Classifications

• • 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
• • 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
  • H05H1/3457—Nozzle protection devices
• • 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
  • H05H1/3463—Oblique nozzles
• • 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
  • H05H1/3478—Geometrical details

Definitions

• the present invention relates generally to a torch tip assembly of a plasma arc torch that includes at least one bore or a counter bore feature having a non-circular cross section.
• Gouging of conductive (e.g., metallic) materials is often needed for a number of material processing applications and products. These gouges typically form troughs/channels in the workpiece by removing materials to a certain desired depth. A gouging process can also be used to remove welds that contain known process defects or fractures. In today's gouging operations with typical plasma arc torches having a circular bore, the width of a gouge is limited by plasma processing, such as by standoff, amperage, and process speed. Thus, to make a wider gouge, a traditional plasma arc torch needs to pass over a workpiece a number of times, essentially forming a series of connected channels with similar depth.
• plasma processing such as by standoff, amperage, and process speed.
• WO 2014/025541 A1 discloses a consumable set that is usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece.
• the consumable set includes a nozzle having: 1) a nozzle body defining a longitudinal axis extending therethrough, and 2) a nozzle exit orifice, disposed in the nozzle body, for constricting the plasma arc.
• the nozzle exit orifice defines an exit orifice axis oriented at a non-zero angle relative to the longitudinal axis.
• the consumable set can also include an alignment surface generally parallel to the exit orifice axis. The alignment surface is dimensioned to align the exit orifice such that the plasma arc impinges orthogonally on the processing surface.
• US 2014/284312 A1 discloses a consumable set that is usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece.
• the consumable set comprises a nozzle and an alignment surface.
• the nozzle includes: 1) a nozzle body defining a longitudinal axis extending therethrough, and 2) a nozzle exit orifice disposed in the nozzle body for constricting the plasma arc.
• the nozzle exit orifice defines an exit orifice axis oriented at a non-zero bevel angle relative to the longitudinal axis.
• the alignment surface is generally parallel to the longitudinal axis and substantially planar. The alignment surface is dimensioned to orient the nozzle exit orifice such that the plasma arc impinges on the processing surface of the workpiece at the bevel angle while the plasma arc torch is substantially perpendicular to the processing surface.
• the present invention provides a consumable tip for a plasma arc torch according to claim 1.
• the invention provides a method for assembling at least a portion of a plasma arc torch according to claim 10.
• a plasma gas flows through a gas inlet tube (not shown) and the gas distribution holes 227 in the swirl ring 220. From there, the plasma gas flows into a plasma chamber 228 and out of the torch 200 through the exit orifice 225 of the nozzle 210 that constricts the plasma gas flow.
• a pilot arc is first generated between the electrode 205 and the nozzle 210. The pilot arc ionizes the gas passing through the nozzle exit orifice 225. The arc then transfers from the nozzle 210 to a workpiece 230 for thermally processing (e.g., cutting or welding) the workpiece 230.
• the two portions of the workpiece 230 can be oriented at any angle and the nozzle 210 can be suitably configured to perform flush cutting in the resulting inner corner.
• FIGS. 2A and 2B show various perspectives of an exemplary configuration of the nozzle 210 designed to facilitate inner-corner flush cutting operations.
• the nozzle 210 includes a nozzle body 250 defining a longitudinal axis A extending therethrough.
• An interior surface 252 of the nozzle 210 can be rotationally symmetrical about the longitudinal axis A while the exterior of the nozzle body 250 is rotationally asymmetric about the longitudinal axis A.
• the nozzle exit orifice 225 disposed in the nozzle body 210, defines an exit orifice axis B extending longitudinally along the length of the nozzle exit orifice 225 from an interior opening 225b to an exterior opening 225a.
• the exit orifice axis B is oriented at a non-zero angle relative to the longitudinal axis A. That is, the nozzle exit orifice 225 can be rotationally asymmetric about the longitudinal axis A.
• the nozzle exit orifice 225 is configured to introduce a plasma arc flow from the interior opening 225b, which is in fluid communication with the interior surface 252 of the nozzle 210, to a workpiece through the exterior opening 225a. Even though the nozzle exit orifice 225 is shown as being substantially straight, the nozzle exit orifice 225 can be curved or have a sequence of non-parallel segments.
