400” ’ from the radial flange 420’ ’ ’ to the distal end 430” ’ .

[0130] In FIG. 22, the inside of the nozzle 400’” is an inner surface that defines a cavity of the nozzle 400’” that receives a portion of the electrode, and also includes several different sections with varying inner diameters and configurations. As the inner surface progresses toward the distal end 430’”, each of section of the inner surface has a smaller inner diameter than the prior section. The inner surface is configured to be similarly shaped to the outer profile of the distal portion 232 of the electrode 200, with a gap formed therebetween for the flow of a plasma gas therein.

[0131] Nozzle 400”’ includes a bore 434’” formed in the distal end 430”’. In this embodiment, the bore 434’” has a central bore portion 434B’” with a cylindrical profile, and an outer bore portion 434A’” that has an inner diameter that is larger than the inner diameter of the central bore portion 434B’”. The outer bore portion 434A’” terminates in an orifice 438”’ at the outer end thereof. The relative lengths of each of the portions of bore 434’” are shown in FIG. 22 as well. Central bore portion 434B’” is the longest part of the bore 434’” with a length dimension b’”. The outer bore portion 434A’” has a length dimension a’”, which is shorter than length dimension b”’ of central bore portion 434B’”.

[0132] As compared to nozzle 400’ illustrated in FIGS. 17 and 18 and also nozzle 400” illustrated in FIGS. 19 and 20, the thickness of the distal end of nozzle 400’” along a longitudinal axis of the nozzle 400’” is greater than the thickness of the distal end of nozzle 400’ along a longitudinal axis of nozzle 400’ and also greater than the thickness of the distal end of nozzle 400” along a longitudinal axis of nozzle 400”. As a result, the length of bore 434’” is greater than the length of bore 434’ and the length of bore 434”, and the length b’” of central bore portion 434B’” is greater than the length b’ of central bore portion 434B’ and greater than the length b” of central bore portion 434B”.

[0133] Turning to FIGS. 23-26, various views of an example embodiment of a shield are illustrated. Shield 600 is an example embodiment of a shield that can be used in a 50 Amp operation, and in particular, used with the nozzle 400’ illustrated in FIGS. 17-18.

[0134] Referring to FIGS. 23-25 initially, the shield 600 has a proximal end 610 and a distal end 620 opposite to the proximal end 610. The shield 600 is sized so that the nozzle 400 can be inserted into a cavity of the shield 600. Adjacent the proximal end 610 is a proximal portion 612, and adjacent the distal end 620 is a distal portion 622. As shown in FIGS. 23 and 24, the shield 600 has an opening or orifice 624 formed in the distal end 620 that is fluidically coupled to the internal cavity 680 of the shield 600.

[0135] In this embodiment, the outside of the shield 600 has two different parts. One part is a cylindrical portion 630 that includes the proximal portion 612 of the shield 600. The other part is an angled or tapered portion 660 that includes the distal portion 622 of the shield 600. The cylindrical portion 630 extends to the angled portion 660. The cylindrical portion 630 has an outer surface 632 that extends to an outer surface 662 of angled portion 660. As shown in FIGS. 23-25, the outer surface 662 has several openings 674 formed therein around the perimeter of the shield 600.

[0136] Referring back to FIG. 23, the shield 600 includes a ledge 654 that extends around an inner perimeter. The ledge 654 has several openings 670 formed therein that are spaced apart from each other.

[0137] Turning to FIG. 26, the various features of the shield 600 are illustrated. The cylindrical portion 630 has an inwardly extending flange 640 that has an inner surface 634. The inner surface 634 extends between an upper ledge 642 of the flange 640 to a lower ledge 644 of the flange 640. In this embodiment, the upper ledge 642 has a beveled or chamfered edge. In addition, the lower ledge 644 has a curved configuration that is continuously connected to an inner wall 650, which is continuously connected to a ledge 654. As shown, the inner wall 650 has curved upper and lower ends. The lower ledge 644, the inner wall 650, and the ledge 654 collectively define an inner groove 652.

[0138] The shield 600 has an inner surface 664 that is angled up to a tip or end 666. As mentioned above, openings 670 are formed in the ledge 654. Each pair of openings 670 and 674is located at opposite ends of a passageway 672. Each passageway 672 extends through the wall of the shield 600. In this embodiment, the passageways 672 extend parallel to a longitudinal axis of the shield 600. As described in greater detail below, shield gas can enter opening 670, travel through passageway 672, and exit opening 674 out of the shield 600.

[0139] Turning to FIGS. 27-28, a side view and a side cross-sectional view of another example embodiment of a shield are illustrated, respectively. Shield 600’ is an example embodiment of a shield that can be used in a 90 Amp operation, and in particular, used with the nozzle 400’” illustrated in FIGS. 21-22.

[0140] In this embodiment, shield 600’ has a proximal end 610’ and a distal end 620’ opposite to the proximal end 610’. The shield 600’ is sized so that the nozzle 400”’ can be inserted into the internal cavity 680’ of the shield 600’. Adjacent the proximal end 610’ is a proximal portion 612’, and adjacent the distal end 620’ is a distal portion 622’. As shown in FIG. 28, the shield 600’ has an opening or orifice 624’ formed in the distal end 620’ that is fluidically coupled to the internal cavity 680’ of the shield 600’.

[0141] In this embodiment, the outside of the shield 600’ has two different parts. One part is a cylindrical portion 630’ that includes the proximal portion 612’ of the shield 600’. The other part is an angled or tapered portion 660’ that includes the distal portion 622’ of the shield 600’. The cylindrical portion 630’ extends to the angled portion 660’. The cylindrical portion 630’ has an outer surface 632’ that extends to an outer surface 662’ of angled portion 660’. The outer surface 662’ has several openings 674’ formed therein around the perimeter of the shield 600’.

