Centralized control architecture for a plasma arc system

Abstract

Apparatus, systems, and methods for monitoring the processing of a workpiece that includes directing an incident laser beam onto the workpiece and using an optical detector for measuring a signal emitted from the workpiece as a result of the incident laser beam. The detector generates at least two signals based upon the optical signal. The method also involves use of a light source monitor in determining workpiece processing quality based upon the quotient of the two outputs as well as a magnitude of one of the two quotients.

1 - 47 . (canceled)  
   
   
       48 . A method of controlling a plasma arc cutting system for cutting a desired shape in a workpiece comprising: 
 inputting process parameters into a computerized numeric controller;    using the computerized numeric controller to generate one or more process parameters that are based on the inputted process parameters;    establishing a cutting arc; and    providing at least one command signal from the computerized numeric controller to at least one of a power supply, an automatic process controller, a torch height controller, or a drive system to control at least one of the generated process parameters.    
   
   
       49 . The method of  claim 48  wherein the input process parameters include at least one of a cut pattern, a shape, a power supply type, a torch type, a material type, a current setting, a plasma or shield gas type, a cutting surface or a material thickness.  
   
   
       50 . The method of  claim 49  wherein the shape is selected from a shape library.  
   
   
       51 . The method of  claim 48  wherein the generated process parameter includes at least one of a cut speed, a kerf diameter, a set arc voltage, a cut height, a pierce height, a the number of retries upon transfer failure, or a pressure setting for a cut gas or a shield gas.  
   
   
       52 . The method of  claim 48  wherein the automatic process controller controls at least one of a flow or pressure of a plasma gas or a shield gas.  
   
   
       53 . The method of  claim 48  further comprising the step of: 
 using a cut program to determine a cut path.    
   
   
       54 . The method of  claim 48  further comprising the steps of: 
 monitoring a process condition; and    adjusting the command signal based on the monitored process condition.    
   
   
       55 . The method of  claim 48  further comprising the step of: 
 controlling the command signal using a feedback mechanism.    
   
   
       56 . The method of  claim 55  wherein the control of the command signal is based on feedback from at least one of the power supply, the automatic process controller, the torch height controller, or the drive system.  
   
   
       57 . A method of controlling a plasma arc cutting system for cutting a desired shape in a workpiece comprising: 
 inputting a process parameter corresponding to at least one of a cut pattern, a shape, a power supply type, a torch type, a material type, a current setting, a plasma or shield gas type, a cutting surface or a material thickness into a computerized numeric controller;    using the computerized numeric controller to generate a process parameter corresponding to at least one of a cut speed, a kerf diameter, a set arc voltage, a cut height, a pierce height, a the number of retries upon transfer failure, or a pressure setting for a cut gas or a shield gas based on the input process parameter;    establishing a cutting arc; and    providing at least one command signal from the computerized numeric controller to at least one of a power supply, an automatic process controller, a torch height controller, or a drive system to control the generated process parameter.    
   
   
       58 . The method of  claim 57  wherein the at least one command signal is adjusted based on one or more feedback signals.  
   
   
       59 . The method of  claim 57  wherein information about the shape to be cut is provided by a part program.  
   
   
       60 . A closely-coupled plasma arc system for cutting a desired shape in a workpiece comprising: 
 a computerized numeric controller that controls cut path and speed;    an automatic process controller that adjusts gas flows;    a power supply that adjusts current levels; and    a drive system that moves a plasma torch over a cutting table, such that the computerized numeric controller provides a command signal to at least one of the automated process controller, the power supply, or the drive system.    
   
   
       61 . The plasma arc system of  claim 60  wherein the command signal is adjusted based upon a feedback signal.  
   
   
       62 . The plasma arc system of  claim 60  further comprising a torch height controller that positions torch height and that receives a command signal from the computerized numeric controller.  
   
   
       63 . The plasma arc system of  claim 62  wherein the command signal from the computerized numeric controller to the torch height controller is adjusted based upon a feedback signal received from the torch height controller.  
   
   
       64 . The plasma arc system of  claim 60  wherein an input process parameter corresponding to one or more of a cut pattern, the shape, a power supply type, a torch type, a material type, a current setting, a plasma or shield gas type, a cutting surface or a material thickness is provided to the computerized numeric controller.  
   
   
       65 . The plasma arc system of  claim 64  wherein the automatic process controller adjusts a flow rate or pressure of a plasma gas or a shield gas based on the input process parameters, in response to a command signal from the computerized numeric controller.  
   
   
       66 . The plasma arc system of  claim 60  wherein the computerized numeric controller generates a process parameter that includes at least one of a cut speed, a kerf diameter, a set arc voltage, a cut height, a pierce height, a the number of retries upon transfer failure, or a pressure setting for a cut gas or a shield gas.  
   
   
       67 . The plasma arc system of  claim 60  wherein the desired shape corresponds to a cut pattern from a shape library.  
   
   
       68 . A method of automatically controlling a plasma arc torch cutting system for cutting a desired shape in a workpiece comprising: 
 establishing a cutting arc;    decreasing torch speed as the torch enters a corner;    adjusting one or more gas flows in response to changes in cut path and speed; and    changing the arc current level from a power supply in response to changes in the cut path and speed.    
   
   
       69 . The method of  claim 68  further comprising the step of: 
 changing the torch height in response to changes in the cut path and speed.    
   
   
       70 . The method of  claim 68  wherein the shape includes a hole, a sharp angle, or a curve.  
   
   
       71 . The method of  claim 68  wherein the shape includes at least one of a rectangle, a circle, a triangle, an L-bracket, a trapezoid, a slant rectangle, a gambrel rectangle, a roofer rectangle, an oval, a circle with a flat side, a circle slice, strait slots, angled slots, a flange, a gusset, an octagon, a rectangle with convex corners, a rectangle with concave corners, a flange slice, an elbow, a cross, a bolt hole circle, a bolt hole flange, or a convex roof trapezoid.