USRE37608E1 - Plasma torch electronic pulsing circuit - Google Patents
Plasma torch electronic pulsing circuit Download PDFInfo
- Publication number
- USRE37608E1 USRE37608E1 US08/352,389 US35238994A USRE37608E US RE37608 E1 USRE37608 E1 US RE37608E1 US 35238994 A US35238994 A US 35238994A US RE37608 E USRE37608 E US RE37608E
- Authority
- US
- United States
- Prior art keywords
- pilot
- current
- electrode
- torch
- arc
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K10/00—Welding or cutting by means of a plasma
- B23K10/006—Control circuits therefor
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- H05H1/00—Generating plasma; Handling plasma
- H05H1/24—Generating plasma
- H05H1/26—Plasma torches
- H05H1/32—Plasma torches using an arc
- H05H1/34—Details, e.g. electrodes, nozzles
- H05H1/36—Circuit arrangements
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/0021—Side-by-side or stacked arrangements
Definitions
- the present invention is in the field of plasma torches and in particular is directed to a plasma torch having an improved pilot and main arc generating circuit.
- Plasma torches otherwise known as electric arc torches, are known in the art for performing operations, such as cutting, welding, etc , on workpieces, and operate by directing a plasma consisting of ionized gas particles towards a workpiece.
- An example of the conventional single gas plasma torch is illustrated in Hatch, U.S. Pat. No. 3,813,510, assigned to the assignee herein
- Other patents disclosing such torches are U.S. Pat. Nos. 4,225,769; 4,663,512; and 4,663,515. The disclosures of all of the above-mentioned patents are incorporated herein by reference thereto.
- a gas to be ionized such as nitrogen
- a gas to be ionized is fed through channels in the torch mechanism in such a manner as to swirl in front of the end of a negatively charged electrode.
- the welding tip which is adjacent the end of the electrode has a sufficiently high voltage applied thereto to cause a spark gap to jump between the electrode and the welding tip, thereby heating the gas and causing it to ionize.
- a pilot DC voltage between the electrode and the welding tip maintains the pilot arc.
- the iononized gas in the gap appears as a flame and extends externally of the tip where it can be seen by the operator.
- the extension of the pilot arc and the flame which for practical purposes, may be considered as being co-extensive depends upon the power in the gap—i.e., the arc current—as well as the pressure of the gas forced into the gap and out of the torch.
- the pilot arc provides a source of light which enables the operator to see the proper position for the torch before starting the welding or cutting operation. In actual practice, when the pilot arc is on, a loop-shaped arc extending out of the torch can be seen. As the torch head is brought down towards the workpiece, the pilot arc jumps from the electrode to the workpiece due to the fact that the impedance of the workpiece current path is lower than the impedance of the welding tip current path.
- pilot arc circuits which provide a 20-40 amp. Pilot arc current at 100-200 volts across the electrode-tip gap, resulting in an extension of the arc about 1 ⁇ 4-1 ⁇ 2 inch past the welding tip. As a consequence, the torch must be brought to within about 1 ⁇ 4-1 ⁇ 2 inch of the workpiece before the transfer arc jumps to the workpiece. This creates difficulties in the starting of cutting or welding operations.
- the present invention comprises new electronic circuit concepts for a plasma arc torch wherein main current regulated power means regulates the pilot current prior to main arch transfer
- the circuit may contain two inductors to which DC current initially flows but is interrupted upon main arc transfer such that one inductor maintains the pilot arc while the current in the second inductor forces the establishment of the transferred arc. Also, advantages are presented in pulsing the cutting arc as well as pulsing the pilot arc.
- FIG. 1 is a schematic wiring diagram of one prior art plasma arc torch operating circuit
- FIG. 2 is schematic wiring diagram of another prior art plasma arc torch operating circuit
- FIG. 2A is a schematic wiring diagram of a prior art pilot arc regulating circuit as used within FIG. 2;
- FIG. 2B is a schematic wiring diagram of another prior art pilot arc regulating circuit as used within FIG. 2;
- FIG. 3 is a schematic wiring diagram depicting a plasma arc torch operating circuit according to the principles of the present invention
- FIG. 4 is a schematic wiring diagram of a modified embodiment of the present invention as it would be configured within the circuit of FIG. 3;
- FIGS. 5A and B are a more detailed schematic wiring diagram of the present invention.
- Torch 10 includes torch tip electrode 12 or torch electrode as is known in the art and annular torch pilot electrode 14 or tip as is known in the art spaced from tiptorch electrode 12 .
- An electronic pilot circuit P connected between tip torch electrode 12 and pilot electrode 14 provides an electric potential between electrodes 12 and 14 to create a pilot arc which heats a supplied gas such as nitrogen causing it to ionize as is well known in the art.