[0142] Referring to FIG. 28, the cylindrical portion 630’ has an inwardly extending flange 640’ that has an inner surface 634’ and a lower ledge 644’ that is shaped differently from lower ledge 644 of shield 600. The inner surface 634’ extends between an upper ledge 642’ of the flange 640’ to a lower ledge 644’ of the flange 640’. In this embodiment, instead of a curved configuration, the upper ledge 642’ has a beveled or chamfered edge, and the lower ledge 644’ is angled toward an inner wall 650’ and includes a beveled or chamfered edge, which is connected to a ledge 654’ . As shown, the inner wall 650’ has planar upper and lower ends, and is cylindrical instead of curved like inner wall 650. The lower ledge 644’, the inner wall 650’, and the ledge 654’ collectively define an inner groove 652’.

[0143] The shield 600’ has an inner surface 664’ that is angled up to a tip or end 666’ . As mentioned above, openings 670’ are formed in the ledge 654’. Each pair of openings 670’ and 674’ is located at opposite ends of a passageway 672’ . Each passageway 672’ extends through the wall of the shield 600’ . In this embodiment, the passageways 672’ extend parallel to a longitudinal axis of the shield 600’. As described in greater detail below, shield gas can enter each opening 670’, travel through passageway 672’, and exit opening 674’ out of the shield 600’.

[0144] Turning to FIGS. 29-30, a side view and a side cross-sectional view of another example embodiment of a shield are illustrated, respectively. Shield 600” is an example embodiment of a shield that can be used in a 110 Amp operation.

[0145] In this embodiment, shield 600” has a proximal end 610” and a distal end 620” opposite to the proximal end 610”. The shield 600” is sized so that a desired nozzle can be inserted into the internal cavity 680 of the shield 600”. Adjacent the proximal end 610” is a proximal portion 612”, and adjacent the distal end 620” is a distal portion 622”. Shield 600” has an opening or orifice formed in the distal end 620” that is fluidically coupled to the internal cavity of the shield 600”.

[0146] In this embodiment, the outside of the shield 600” has two different parts, similar to shield 600’. Shield 600” includes a cylindrical portion 630” that includes the proximal portion 612”, and an angled or tapered portion 660” that includes the distal portion 622”. The cylindrical portion 630” has an outer surface 632” that extends to an outer surface 662” of angled portion 660”. The outer surface 662” has several openings 674” formed therein around the perimeter of the shield 600”.

[0147] Referring to FIG. 30, shield 600” has a slightly different internal configuration from that of shield 600 and from that of shield 600’. In shield 600”, cylindrical portion 630” has an inwardly extending flange 640” that has an inner surface that extends between an upper ledge of the flange 640” to a lower ledge 644” of the flange 640”. In this embodiment, the upper ledge has a beveled or chamfered edge, and the lower ledge 644” is angled toward an inner wall 650”, which is connected to a ledge 654”. As shown, the inner wall 650” has planar upper and lower ends. The lower ledge 644”, the inner wall 650”, and the ledge 654” collectively define an inner groove 652”.

[0148] The shield 600” has an inner surface 664” that is located on an angled portion 660” that has a different configuration from angled portion 660 of shield 600 and from angled portion 660’ of shield 600’. The inner surface 664” has an upper end with a cylindrical wall portion 668”. As mentioned above, openings 670” are formed in the ledge 654”. Each pair of openings 670” and 674” is located at opposite ends of a passageway 672”. Each passageway 672” extends through the wall of the shield 600”. In this embodiment, the passageways 672” extend parallel to a longitudinal axis of the shield 600’. As described in greater detail below, shield gas can enter each opening 670”, travel through passageway 672”, and exit opening 674” out of the shield 600”.

[0149] As noted above, the example embodiments of the shields have slightly different dimensions. In one example embodiment, a shield or shield cap 600 for a 30 Amp or a 50 Amp application has a diameter of its distal end (such as 620) of 0.315 inches. The length of its outer cylindrical portion (such as 630) is 0.178 inches, and the length of its outer angled portion (such as 660) along the longitudinal axis of the shield is 0.390 inches. The angle at which outer angled portion is oriented relative to the distal end is 53.3 degrees.

[0150] Similarly, in one example embodiment, a shield or shield cap 600’ for a 70 Amp or a 90 Amp application has a diameter of its distal end of 0.370 inches. The length of its outer cylindrical portion is 0.188 inches, and the length of its outer angled portion along the longitudinal axis of the shield is 0.415 inches. The angle at which outer angled portion is oriented relative to the distal end is 55 degrees.

[0151] Also, in another example embodiment, a shield or shield cap 600” for a 110 Amp application has a diameter of its distal end of 0.402 inches. The length of its outer cylindrical portion is 0.230 inches, and the length of its outer angled portion along the longitudinal axis of the shield is 0.431 inches. The angle at which outer angled portion is oriented relative to the distal end is 60 degrees.

[0152] The foregoing discussion related to various components of a consumable cartridge. Now turning to FIGS. 31-32, an example embodiment of a torch head assembly is described. Referring initially to FIG. 31, a perspective view of a torch head assembly is shown. Torch head assembly 900 includes a shield 600, a distal shield cup member 710, an intermediate shield cup member 740, and a cylindrical conductor 800.

[0153] The torch head assembly 900 includes several torch head components, including torch head component 910. Torch head component 910 includes an opening 912 formed therein through which a camera tube or housing 930 extends. The camera housing 930 receives a camera therein that is positioned to read and identify indicia on a consumable cartridge, which is used to confirm that an appropriate consumable cartridge is inserted. Torch head component 910 also includes an opening 914 formed therein. A sensor probe 950 extends through the opening 914. The sensor probe 950 extends from the torch head assembly toward the consumable cartridge. When a consumable cartridge is inserted into the torch head assembly, the consumable cartridge presses on the sensor probe 950, which closes a switch, as described in greater detail below.