• the guiding surface 236 is illustrated as a portion of the workpiece 234, the guiding surface 236 may be a portion of a separate template (not shown) used to guide the torch 200 into position.
• the separate template which includes the guiding surface 236, can be attached to the torch 200 and/or the workpiece 234 for positioning the torch 200 to perform flush cutting.
• a distance 260 between the center of the exterior opening 225a of the nozzle exit orifice 225 and the alignment surface 254 may be less than or equal to about 12.7 mm, 6.35 mm, 2.54 mm ( 0.5 inches, 0.25 inches, or 0.1 inches). This distance controls how close the cut path 237 is to the horizontal portion 234 of the workpiece 230. Hence, the smaller the distance 260, the closer the plasma arc torch cuts to the base of the flange 232 from the horizontal portion 234.
• the nozzle 210 can also include a second alignment surface 256 angled relative to the alignment surface 254 and a curved surface 258 that interconnects the two alignment surfaces.
• the second alignment surface 256 in cooperation with the alignment surface 254, enhances orthogonal impingement of the plasma arc against the processing surface 238 of the flange 232.
• the second alignment surface 256 can be oriented at an angle from the alignment surface 254 such that the second alignment surface 256 lays substantially flush against the processing surface 238 of the flange 232 while the alignment surface 254 lays substantially flush against the guiding surface 236 of the horizontal portion 234.
• the curved surface 258 of the nozzle 210 is configured to inter-fit within the corner created by the processing surface 238 and the guiding surface 236 of the workpiece 230.
• the two alignment surfaces of the nozzle 210 ensure that the plasma arc torch is positioned tightly and securely into the inner corner of the workpiece 230 while a plasma arc is delivered to the processing surface 238 by the torch 200 via the exterior opening 225a of the nozzle exit orifice 225.
• the exterior opening 225a of the nozzle exit orifice 225 is located on the second alignment surface 256 of the nozzle 210.
• first alignment surface 254 and the second alignment surface 256 are substantially perpendicular to each other such that the nozzle 210 can be securely positioned into an inner corner of about 90 degrees.
• nozzles with different angles between the alignment surfaces e.g., 60 degrees, 30degrees and 15 degrees
• the angle between the first alignment surface 254 and the second alignment surface 256 of a nozzle 210 may be adjustable, such that the operator can adjust one or both of the alignment surfaces to produce a secure fit of the nozzle 210 into any given corner of a workpiece. For example, adjustments can be made such that both of the alignment surfaces of the nozzle 210 can contact respect processing surface 238 and guiding surface 236 of the workpiece 230 during a cutting operation.
• a plane can be defined to include the exit orifice axis B, thereby segmenting the nozzle 210 into two portions: 1) a first, smaller portion 280 on one side of plane and 2) a second, larger portion 282 on the other side of the plane.
• the alignment surface 254 of the nozzle 210 is located on the external surface of the first portion 280 and can contact the guiding surface 236 of the workpiece once the torch 200 is positioned into the inner corner of the workpiece.
• the second alignment surface 256 is located on the external surface of the second portion 282 and can contact the processing surface 238 of the workpiece during a cutting operation.
• the first portion 280 can be about 1/3, 1/4, or 1/5 of the volume of the second portion 282.
• the second alignment surface 256 may be designed to include a similar rounded-arc portion.
• the guiding surfaces are disposed on one or more separate templates that are attachable to the workpiece 308 and/or the nozzle 300.
• the three alignment surfaces of the nozzle 300 in cooperation with each other, align the plasma arc to impinge orthogonally on the processing surface of the workpiece 308.
• the alignment surfaces 302 and 304 can lay substantially flush against the two guiding surfaces of the workpiece 308 while the alignment surface 306, which includes the exterior opening 225a of the nozzle exit orifice 225, lays substantially flush against the processing surface of the workpiece 308.
• the asymmetric design described with respect to FIGS. 1-5C can be introduced to a plasma arc torch that includes a shield.
• the shield can include at least one of the alignment surface 254 or the second alignment surface 256 describe above with respect to the nozzle 210.
• the shield can include at least one of the alignment surface 302, the second alignment surface 304, or the third alignment surface 306 describe above with respect to the nozzle 300.
• the asymmetric shield can further include a shield exit orifice coplanar with the nozzle exit orifice for delivering the plasma arc to impinge on a processing surface of a workpiece.