- FIG. 1 a schematic wiring diagram for one prior art plasma arc torch, generally referred to by the reference numeral 10 .
- Torch 10 includes torch tip electrode 12 or torch electrode as is known in the art and annular torch pilot electrode 14 or tip as is known in the art spaced from tiptorch electrode 12 .
- An electronic pilot circuit P connected between tip torch electrode 12 and pilot electrode 14 provides an electric potential between electrodes 12 and 14 to create a pilot arc which heats a supplied gas such as nitrogen causing it to ionize as is well known in the art.
- FIG. 1 shows prior art circuit C which uses a resistively regulated pilot arc having a current regulated power means 16 and a pilot regulator means 18 including a disconnect means 20 in series with a resistor 22 .
- a high frequenty pilot initiation means 24 is positioned in series with pilot regulator means 18 and may be inserted in the circuit adjacent either electrode 12 or electrode 14 as shown in FIG. 1 to initiate investigation ionization of plasma gas to commence pilot operations.
- a current sensing means 26 is connected in parallel with pilot regulator means 18 and connects with the metal to be worked at series with work 28 in main circuit M.
- pilot regulator means 18 When tip torch electrode 12 is placed sufficiently close to the metal work 28 the arc will transfer to the work 28 causing current to flow through main circuit M and current sensing means 26 will sense the current differential and act to disconnect pilot regulator means 18 by opening pilot regulator means 18 by opening its disconnect means 20 .
- circuit voltage of current regulated power means 16 must be large compared with the torch piloting voltage between tip torch electrode 12 and pilot electrode 14 to allow the pilot regulator means 18 to perform the function of a current source during pilot opration. This causes circuit 10 to be inefficient, power being dissipated as heat in pilot regulator means 18 .
- FIG. 2 shows another prior art circuit 10 ′ similar to that of FIG. 1 in that it also contains electronically controlled pilot regulator means 18 ′ in pilot circuit P′ and a parallel main circuit M′.
- the circuit 10 ′ of FIG. 2 also includes similar current operated power means 16 ′, tip torch electrode 12 ′, pilot electrode 14 ′, current sensing means 26 ′, pilot initiation means 24 ′ (alternatively positioned as shown) and work piece or member 28 ′.
- the difference between circuit 10 ′ of FIG. 2 and circuit 10 of FIG. 1 is the provision of circuit connection on the opposite side of power means 16 from current means 26 ′ connected to pilot regulator means 18 ′ in order to provide a second current regulated control loop, one for pilot arc operation and one for transferred main arc cutting that FIG. 2 uses an active loop with feedback, either linear (FIG. 2 a) or switching (FIG. 2 b) regulator, while FIG. 1 uses a passive current limiting means (resistor).
- FIG. 2A shows one prior art pilot regulating circuit 18 ′a wherein the pilot is linearly regulated; that is, the pilot current is regulated against a set demand means 3 d by varying the conductance of a linear element 3 a.
- FIG. 2B shows another prior art pilot regulating 18 ′b wherein the pilot is switch regulated. That is, the pilot is regulated against a set demand 3 d′ to vary the duty cycle of a switching element 3 g within a feedback loop.
- Either scheme can tightly regulate the pilot arc against AC line variations and against plasma gas in use, however, both add parts count and cost to the torch and are relatively inefficient.
- FIG. 3 shows the preferred plasma torch circuit 100 in accordance with the principles of the present invention.
- Circuit 100 includes torch tip electrode 112 , pilot electrode 114 , current regulated power means 116 , pilot regulator means 118 , alternatively positionable pilot initiation means 124 , current sensing means 126 , and metal work 128 .
- Pilot regulator means 118 comprises an electronic disconnect 120 in series with a current smoothing and energy storage inductor 130 , and a free-wheeling diode 132 connected in parallel with disconnect 120 and in series with inductor 130 .
- current sensing means 126 not only controls disconnect 120 through line 134 , but also sends a current signal to comparator 136 through line 138 which controls the output of power means 116 .
- disconnect means 120 is “on” and is in its saturated state.
- the voltage seen between the metal work piece 128 and torch tip electrode 112 is essentially the voltage at which the torch maintains the pilot arc determined by torch geometry and the plasma gas used. This voltage is considerably lower than the open circuit voltage used in prior art torch circuits.
- the pilot arc is maintained by current flowing through energy storage inductor means 130 and the free-wheeling diode means 132 .
- the current flowing in through the smoothing inductor means 140 of power regulator 116 is forced to flow between the workpiece 128 and torch tip electrode 112 ,.