[0154] Torch head component 910 also has an open central portion in which a torch head fitting 920 is positioned. The torch head fitting 920 includes a central passageway in which the proximal portion of the electrode 200 is located. Beneath torch head component 910 is another torch head component 1000, which is described in greater detail below.

[0155] Turning to FIG. 32, the same perspective view of the torch head assembly 900 is illustrated, however, the torch head component 910 has been removed. With torch head component 910 removed, more of each of the camera housing 930 and the sensor probe 950 is visible. In addition, torch head components 1000 and 1200 are shown in FIG. 32. Torch head component 1200 is located in the cavity or passageway defined by torch head component 1000. Sensor probe 950 extends upwardly from torch head component 1200.

[0156] Several of the torch head components are now described. Referring to FIGS. 33- 35, several different views of a few of the torch head components are illustrated. In FIG. 33, torch head component 1200 is located inside torch head component 1000. Torch head component 1200 has a rounded or protruding portion 1208 through which sensor probe 950 extends. The camera housing 930 is also shown in this view. Torch head component 1200 defines a through channel that extends between opposite ends of component 1200. Located on an inner wall surface of torch head component 1200 are several openings 1222.

[0157] Referring to FIGS. 34 and 35, exploded perspective views of torch head components 1000, 1100, and 1200 are illustrated. Each of the torch head components 1000, 1100, and 1200 is generally cylindrical and has an inner surface that defines a passageway or cavity thatends between the opposite ends of the component. In this embodiment, torch head component 1000 has the largest inner diameter and internal cavity, and both of the other torch head components 1100 and 1200 are inserted into torch head component 1000. Torch head component 1200 is inserted into the cavity of torch head component 1000, such as via the opening at the upper end of component 1000. The result is that torch head component 1200 is seated within torch head component 1000 as shown in FIG. 33. Torch head component 1100 is inserted into torch head component 1000 as well, such as via the opening at the lower end of component 1000. In addition, torch head component 1100 is also positioned into of torch head component 1200. A cross- sectional view of the torch head components 1000, 1100, and 1200 in their assembled configuration is illustrated in FIG. 41, which will be described in greater detail below.

[0158] As shown in FIG. 34, torch head component 1100 has a proximal end 1102 and a distal end 1104 opposite to the proximal end 1102. Torch head component 1100 has an inner surface 1120 that defines a passageway or channel extending through the component 1100, and an opposite outer surface 1130 that defines an outer perimeter of the component 1100. In this embodiment, the inner surface 1120 of torch head component 1100 has several openings 1122 formed therein that lead to passageways extending through the wall of the component 1100. Each passageway extends to the outer surface 1130 of the component 1100 and terminates at one of the openings 1140 formed in the outer surface 1130. While only three openings 1122 and three openings 1140 are shown in FIG. 34, it is to be appreciated that additional openings 1122 and openings 1140 are spaced apart around the inner and outer perimeters, respectively, of the component 1100. The openings 1122 are sized so that gas located in the channel or cavity can travel therethrough and into passageways, and subsequently exit one of the openings 1140.

[0159] Similarly, torch head component 1200 has an inner surface 1212 that has openings 1222 defined therein, and an outer surface 1230 that has openings 1240 defined therein. Each pair of openings 1222 and 1240 defines a passageway therebetween that extends from the inner surface 1212 to the outer surface 1230. When the torch head components 1000, 1100, and 1200 are assembled, the lower portion of the inner surface 1212 of torch head component 1200 is adjacent to the outer surface 1130 of torch head component 1100. The torch head components 1200 and 1100 are aligned so that each of the outer openings 1140 of component 1100 is adjacent to one of the inner openings 1222 of component 1200. As a result, each of the passageways extendingthrough the wall of component 1100 is aligned with one of the passageways extending through the wall of component 1200. Torch head component 1200 also includes an extending or protruding portion 1208 that has a hole 1210 formed therein. The hole 1210 is sized to receive the sensor probe 950.

[0160] Torch head component 1000 has an inner surface 1020 that has spaced apart openings 1022 formed therein along its inner perimeter. When torch head component 1200 is inserted into component 1000, the outer openings 1240 of component 1200 are located adjacent to the inner openings 1022 of component 1000. Each of the passageways extending through the wall of component 1000 is aligned with one of the passageways extending through the wall of component 1200. As a result, the passageways extending through each of the components 1000, 1100, and 1200 are aligned with respective ones of the passageways extending through the other of the components 1000, 1100, and 1200. FIG. 35 illustrates a different perspective view of the torch head components 1000, 1100, and 1200.

[0161] Turning to FIGS. 36-37, torch head component 1000 is described in greater detail. In this embodiment, torch head component 1000 is generally cylindrical and has a proximal end 1002 and a distal end 1006 opposite its proximal end 1002. A proximal portion 1004 is located adjacent to the proximal end 1002, and a distal portion 1008 is located adjacent to the distal end 1006. The distal end 1006 has several spaced apart openings 1010 formed therein, as shown in FIGS. 36 and 37. The function of openings 1010 is described in detail below.

[0162] As shown in FIG. 37, component 1000 has an inner surface 1020 that defines a passageway or channel 1028 through the component 1000. The distal end 1006 has a centrally located opening 1012 that is located at one end of the channel 1028.

[0163] Referring back to FIG. 36, torch head component 1000 has an outer surface 1030 that has several different outer diameter portions with a variety of shapes. Most notably, the outer surface 1030 has two ring portions 1032 and 1034 that are spaced apart from each other. Located between ring portions 1032 and 1034 is an outer surface portion 1033, which collectively with ring portions 1032 and 1034 defines a gap or groove 1038 in the outer surface 1030. Ring portion 1034 has a surface 1036 that defines the groove 1038 in part. Formed partially in both outer surface portion 1033 and in surface 1036 are several spaced apart openings 1050. Each of these openings1050 is the start of a different passageway that extends through the lower portion of component 1000 and along a longitudinal axis 1005 of component 1000 to one of the openings 1010 in the distal end 1006. Formed in outer surface portion 1033 are several openings 1040 from which gas located inside of component 1000 travels into groove 1038. When the torch head components are assembled in the torch head, the gas that exits openings 1040 travels within groove 1038 and then into one of the openings 1050. Once the gas enters an opening 1050, it travels through the passageway and out of one of the openings 1010.

