Abstract:
In some aspects, methods for preserving a usable life of a plasma arc electrode consumable installed in a plasma arc torch can include measuring a characteristic of an electrical signal being provided to the torch to generate a plasma arc between the torch and a workpiece to be processed; monitoring the characteristic during operation of the torch over a time period; comparing the characteristic to a threshold value; and responsive to determining that a measured characteristic meets and/or exceeds the threshold value, initiating an arc extinguishing sequence to preserve the life of the electrode.
Abstract:
A method of operating a plasma arc torch system is provided. A first plasma gas supply source, a second plasma gas supply source, and a control unit are provided. A first plasma gas composition is flowed through a first plasma gas flow path, and a plasma arc is generated using the first plasma gas composition. After arc generation, the plasma gas composition is changed to a second plasma gas composition, and the plasma gas flow path is changed to a second plasma gas flow path, wherein the second plasma gas flow path is different from the first plasma gas flow path. The plasma arc is sustained using the second plasma gas composition. The first and second plasma gas flow paths are both at least partially disposed within the plasma arc torch.
Abstract:
A plasma arc torch is provided that includes a torch head, a pre-flow gas conduit for directing a pre-flow gas through the plasma arc torch, at least one plasma gas conduit for directing a plasma gas through the plasma arc torch, and a gas control device. The pre-flow gas conduit and the plasma gas conduit extend into a proximal end portion of the torch head. The gas control device is disposed proximate the torch head and extends between a distal end portion of the pre-flow gas conduit and a distal end portion of the plasma gas conduit. The gas control device is operatively connected to each of the pre-flow gas conduit and the plasma gas conduit. The gas control device selectively allows one of the pilot gas and the plasma gas to flow through the plasma arc torch.
Abstract:
To lengthen the service period on DC plasma abatement devices a modified DC plasma torch is provided with an electrically conductive cathode and an electrically conductive anode spaced apart from one another to form a gap therebetween; a metal swirl bush at least partially located within the gap and comprising a channel adapted to permit, in use, a gas to flow through the gap; and a ceramic element interposed between any one or more of: the cathode and the swirl bush; and the anode and the swirl bush.
Abstract:
An electrode for a contact start plasma arc torch includes an elongated electrode body formed of an electrically conductive material that defines a longitudinal axis and a distal end for housing an emissive element. The electrode includes a second end positioned adjacent the electrode body. The second end defines an extensive portion having a first length along a first direction and a second length along a second direction. The second length is greater than the first length. A component for use with the electrode includes a hollow body element having an interior surface with one or more of a contour, step, or flange that defines a shaped opening capable of slideably receiving a complementary-shaped portion of an electrode body.
Abstract:
A contact start plasma arc torch (120) is provided that comprises an electrode, a tip, and an initiator (50) that is resiliently biased into contact with the tip (40), the initiator being movable against the resilient bias to separate from the tip and establish a pilot arc between the initiator and the tip. The initiator is disposed within a start cartridge (42), which preferably comprises a coil spring that biases the initiator into contact with the tip. The plasma arc torch (12) further comprises a plurality of head vent holes to vent gas from within the start cartridge during operation of the torch. Additionally, the tip defines a plurality of swirl holes and secondary gas holes to generate and control a plasma stream that is subsequently blown from a central exit orifice in the tip.
Abstract:
A process and apparatus for reducing wear of an electrode in a plasma arc torch involves altering the gas flow in a plasma chamber surrounding the electrode (22) immediately before and continuing after cutting of the current that sustain the arc (18). The altering includes closing off the gas flow upstream of the chamber (32), switching from a swirling flow to a radial/axial flow through the plasma chamber (32), reducing the arc current level in conjunction with either of the above, and venting the plasma chamber (32) to rapidly change the gas flow and pressure in the chamber. The interval is sufficient to reduce electrode wear, but short enough that the arc remains stabilized until cut-off. In the flow stop mode, a solenoid valve (48) is placed on an inlet tube (46) for the plasma gas. Flow altering also occurs on start up. A gas preflow is established prior to pilot arc ignition. On transfer, the flow increases to its full operating value in conjunction with an increase in the arc current. The preflow can be axial, or partially axial. Also, the type or composition of the gas used in the preflow and in the operating flow can change during the start up from a less reactive to more reactive gas.
Abstract:
A plasma arc torch (100, 400) includes a cathode adaptor body (501) having at least two sealant channels with sealant rings. The torch (100, 400) also includes a cathode body (505) having at least two sealant channels with sealant rings. The torch (100, 400) further includes a pilot arc connector (509) having at least two sealant channels with sealant rings. The torch (100, 400) additionally includes a rear isolator (513, 513') that includes at least two sealant channels with sealant rings that engage an anode body (519) and are spaced apart from each other by a distance that is in a range of 2 percent to 50 percent of an over all length of the rear isolator (513, 513'). The rear isolator (513, 513') also includes at least two sealant channels with sealant rings that engage a ring isolator (521) and are spaced apart from each other by a distance that is in a range of 2 percent to 50 percent of the overall length of the rear isolator (513, 513').
Abstract:
A high power DC steam plasma torch system (S) includes a steam plasma torch assembly (1) wherein superheated steam (46) is used as the main plasma forming gas, thereby resulting in a very reactive steam plasma plume. The superheated steam (46) is injected internally directly into the plasma plume via a ceramic lined steam feed tube (25) for reducing condensation of steam before reaching the plasma plume. The superheated steam (46) flows through a gas vortex (16) which has tangentially drilled holes thereby resulting in a high speed gas swirl that minimizes electrode erosion. In the present steam plasma torch system (S), the plasma torch assembly (1) is ignited using an ignition contactor which is housed external to the plasma torch assembly (1). The superheated steam (46) is injected into the plasma plume using a water cooled steam vortex generator assembly (15).