• the asymmetric shield upon installation into a plasma arc torch, can provide similar functions as the asymmetric nozzle 210 or 300, such as allowing an operator to securely and tightly position the torch into an inner corner of a workpiece created by two or three workpiece surfaces, while the torch delivers a plasma arc flow to one of the workpiece surfaces.
• the contour of at least one of the alignment surfaces of the asymmetric shield has a rounded-arc portion, similar to the contour illustrated in FIG. 4 .
• a plasma arc torch with a nozzle may be provided for making a bevel cut on a workpiece.
• the torch can remain perpendicular (e.g., at a fixed 90 degree angle) to the workpiece during the cut operation.
• the bevel feature is provided by the nozzle itself, rather than the angularity of the torch.
• a template can be provided to guide the torch, which is useful in situations where an operator desires to make the bevel cut at a consistent angle over a distance.
• the plasma arc torch of the present technology can improve the quality of bevel cuts, thereby decreasing the need for secondary processing work or accessories.
• the contour of the second alignment surface 456 of the nozzle 410 may be asymmetric, including at least a rounded-arc portion 468 and a straight portion 470, as shown from a top view of the nozzle 410 in FIG. 8 .
• the straight portion 470 can be located on a side of the second alignment surface 456 close to the alignment surface 454.
• the straight portion 470 can be positioned substantially parallel to the guiding surface 436 of the template 432 so as to be guided by the template 432 during cutting.
• the nozzle exit orifice 225 can be angled such that the plasma arc path 437 is directed toward the straight portion 370 (i.e., the alignment surface 454) as the plasma arc exits the exterior opening 425a located on the second alignment surface 456.
• the exterior opening 425a may be located off-centered on the second alignment surface 456 (i.e., closer to the straight portion 470 than to the rounded-arc portion 468). This off-centered feature allows the plasma arc to be more easily imparted at a bevel angle closer to the straight portion 470.
• the interior opening 425b (as shown in FIG. 7A ) can be centered relative to the nozzle body 450 so as to align with the hafnium insert 406 in the electrode 405.
• the use of the template 432 may be optional.
• the shield can include at least one of the alignment surface 454 or the second alignment surface 456 described above with respect to the nozzle 410.
• the shield can include at least one of the alignment surface 502, the second alignment surface 504, or the third alignment surface 506 described above with respect to the nozzle 500.
• the shield can further include a shield exit orifice coplanar with the nozzle exit orifice for delivering the plasma arc to impinge on a processing surface of a workpiece.
• the shield 1102 has an asymmetric shield exit orifice 1104 configured to deliver a plasma arc from the nozzle 210 to the workpiece in a flush cutting operation.
• a locking element 1106 is employed to radially affix at least two of the consumable components of the consumable tip 1001 with respect to each other while permitting the asymmetric feature(s) to be radially and/or axially aligned. As shown in FIG. 11 , the locking element 1106 couples the shield 1102 to the nozzle 210 such that the shield exit orifice 1104 is radially and axially aligned with the nozzle exit orifice 225 upon assembly of the consumable tip 1001.
• the mounting element 1002 can be fixedly engaged to the plasma processing interface 1004 (e.g., by tightening the threads) to lock the main consumable body 1003 and/or the consumable tip 1001 in place at the adjusted radial orientations.
• the mounting element 1002 is rotatable about and/or translatable along the longitudinal axis A to enable its threading to the plasma processing interface 1004.
• the proximal end 1014 of the mounting element 1002 can fixedly engage the plasma processing interface 1004 that is coupled to the torch body 1005.
• Such fixed engagement can be achieved through full threading of the mounting element 1002 relative to the torch body 1005, for example.
• This securement causes the mounting element 1002 to impart a frictional force on the consumable tip 1001 via at least one of the interface 1112 or interface 1114 at the distal end 1012 of the mounting element 1002, thereby causing the mounting element 1002 to clamp down on the consumable tip 1001 to fixedly engage the consumable tip 1001 at a particular radial orientation about the longitudinal axis A.
• the consumable body 1003 is rotatable independent of the mounting element 1002 and/or the consumable tip 1001 during the loose engagement between the mounting element 1002 and the plasma processing interface 1004. Therefore, an operator can adjust the radial orientation of the consumable body 1003 about the longitudinal axis A such that it is positioned at a desired radial orientation with respect to the plasma processing interface 1004 prior to being locked into place by the fixed engagement between the mounting element 1002 and the plasma processing interface 1004.