[0164] Referring to FIGS. 38-41, several cross-sectional views of different ones of the torch head components 1000, 1100, and 1200 are illustrated. Turning initially to FIGS. 38 and 39, different horizontal cross-sectional views of torch head component 1000 are shown. In FIG. 38, the cross-section is taken horizontally through the wall of component 1000. The inner surface 1020 and the outer surface 1030 of the wall are shown. Located around the wall are five sets of openings 1022 in the inner surface 1020 and openings 1040 in the outer surface 1030. Between each set of openings 1022 and 1040 is a passageway 1042. While in this embodiment, five pairs of openings are disclosed, in different embodiments, the quantity of pairs of openings can vary.

[0165] In addition, several openings 1050 are spaced around the outer surface 1030 of the component 1000 in the groove 1038. As described above, each of the openings 1050 is proximate to a passageway 1052 that extends to the distal end 1006. In this embodiment, there are four sets of openings 1050 and passageways 1052. However, in alternative embodiments, the quantity of openings 1050 and passageways 1052 can be more or less than four. Turning to FIG. 39, a cross- sectional view is taken of torch head component 1000 at a level lower than the cross-sectional view in FIG. 38. As shown, the passageways 1052 continue through the lower portion of the component 1000 to the distal end 1006.

[0166] Returning to FIG. 38, torch head component 1000 includes two recessed or curved portions 1024 and 1026. Recessed portion 1024 is sized to receive a portion of the camera housing 930. Recessed portion 1026 is sized to receive the protruding portion of torch head component 1200 in which the sensor probe 950 is located.

[0167] Turning to FIGS. 40 and 41, horizontal and vertical cross-sectional views of torch head components 1000, 1100, and 1200 are illustrated. Component 1100 has a hole 1160 throughwhich the sensor probe 950 extends. Referring initially to FIG. 40, torch head component 1100 is positioned inside of the thin lower portion of torch head component 1200, which is positioned inside of torch head component 1000. Gas passageways 1052 are shown around the perimeter of torch head component 1000. Gas passageway 1142 extending between openings 1122 and 1140 is illustrated. Aligned with each of the passageways 1142 is a passageway 1242 through the thin wall of component 1200 and a passageway 1042 through the wall of component 1000. In FIG. 40, arrows for plasma gas flow 1272 represent the directions of gas flows through passageways 1142, 1242, and 1042 and then into passageways 1052.

[0168] Referring to FIG. 41, a vertical cross-sectional view of the assembled torch head components 1000, 1100, and 1200 is illustrated. As shown, the thicker upper portion of component 1200 is located in the upper portion of component 1000. Longitudinal movement of component 1200 within component 1000 is limited by the engagement of surface 1246 with surface 1046. The thinner lower portion of component 1200 is located between component 1100 and component 1000. In particular, component 1100 slides into the inner channel or cavity of component 1200. When the components 1000, 1100, and 1200 are aligned, their passageways 1042, 1142, and 1242 are aligned as well. As a result, a gas flow can enter openings 1122, travel through passageways 1042, 1142, and 1242 to groove 1038, and then into openings 1050 and through passageway 1052 to exit as a shield gas flow 1274 into the interior of the shield 600.

[0169] Now turning to FIGS. 42-50, various components are described. Referring initially to FIG. 42, a perspective view of the camera housing 930 and a spring 940 are illustrated. The camera housing 930 is an elongate member that has an outer surface that is predominantly hexagonal with a cylindrical end portion. The camera housing 930 defines an internal channel 932 in which a camera can be inserted. The spring 940 is a resilient member that is placed on a portion of the electrode 200 that is inserted into torch head fitting 920.

[0170] Turning to FIG. 43, a perspective view of torch head fitting 920 is shown. Torch head fitting 920 is also an elongate member that defines an internal channel or passageway 921 that extends along the longitudinal axis of the fitting 920. The fitting 920 has an outer surface 922 that has several different sections with varying outer diameters. In particular, the outer surface 922 includes a ring portion 923 that is spaced apart from another ring portion 925. The ring portions 923 and 925 define a groove 924 therebetween. The outer surface 922 includes an outerwall portion 927 that defines the groove 924 along with ring portions 923 and 925. Formed in the outer wall portion 927 are openings 926 through which a fluid, such as a gas may flow. Each of the openings 926 is the outer end of a passage 928 that extends through the wall of the torch head fitting 920. Also shown in FIG. 43 is a perspective view of torch head component 910 that defines a cavity 916 therethrough in which a portion of torch head fitting 920 is located when the torch head is assembled.

[0171] Turning to FIGS. 44 and 45, different exploded perspective views of several components are illustrated. Starting at the bottom of FIG. 44, the shield 600 is provided with a shield cup assembly 700 and a conductor 800. In this embodiment, the shield cup assembly 700 includes several different parts. In particular, the shield cup assembly 700 includes a distal shield cup member 710, an intermediate shield cup member 740, and a proximal shield cup member 770. When the distal shield cup member 710 and the intermediate shield cup member 740 were introduced above relative to FIG. 31, each of them is visible on the outside of the torch head assembly distal to the conductor 800. The proximal shield cup member 770 is not illustrated in either of FIG. 31 or FIG. 32 because it is located inside of the intermediate shield cup member 740 and the conductor 800.

