Method and apparatus for sensing the length of a lead

1. A lead set measurement system for a thermal processing system comprising:

a lead set having a length extending from a first end of the lead set coupled to a thermal processing system power source to a second end connected to a plasma arc torch;

a component, comprising a tube, disposed along the length of the lead set for transporting at least one gas through the tube, the component having a tube volume that is a function of the length of the lead set; and

a sensing apparatus disposed in the thermal processing system power source and configured to receive a first signal and a second signal, wherein (i) one of the first or second signal corresponds to actuating a gas valve disposed relative to the lead set and (ii) the length of the lead set is determined based upon a time period between the first signal and the second signal that is dependent on the tube volume.

2. The system of claim 1 wherein one of the first or second signal corresponds to a drive pulse of an inverter, disposed in the power source, being wider than a predetermined quantity.

3. The system of claim 1 wherein the thermal processing system power source is within a plasma torch system.

4. The system of claim 1 wherein the time period corresponds to a change in a duty cycle.

5. The system of claim 1 wherein the time period is a time between actuating the gas valve and one of (i) displacement of an electrode relative to a nozzle within a plasma chamber of the plasma arc torch; or (ii) displacement of a nozzle relative to an electrode within a plasma chamber of the plasma arc torch; or (iii) movement of an element relative to a nozzle and an electrode within a plasma chamber of the plasma arc torch.

6. A lead set of a thermal processing system comprising:

a lead set having a length extending from a first end coupled to a thermal processing system power source to a second end connected to a plasma arc torch, the lead set including at least one gas through which gas flows to the plasma arc torch;

a component, comprising a tube, disposed along the length of the lead set for transporting the at least one gas through the tube, the component having a tube volume that is a function of the length of the lead set; and

a sensing apparatus disposed within the lead set and configured to receive a first signal and a second signal, wherein (i) one of the first or second signal corresponds to actuating a gas valve disposed relative to the lead set and (ii) the length of the lead set is determined based upon a time period between the first signal and the second signal that is dependent on the tube volume.

7. The lead set assembly of claim 6 wherein one of the first or second signal corresponds to an inverter drive pulse being wider than a predetermine quantity.

8. A system for adjusting a control parameter in a thermal processing system, comprising:

a lead set having a length extending from a first end to a second end connected to a plasma arc torch;

a component, comprising a tube, disposed along the length of the lead set for transporting at least one gas through the tube, the component having a tube volume that is a function of the length of the lead set; and

a thermal processing system power source coupled to the first end of the lead set and configured to determine the length of the lead set based on the a time period between a first signal and a second signal that is dependent on the tube volume, the thermal processing system power source having at least one control parameter controlling operation of the thermal processing system, the at least one control parameter selected from the group of: gas pressure, gas delivery, gas type, gas concentration, current flow, voltage limits, duty cycle, and timing, wherein the thermal processing system power source sets the at least one control parameter based upon the determined length of the lead set.

9. The lead set of claim 6 wherein the sensing apparatus is disposed within the first end of the lead set.

10. The lead set of claim 6 wherein the sensing apparatus is disposed within the second end of the lead set.

11. The lead set of claim 1 wherein the lead set is composed of individual components such that the multiple individual components formed together equals the length of the lead set.

12. The system of claim 6 wherein the time period is a time between actuating the gas valve and one of (i) displacement of an electrode relative to a nozzle within a plasma chamber of the plasma arc torch; or (ii) displacement of a nozzle relative to an electrode within a plasma chamber of the plasma arc torch; or (iii) movement of an element relative to a nozzle and an electrode within a plasma chamber of the plasma arc torch.

13. The system of claim 8 wherein one of the first signal or the second signal corresponds to actuating a gas valve disposed relative to the lead set.

14. The system of claim 8 wherein one of the first or second signal corresponds to a drive pulse of an inverter, disposed in the thermal processing system power source, being wider than a predetermined quantity.

15. The system of claim 8 wherein the time period is a time between actuating a gas valve and one of (i) displacement of an electrode relative to a nozzle within a plasma chamber of the plasma arc torch; or (ii) displacement of a nozzle relative to an electrode within a plasma chamber of the plasma arc torch; or (iii) movement of an element relative to a nozzle and an electrode within a plasma chamber of the plasma arc torch.

16. A lead set measurement system for a thermal processing system comprising:

a lead set having a length extending from a first end of the lead set coupled to a thermal processing system power source to a second end connected to a plasma arc torch;

a component, comprising a tube, disposed along the length of the lead set for transporting at least one gas through the tube, the component having a tube volume that is a function of the length of the lead set; and

a sensing apparatus disposed in the thermal processing system power source and configured to receive a first signal and a second signal, wherein the length of the lead set is determined based upon a time period between the first signal and the second signal that is dependent on the tube volume, the time period being a time between actuating a gas valve and one of (i) displacement of an electrode relative to a nozzle within a plasma chamber of the plasma arc torch; or (ii) displacement of a nozzle relative to an electrode within a plasma chamber of the plasma arc torch; or (iii) movement of an element relative to a nozzle and an electrode within a plasma chamber of the plasma arc torch.

17. The system of claim 16 wherein one of the first or second signal corresponds to actuating a gas valve disposed relative to the lead set.

18. The system of claim 16 wherein one of the first or second signal corresponds to an inverter drive pulse being wider than a predetermine quantity.

19. The system of claim 16 wherein the time period corresponds to a change in a duty cycle.