• the fixed engagement between the mounting element 1002 and the plasma processing interface 1004 can impart a frictional force between the mounting element 1002 and the consumable body 1003 to lock the consumable body 1003 in place both radially and axially relative to the plasma processing interface 1004.
• the consumable body 1003 may have one or more asymmetric features with respect to the longitudinal axis A that require the specific radial orientation in order to achieve a desired alignment with the processing interface 1004.
• the plasma processing interface 1004 can define an asymmetric geometry configured to receive and mate with the consumable body 1003 at the specific radial orientation. For example, clocking of the plasma processing interface 1004 with the proximal end 1011 of the consumable body 1003 at a predefined radial orientation can enable alignment of various data, electrical, liquid coolant, and gas channels between the torch body 1005 and the consumable body 1003 via the plasma processing interface 1004.
• the plasma processing interface 1004 is fixedly attached to the torch body 1005, such as integrally formed with the torch body 1005.
• the cartridge frame 1212 is adapted to physically interface with the plasma processing interface 1004, thereby connecting the cartridge 1200 to the torch body 1005.
• FIG. 13 shows a view of the proximal end 1204 of the cartridge frame 1212 of the cartridge 1200 of FIG. 12 .
• the proximal end 1204 of the cartridge frame 1212 can include a clocking feature (e.g., a pin cavity) 1302 that can interact with a corresponding clocking feature of the plasm processing interface 1004 to connect the torch body 1005 to the cartridge 1200.
• a clocking feature e.g., a pin cavity
• a third liquid coolant channel opening 1460c on the plasma processing interface 1004 is aligned with a third coolant channel opening 1378a at the proximal end 1204 of the cartridge frame 1212 to fluidly connect athird coolant channel (not shown) of the torch body 1005 with a third coolant channel (not shown) of the cartridge frame 1212 to again deliver a liquid coolant flow from the torch body 1005 to the cartridge 1200.
• the main consumable body 1003 prior to the fixed engagement, is also independently rotatable about the longitudinal axis A (as indicated by the arrow) such that it can be clocked into a predetermined radial orientation with the plasma processing interface 1004 in order to maintain certain electrical, data, gas and/or liquid connections between the torch body 1005 and the consumable set 1000.
• Fixed engagement between the mounting element 1004 and the torch body 1005 via the plasma processing interface 1004 allows the various radial orientations of the elements in the consumable set 1000 to be locked into place during torch operation.
• the consumable tip 1001 includes multiple consumable components, where at least one consumable component has an asymmetric feature that is asymmetrically disposed in the consumable tip 1001 relative to the longitudinal axis A.
• the consumable tip 1001 can be implemented (i) as the design of FIG. 15 for flush cutting or (ii) include the asymmetric nozzle 1600 of FIG. 16 for selectively performing a cutting or gouging operation.
• the locking of the consumable components in the consumable tip 1001 is adapted to axially and radially align the one or more asymmetric features in the consumable tip 1001 while enabling the consumable tip 1001 to function as a unitary structure.
• the consumable body 1003 can be disposed in the hollow body of the mounting element 1002 and the consumable tip 1001 can be rotatably engaged to the distal end 1012 of the mounting element 1002.
• the consumable tip 1001 can be oriented/adjusted relative to the mounting element 1002 about the longitudinal axis A to attain a specific radial orientation of the asymmetric feature of the consumable tip 1001 with respect to the longitudinal axis A (step 1804).

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• Physics & Mathematics (AREA)
• Engineering & Computer Science (AREA)
• Plasma & Fusion (AREA)
• Spectroscopy & Molecular Physics (AREA)
• Geometry (AREA)
• Plasma Technology (AREA)
• Arc Welding In General (AREA)

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• 2017
  • 2017-12-05 CN CN201780075063.5A patent/CN110291846A/zh active Pending
  • 2017-12-05 EP EP23216683.5A patent/EP4319490B1/en active Active
  • 2017-12-05 EP EP17817619.4A patent/EP3549409B1/en active Active
  • 2017-12-05 PL PL23216683.5T patent/PL4319490T3/pl unknown
  • 2017-12-05 EP EP23216691.8A patent/EP4319491A3/en active Pending
  • 2017-12-05 WO PCT/US2017/064691 patent/WO2018106676A1/en not_active Ceased

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