[0172] Returning to FIGS. 44-46, the distal shield cup member 710 is described first. In this embodiment, the distal shield cup member 710 has a proximal portion 712 that is adjacent to a proximal end 714 and a distal portion 718 that is adjacent to a distal end 720, which is opposite to proximal end 714. The distal end 720 defines an opening 722. The distal portion 718 has an outer diameter that is smaller than the outer diameter of proximal portion 712. The distal portion 718 is sized small enough to be insertable into the internal cavity of the shield 600. The proximal portion 712 has a bottom or outer ledge 724 (see FIG. 44) from which the distal portion 718 extends. The inner features of distal shield cup member 710 are illustrated in FIG. 45. As shown, the proximal end 714 defines an opening 716 that is in fluid communication with a channel or cavity 728 that is in fluid communication with the opening 722 in the distal end 720. The distal shield cup member 710 includes an inner ledge 726 that is located on the opposite side of outer ledge 724.

[0173] Referring to FIG. 46, the distal shield cup member 710 also includes an inner wall surface 730 that has a raised or protruding portion 732 that extend around the inner circumference of the inner wall surface 730.

[0174] Next, the intermediate shield cup member 740 is described. As shown in FIG. 44, in this embodiment, the intermediate shield cup member 740 includes a proximal portion 742 adjacent to a proximal end 744 that defines an opening 746 (see FIG. 45), and an oppositely located distal portion 748 that is adjacent to a distal end 750 that defines an opening 752 (see FIG. 44).

[0175] The intermediate shield cup member 740 has an outer surface 754 that has a generally cylindrical portion 755 that forms an outer surface of the torch head assembly. The outer surface 754 also includes a grooved portion 756 and a lower angled portion 758, both of which are inserted into the cavity 728 of the distal shield cup member 710, and as a result, do not form an outer surface of the torch head assembly. When the intermediate shield cup member 740 is inserted into the distal shield cup member 710 (see FIG. 46), the distal end 750 engages the inner ledge 726, and the grooved portion 756 receives the protruding portion 732 formed on the inner surface 730 of distal shield cup member 710. In this assembled configuration, the lower angled portion 758 of the intermediate shield cup member 740 engages an angled inner surface 727 of the distal shield cup member 710. Referring back to FIG. 45, the intermediate shield cup member 740 includes an inner ledge 760 that is also a support or engaging surface when the components are assembled.

[0176] Referring to FIGS. 44 and 45, the proximal shield cup member 770 has a proximal portion 772 that is adjacent to a proximal end 774 that defines an opening 776, and a distal portion 778 that is adjacent to a distal end 780 that defines an opening 784. In this embodiment, the distal portion 778 of the proximal shield cup member 770 includes an extending portion 782, which forms part of an outer surface of the proximal shield cup member 770. In particular, the outer surface of member 770 includes a cylindrical surface portion 786 and an angled surface portion 788 between the cylindrical surface portion 786 and the extending portion 782.

[0177] Referring to FIG. 45, the inner surfaces of the proximal shield cup member 770 are illustrated. As shown, one of the inner surfaces is an angled inner surface 790 that leads from cylindrical inner surfaces to a radial ledge 792 that has several openings 794 formed therein. Aninner wall 796 that extends parallel to a longitudinal axis of the proximal shield cup member 770 intersects with the radial ledge 792 around the inner circumference of member 770. The inner wall 796 includes several openings 798 formed therein. Each of the openings 798 is connected to one of the openings 794 in the radial ledge 792 via a passageway between them. The openings 794 and 798 and associated passageway are sized to receive and have fluid pass therethrough.

[0178] As shown in FIG. 46, when proximal shield cup member 770 is inserted into intermediate shield cup member 740, the distal end 780 of member 770 engages the inner ledge 760 of member 740. The openings 798 formed in inner wall 796 are free so that any fluid can pass therethrough. The openings 722, 752, and 784 in the distal ends 720, 750, and 780, respectively, are aligned with each other.

[0179] Referring to FIGS. 47 and 48, longitudinal or front / side cross-sectional views of components of the torch head assembly and the consumable cartridge are illustrated. Torch head component 910 is shown along with the camera housing 930, which has its channel 932. A camera (not shown) is inserted into channel 932 and positioned to have an area in which indicia on a component of the consumable cartridge can be viewed by the camera. The indicia identifies the consumable cartridge, which is associated with a particular amperage. This way, the torch can confirm that an appropriate consumable cartridge was inserted. Also shown in FIG. 47 is the proximal end of the sensor probe 950, and the spring 940 that is placed between an outer surface of the electrode 200 and an inner surface of the torch head fitting 920.

[0180] A fluid flow 1270, which in this embodiment is a gas, is shown entering the proximal end of torch head fitting 920. The fluid flow 1270 enters the passageway 921 of fitting 920 and then enters the channel 216 of the electrode 200. The fluid flow 1270 travels to the distal end 220 of the channel 216 and travels outward through the openings 222. At this point, the fluid flow 1270 is split into two different flows. Flow 1272 is a plasma gas flow that is routed to the plasma chamber and has a first fluid path. Flow 1274 is a shield gas flow that is routed to the shield 600 and has a second fluid path.

[0181] Turning to the shield gas flow 1274 first, a portion of the fluid exiting openings 222 of the electrode 200 travels through passageways 928 formed in the torch head fitting 920 and outward through openings 926 (see FIG. 48). Adjacent to the torch head fitting 920 is torch headcomponent 1100. The flow 1274 then travels through passageways 1142 formed in the wall of component 1100, and through passageways 1242 formed in the wall of component 1200. The flow 1274 next travels through the passageways 1042 in torch head component 1000 and into the groove 1038. The flow 1274 enters openings 1050 (not shown in FIGS. 47 or 48) and travels in passageways 1052 to the openings 1010 in the distal end 1006 of component 1000.