- disconnect 120 open circuits the inductor means 140 to generate a transient voltage between the torch electrode and the workpiece using the stored energy in the inductor means 140 , greatly in excess of the pilot voltage, that initiates and initially supports the transfer to the main arc, thereby maintaining the transferred plasma arc.
- the pilot arc between torch tip electrode 112 and pilot electrode 114 self extinguishes.
- transfer is detected in current sensing means 126 the pilot demand means 1 e is changed and the power means 116 changes the power to that demanded for the torch operation on work piece 128 .
- a further embodiment of the present invention resides in additionally pulsing the pilot current.
- the demand may be pulsed between two (or more levels) at various frequencies and duty cycles. During this pulsing the pilot arc is maintained throughout and no high frequency arc initiation means 124 is required, as would be the case for a ‘blown-out’ pilot.
- This pulsing feature offers several advantages. First, higher standoff instances between the work metal 128 and torch tip electrode 112 at the moment of transfer. Second, a tip cleaning action is observed i.e. during plasma cutting molten metal is blown onto the tip face where it adheres in particulate form. At the same time, electrode material is removed from the torch electrode and adheres to the inside tip. Both forms of contamination can cause the tip orifice to become distorted. When the pilot arc is pulsed following each cut significantly more power is dissipated in the tip torch electrode 112 for the pulse duration. This thermal modulation is believed to be responsible for dislodging metal particles from the inner and outer tip surfaces.
- FIG. 4 there is shown an alternative circuit wherein a small resistor 142 is added in series with the pilot means 118 .
- This modification can further improve the obtainable standoff on some plasma torch designs.
- the pilot current (Ip) flows through resistor 142 to generate a voltage drop (Ip ⁇ R) which is in series with the pilot voltage measured between torch tip electrode 112 and pilot electrode 114 .
- Ip ⁇ R voltage drop
- the power dissipated in this resistor is then a function of the pilot demand and pulse duration.
- a further alternative circuit provides a pulsing cutting or main arc. From the invention pulsing the pilot arc before transfer it is clear that it is possible to pulse the means 1 e, after the arc has transferred and while the transferred plasma arc is cutting the work metal means 128 .
- This provision of pulsing the main arc offers several potential advantages. First, by selecting the appropriate pulse rate and duty cycle in relation to the cutting variables, it will offer a proportionally greater arc cutting capacity/penetration for a small increase in power consumption. Second, it allows the tip orifice size to be reduced in comparison to a conventional plasma cutting system operating in response to a DC demand level. This will, allow, a smaller focussed plasma column and result in smaller kerf widths. Plasma arc stability may also improve as a result of pulsing.
- FIGS. 5A and B are a more specific electronic circuit schematic diagram embodying some of the concepts of the invention as enumerated above.
- Like reference numerals appearing in FIG. 5 refer to like circuit components or group of components as appear in FIGS. 3 and 4.
- Reference numberal 120 c depicts the control circuity for disconnecting means 120 .
- the power supply means is not shown in FIG. 5 .
- FIGS. 3 through 5 fulfills the objects and provides the advantages set forth above.
- the scope of the invention is to be determined solely by the language of the following claims as interpreted by the patent laws and in particular the doctrine of equivalents.
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Arc Welding Control (AREA)
Abstract
Description
Claims (30)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/352,389 USRE37608E1 (en) | 1991-04-08 | 1994-12-08 | Plasma torch electronic pulsing circuit |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US07/682,727 US5189277A (en) | 1991-04-08 | 1991-04-08 | Modular, stackable plasma cutting apparatus |
US07/762,852 US5170030A (en) | 1991-04-08 | 1991-09-18 | Plasma torch electronic pulsing circuit |
US08/352,389 USRE37608E1 (en) | 1991-04-08 | 1994-12-08 | Plasma torch electronic pulsing circuit |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US07/762,852 Reissue US5170030A (en) | 1991-04-08 | 1991-09-18 | Plasma torch electronic pulsing circuit |
Publications (1)
Publication Number | Publication Date |
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USRE37608E1 true USRE37608E1 (en) | 2002-03-26 |
Family
ID=46202530