[0182] Once the flow 1274 has exited component 1000, it enters the openings 794 formed in ledge 792 of proximal shield cup member 770. The flow 1274 exits the proximal shield cup member 770, travels through opening 752 in the intermediate shield cup member 740, and then through the opening 722 in the distal shield cup member 710. At this point, the flow 1274 has reached the internal cavity 680 of the shield 600. A portion of the flow 1274 travels through the passageways 672 of the shield 600. The other portion of the flow 1274 travels along the inner surface 664 of the shield 600 and out through the orifice 624.

[0183] Now turning to the plasma gas flow 1272, the other portion of the fluid exiting openings 222 of the electrode 200 travels inside the torch head fitting 920 between an inner surface of the fitting 920 and an outer surface of the electrode 200. The distal end of the torch head fitting 920 is mounted inside of the gas distributor 300. As a result, the flow 1272 exits the torch head fitting 920 and enters the gas distributor 300. The flow 1272 travels through passageways 362 in the gas distributor 300 and exits through openings 324. The flow 1272 travels around the distal end of the electrode 200 between the electrode 200 and the nozzle 400. The flow 1272 travels through the bore 434 located at the distal end 430 of the nozzle 400.

[0184] As different nozzles with different outer profiles are inserted into the shield cup assembly, different sized annular gaps are defined between the nozzle outer profile or surface and the inner surface of the shield assembly. The annular gap is the space through which a shield gas flow travels. Due to the differences in the outer profiles, the sizes of the annular gaps between the nozzles and the shield assembly will vary. When the size of the annular gap decreases from one nozzle to the other nozzle, the flow restriction on the shield gas flow increases and the flow of the shield gas decreases, which will increase the flow of the plasma gas. This aspect is discussed in greater detail below.

[0185] Referring to FIGS. 47 and 48, the inner surfaces of each of the distal shield cup member 710, the intermediate shield cup member 740, and the proximal shield cup member 770 define an annual gap with the outer surface of the nozzle inserted into the shield cup assembly 700. When nozzles with outer surfaces with different outer diameters and profiles are inserted into the shield cup assembly, the size of the annual gap varies. If a smaller annular gap is desired so that the pressure drop in the shield gas flow increases, then a nozzle that has a larger outer diameter or profile is used because the shield cup assembly remains the same. If a larger annular gap is desired so that the pressure drop in the shield gas flow decreases, then a nozzle that has a smaller outer diameter or profile is used in the shield cup assembly. By utilizing different sets of consumables, each of which has a different nozzle, with a constant shield cup assembly, the operation and functionality of the torch head can be adjusted. Namely, the use of different shaped and sized nozzles with a similar shield cup assembly results in different back pressures in the shield gas flow and a different flow for the plasma gas flow.

[0186] Turning to FIGS. 49-51, the structure and operation of the sensor probe 950 is described. Referring to FIG. 49, in this embodiment, the sensor probe 950 includes a central body portion 952 that has a generally cylindrical outer profile. At opposite ends of the central body portion 952 are ends 954 and 956, each of which is a slightly smaller outer diameter than the central body portion 952. A head 958 is located at the distal end of the sensor probe 950. The head 958 is positioned so that when a consumable stack is inserted or mounted to the torch head, the consumable stack engages and presses the head 958 to move the sensor probe along its longitudinal axis 955. When the sensor probe 950 is moved, it engages a switch 960 (see FIG. 50) located in the torch head and closes the switch 960. The sensor probe 950 is moved only by an appropriate consumable stack. In other words, when an incorrect (such as from an incorrect consumable stack is inserted into a torch head, the sensor probe 950 will not be moved, and the switch 960 will not be closed. The sensor probe 950 can be used to confirm that the appropriate consumables for a particular torch head are used.

[0187] Referring to FIGS. 49-51, torch head component 1200 has a proximal portion 1202 near a proximal end 1204. The proximal end 1204 has an opening 1206 defined therein. The torch head component 1200 includes a protruding portion 1208 that has hole 1210 through which the sensor probe 950 extends. The component 1200 also has an inner surface 1212 that has a channel1214 formed therein that is also defined in part by an inner surface of a sleeve 1216. The channel 1214 is sized to slidably receive the sensor probe 950.

[0188] Torch head component 1200 has a distal portion 1250 that is adjacent to a distal end 1252 that defines an opening 1254 therethrough. The body of the torch head component 1200 defines a channel or passageway 1256 extending therethrough. In a wall defining the body of component 1200, a gap or notch 1258 is defined, as shown in FIG. 51.

[0189] Referring to FIG. 52, an example embodiment of a consumable is illustrated. Consumable 1300 includes a tip or nozzle 1302 and an electrode 1304 that is inserted into the nozzle 1302. The consumable 1300 includes a gas distributor 1306 that is located around the electrode 1304. While this embodiment of consumable 1300 includes a ring 1308 with a positioner 1310, the ring 1308 is not included in other embodiments of consumables described herein. A camera 1320 that is located in a torch head is used to read indicia on the consumable 1300 to confirm that the consumable 1300 is appropriate (such as in its amperage) for the planned operation of the torch. A microswitch 1322 is located the torch head as well.

[0190] Referring to FIG. 53, a schematic view of the consumable 1300 and the electrical connections of the torch head for the camera and for the microswitch are illustrated. In this implementation, a microswitch is introduced so there is no shared electrical contact. As a result, the 3E PCB is electrically isolated from the product identification (PID) or PIP. The microswitch is normally open and its distal end is made of electrically insulating material. When a DCM is in place in a torch with physical contact to the bottom of the torch body, it turns the switch on for PIP recognition.

[0191] In one implementation, a plasma torch has a PIP function with a microswitch (or switch probe) and a PID function with optical camera. Both functions are independent without sharing any inputs of electrical signal. The PIP function with a microswitch (or switch probe) and the PID function with a displacement sensor or a potentiometer are embedded in the torch body. In one implementation, the measuring point can be any geometrical surface of the shield retaining cup or shield cap which is installed in front of the shield retaining cup.

[0192] In different implementations, the identification features can vary. The identification of the DCM is an improved method of addressing electrical components that mayexperience “drift,” noise, or other loss of calibration, or to conduct initial calibration at a factory. A torch head may have more than one linear analog potentiometer (or similar digital or mechanical element) for sensing different combinations of DCM component configurations (for example, two sensors = several component option possibilities). Multiple geometric (or electrical) registering features may be provided.

[0193] In some instances, calibration DCMs may include four positions (one for each possible DCM orientation within the torch). Each discreet position could calibrate the sensor(s) for a different amperage and component type (such as gouging, cutting, marking, etc.). A calibration DCM could be physically marked to clearly indicate which amperage combination is being calibrated for any given (or deliberately installed) orientation. A (Re)Calibration DCM may also be a tool required throughout the service life of the torch due to component wear at the tip of the sensor(s). If sensor(s) were sufficiently robust, and the specific orientation of each regular DCM was not critical, during installation the DCM could spin across these sensors which could detect a prescribed series of “speedbumps” registering the component configuration being installed, in a manner similar to a radial topographical barcode. In other implementations, sensor(s) could also have a roller at the distal end to increase life, mitigate component wear, and limit the frequency of recalibration.

[0194] In some implementations, leading characters or features could be a codified and textured logo, that may mechanically signal the sensor(s) to start reading and diagnosing the following characters as the DCM rotates into position as the user threads the DCM retaining component(s) into place. In one instance, the bumps may be Braille characters. In another instance, the bumps could also be protrusions that engage a component such as a “tuning fork” to produce a sound (or combination of sounds) that are picked up (and possibly translated) by a receiver.

[0195] Referring to FIGS. 54 and 55, perspective and top views of another example embodiment of a consumable are illustrated, respectively. Consumable 1400 includes a surface 1410 that has identifying indicia 1420 in multiple locations. The identifying indicia 1420 contains information that can be read by a camera when the indicia 1420 is located in the view 1430 of a camera.

[0196] Referring to FIG. 56, a side of an alternative embodiment of a sensor probe is illustrated. Sensor probe 1 00 has several different sections, including a tip 1502 and a threaded section 1504.

[0197] While the consumables presented herein have been illustrated and described in detail and with reference to specific embodiments thereof, it is nevertheless not intended to be limited to the details shown, since it will be apparent that various modifications and structural changes may be made therein without departing from the scope of the inventions and within the scope and range of equivalents of the claims. For example, as mentioned, the consumables presented herein may be modified to connect to or be used with any other desired consumable or non-consumable components, including to facilitate a specific arc initiation technique. Additionally, the consumables presented herein may be suitable for automated (e.g., mechanized) and / or manual (e.g., handheld) cutting.

[0198] In addition, various features from one of the embodiments may be incorporated into another of the embodiments. That is, it is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in a preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions, and / or properties disclosed herein. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure as set forth in the following claims.

[0199] It is also to be understood that terms such as “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “inner,” “outer” and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration. Further, the term “exemplary” is used herein to describe an example or illustration. Any embodiment described herein as exemplary is not to be construed as a preferred or advantageous embodiment, but rather as one example or illustration of a possible embodiment of the invention. Additionally, it is also to be understood that the consumables described herein, or portions thereof may be fabricated fromany suitable material or combination of materials, such as plastic or metals (e.g., copper, bronze, hafnium, etc.), as well as derivatives thereof, and combinations thereof.

[0200] Finally, when used herein, the term “comprises” and its derivations (such as “comprising”, etc.) should not be understood in an excluding sense, that is, these terms should not be interpreted as excluding the possibility that what is described and defined may include further elements, steps, etc. Similarly, where any description recites “a” or “a first” element or the equivalent thereof, such disclosure should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Meanwhile, when used herein, the term “approximately” and terms of its family (such as “approximate,” etc.) should be understood as indicating values very near to those which accompany the aforementioned term. That is to say, a deviation within reasonable limits from an exact value should be accepted, because a skilled person in the art will understand that such a deviation from the values indicated is inevitable due to measurement inaccuracies, etc.). For example, the term “approximately” may denote a tolerance of plus or minus 0.002 inches, 0.001 inches, or up to 0.005 inches. The same applies to the terms “about” and “around” and “substantially.”

Claims

We claim:

1. A plasma arc torch that receives a flow of fluid from a fluid source, comprising: a shield assembly, the shield assembly including a shield, a shield cup, and a shield cup insulator, the shield cup insulator including a plurality of passageways formed therein; and a first set of consumables positionable in the shield assembly, the first set of consumables including a first nozzle, a first electrode, and a first gas distributor, wherein the flow of fluid flows into the first electrode and is separated into a first flow portion and a second flow portion, the first flow portion travels between the first nozzle and the first electrode and forms a plasma gas flow, and the second flow portion travels between the first nozzle and the shield assembly and forms a shield gas flow, the second flow portion traveling through the plurality of passageways of the shield cup insulator.

2. The plasma arc torch of claim 1, wherein the first nozzle has a first nozzle outer surface with a first profile, the plasma arc torch further comprising: a second set of consumables that is positionable in the shield assembly, the second set of consumables includes a second nozzle, a second electrode, and a second gas distributor, the second nozzle has a second nozzle outer surface with a second profile that is different than the first profile.

3. The plasma arc torch of claim 2, wherein when the first set of consumables is placed in the shield assembly, a first annular gap is formed between the first nozzle outer surface and the shield assembly, and when the second set of consumables is placed in the shield assembly, a second annular gap is formed between the second nozzle outer surface and the shield assembly, the second annular gap being different from the first annular gap.