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US08/352,389 Expired - Lifetime USRE37608E1 (en) | 1991-04-08 | 1994-12-08 | Plasma torch electronic pulsing circuit |
Country Status (1)
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US (1) | USRE37608E1 (en) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20040045942A1 (en) * | 2002-09-05 | 2004-03-11 | Norris Stephen W. | Plasma ARC torch system with pilot re-attach circuit and method |
US7022935B1 (en) | 2003-12-08 | 2006-04-04 | Illinois Tool Works Inc. | Plasma-cutting torch with integrated high frequency starter |
US7034245B2 (en) | 2004-06-29 | 2006-04-25 | The Esab Group, Inc. | Systems and methods for controlling pilot arc current in an arc cutting or welding machine |
US20070045241A1 (en) * | 2005-08-29 | 2007-03-01 | Schneider Joseph C | Contact start plasma torch and method of operation |
US8946584B2 (en) | 2011-05-26 | 2015-02-03 | Retro Systems, LLC | Angled cut height control system for a plasma arch torch |
US8946583B2 (en) | 2011-05-26 | 2015-02-03 | Retro Systems, LLC | Angled cut height control system for a plasma arch torch |
US9833860B1 (en) | 2016-07-22 | 2017-12-05 | Lincoln Global, Inc. | System and method for plasma arc transfer for plasma cutting |
US9878395B2 (en) | 2008-03-14 | 2018-01-30 | Illinois Tool Works Inc. | Method for detecting current transfer in a plasma arc |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4280042A (en) * | 1979-02-01 | 1981-07-21 | L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude | Process and installation for automatic ignition of a plasma cutting torch |
US4324971A (en) * | 1980-07-09 | 1982-04-13 | Thermal Dynamics Corporation | Torch height acquisition using arc transfer |
US4598191A (en) * | 1984-04-04 | 1986-07-01 | L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Procedes Georges Claude | Very low power plasma arc cutting equipment |
US4839499A (en) * | 1988-06-13 | 1989-06-13 | Cyclomatic Industries, Inc. | System for supplying power to different cutting torches |
US4943699A (en) * | 1988-06-09 | 1990-07-24 | Powcon Inc. | System for supplying power |
US5036176A (en) * | 1988-03-24 | 1991-07-30 | Kabushiki Kaisha Komatsu Seisakusho | Plasma arc cutter and method of controlling the same |
JPH0675791A (en) | 1992-08-27 | 1994-03-18 | Nec Corp | Resource management system |
-
1994
- 1994-12-08 US US08/352,389 patent/USRE37608E1/en not_active Expired - Lifetime
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4280042A (en) * | 1979-02-01 | 1981-07-21 | L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude | Process and installation for automatic ignition of a plasma cutting torch |
US4324971A (en) * | 1980-07-09 | 1982-04-13 | Thermal Dynamics Corporation | Torch height acquisition using arc transfer |
US4598191A (en) * | 1984-04-04 | 1986-07-01 | L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Procedes Georges Claude | Very low power plasma arc cutting equipment |
US5036176A (en) * | 1988-03-24 | 1991-07-30 | Kabushiki Kaisha Komatsu Seisakusho | Plasma arc cutter and method of controlling the same |
US4943699A (en) * | 1988-06-09 | 1990-07-24 | Powcon Inc. | System for supplying power |
US4839499A (en) * | 1988-06-13 | 1989-06-13 | Cyclomatic Industries, Inc. | System for supplying power to different cutting torches |
JPH0675791A (en) | 1992-08-27 | 1994-03-18 | Nec Corp | Resource management system |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20040045942A1 (en) * | 2002-09-05 | 2004-03-11 | Norris Stephen W. | Plasma ARC torch system with pilot re-attach circuit and method |
WO2004022276A1 (en) * | 2002-09-05 | 2004-03-18 | Thermal Dynamics Corporation | Plasma torch with pilot re-attach circuit |
US6794601B2 (en) * | 2002-09-05 | 2004-09-21 | Thermal Dynamics Corporation | Plasma arc torch system with pilot re-attach circuit and method |
US7022935B1 (en) | 2003-12-08 | 2006-04-04 | Illinois Tool Works Inc. | Plasma-cutting torch with integrated high frequency starter |
US7034245B2 (en) | 2004-06-29 | 2006-04-25 | The Esab Group, Inc. | Systems and methods for controlling pilot arc current in an arc cutting or welding machine |
US20070045241A1 (en) * | 2005-08-29 | 2007-03-01 | Schneider Joseph C | Contact start plasma torch and method of operation |
US9878395B2 (en) | 2008-03-14 | 2018-01-30 | Illinois Tool Works Inc. | Method for detecting current transfer in a plasma arc |
US8946584B2 (en) | 2011-05-26 | 2015-02-03 | Retro Systems, LLC | Angled cut height control system for a plasma arch torch |
US8946583B2 (en) | 2011-05-26 | 2015-02-03 | Retro Systems, LLC | Angled cut height control system for a plasma arch torch |
US9833860B1 (en) | 2016-07-22 | 2017-12-05 | Lincoln Global, Inc. | System and method for plasma arc transfer for plasma cutting |
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