4. The plasma arc torch of claim 3, wherein the first annular gap is larger than the second annular gap.

5. The plasma arc torch of claim 4, wherein the second flow portion has a first flow rate through the first annular gap and a second flow rate through the second annular gap, the first flow rate being larger than the second flow rate.

6. The plasma arc torch of claim 5, wherein when the second flow portion is at the first flow rate, the first flow portion is at a third flow rate, and when the second flow portion is at the second flow rate, the first flow portion is at fourth flow rate, the third flow rate being less than the fourth flow rate.

7. The plasma arc torch of claim 2, wherein the first nozzle outer surface has a first outer diameter, the second nozzle outer surface has a second outer diameter, when the first nozzle is inserted into the shield assembly, the first nozzle outer surface is proximate to the shield cup insulator, and when the second nozzle is inserted into the shield assembly, the second nozzle outer surface is proximate to the shield cup insulator, and the second outer diameter is different from the first outer diameter.

8. The plasma arc torch of claim 7, wherein the shield cup has an inner surface, and, when the first nozzle is located inside the shield assembly, the first nozzle outer surface is spaced from the inner surface of the shield cup to form a first gap therebetween for the second flow portion, and when the second nozzle is located inside the shield assembly, the second nozzle outer surface is spaced from the inner surface of the shield cup to form a second gap therebetween for the second flow portion, and the second gap is smaller than the first gap.

9. The plasma arc torch of claim 8, wherein a first pressure drop is created in the second flow portion by a size of the first gap, a second pressure drop is created in the second flow portion by a size of the second gap, and the second pressure drop is higher than the first pressure drop.

10. The plasma arc torch of claim 9, wherein the second pressure drop causes an increased flow of the first flow portion relative to the first pressure drop.

11. The plasma arc torch of claim 2, wherein the first gas distributor has first passageways formed therein, the second flow portion travels through the plurality of passageways of the shield cup insulator, and the first flow portion travels through the first passageways of the first gas distributor.

12. The plasma arc torch of claim 11, wherein the second gas distributor has second passageways formed therein, and the second passageways have similar dimensions to the first passageways.

13. The plasma arc torch of claim 1, wherein the shield cup insulator has a body portion and a radial flange portion, and each of the plurality of passageways is formed through the radial flange portion.

14. A plasma arc torch that receives a flow of fluid from a fluid source, comprising: a shield assembly; a first set of consumables disposable in the shield assembly, the first set of consumables including a first nozzle, a first electrode, and a first gas distributor, the first nozzle having a first nozzle outer surface, the first nozzle outer surface and the shield assembly defining a first annular gap therebetween; and a second set of consumables disposable in the shield assembly, the second set of consumables including a second nozzle, a second electrode, and a second gas distributor, the second nozzle having a second nozzle outer surface, the second nozzle outer surface and the shield assembly defining a second annular gap therebetween, the second annular gap being smaller than the first annular gap, wherein the flow of fluid is separated into a first flow portion and a second flow portion, when the first set of consumables is in the shield assembly, the first flow portion travels between the first nozzle and the first electrode and forms a first plasma gas flow, and the second flow portion travels between the first nozzle and the shield assembly and forms a first shield gas flow, and when the second set of consumables is in the shield assembly, the first flow portion travelsbetween the second nozzle and the second electrode and forms a second plasma gas flow, and the second flow portion travels between the second nozzle and the shield assembly and forms a second shield gas flow, the second shield gas flow being less than the first shield gas flow, and the second plasma gas flow being greater than the first plasma gas flow.

15. The plasma arc torch of claim 14, wherein the shield assembly includes a shield, a shield cup, and a shield cup insulator, the shield cup insulator has a body portion and a radial flange portion, the radial flange portion includes passageways formed therein, and both of the first shield gas flow and the second shield gas flow travels through the passageways of the shield cup insulator.

16. The plasma arc torch of claim 14, wherein the first nozzle outer surface has a first outer profile, the second nozzle outer surface has a second outer profile, and the second outer profile is different than the first outer profile.

17. The plasma arc torch of claim 14, wherein a first pressure drop is created in the second flow portion by a size of the first annular gap, a second pressure drop is created in the second flow portion by a size of the second annular gap, and the second pressure drop is higher than the first pressure drop, and the second pressure drop causes an increased flow of the first flow portion relative to the first pressure drop.

18. The plasma arc torch of claim 14, wherein the first set of consumables is for a first current, the second set of consumables is for a second current, the second current being different than the first current.

19. A plasma arc torch that receives a flow of fluid from a fluid source, comprising: a shield assembly; a first set of consumables disposable in the shield assembly, the first set of consumables including a first nozzle having a first nozzle outer surface, the first nozzle outer surface and the shield assembly defining a first annular gap therebetween; and a second set of consumables disposable in the shield assembly, the second set of consumables including a second nozzle having a second nozzle outer surface, the second nozzle outer surface and the shield assembly defining a second annular gap therebetween, the second annular gap being smaller than the first annular gap, wherein the flow of fluid is separated into a first flow portion and a second flow portion, when the first set of consumables is in the shield assembly, the first flow portion travels in the first nozzle and forms a first plasma gas flow, and the second flow portion travels between the first nozzle and the shield assembly and forms a first shield gas flow, the first annular gap creating a first pressure drop in the first shield gas flow, and when the second set of consumables is in the shield assembly, the first flow portion travels in the second nozzle and forms a second plasma gas flow, and the second flow portion travels between the second nozzle and the shield assembly and forms a second shield gas flow, the second annular gap creating a second pressure drop in the second shield gas flow, the second pressure drop being greater than the first pressure drop, and the second pressure drop causes the second plasma gas flow to be greater than the first plasma gas flow.

20. The plasma arc torch of claim 19, wherein the first nozzle outer surface has a first outer profile, the second nozzle outer surface has a second outer profile that is different from the first outer profile, the first set of consumables is for a first current, and the second set of consumables is for a second current different from the first current.

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