WO2021108304A1 - Système de coupe à jet de suspension abrasive à usure réduite de système et récupération de matériaux de traitement - Google Patents

Système de coupe à jet de suspension abrasive à usure réduite de système et récupération de matériaux de traitement Download PDF

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Publication number
WO2021108304A1
WO2021108304A1 PCT/US2020/061780 US2020061780W WO2021108304A1 WO 2021108304 A1 WO2021108304 A1 WO 2021108304A1 US 2020061780 W US2020061780 W US 2020061780W WO 2021108304 A1 WO2021108304 A1 WO 2021108304A1
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WIPO (PCT)
Prior art keywords
slurry
nozzle
abrasive
shielding fluid
fluid
Prior art date
Application number
PCT/US2020/061780
Other languages
English (en)
Inventor
Robert C. DEAN Jr.
Erik Keith JOHNSON
Alex David PERKINS
Read Ferguson FROST
Original Assignee
Synticos, LLC
Priority date (The priority date 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 date listed.)
Filing date
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Application filed by Synticos, LLC filed Critical Synticos, LLC
Publication of WO2021108304A1 publication Critical patent/WO2021108304A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C9/00—Appurtenances of abrasive blasting machines or devices, e.g. working chambers, arrangements for handling used abrasive material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/04—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for treating only selected parts of a surface, e.g. for carving stone or glass
    • B24C1/045—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for treating only selected parts of a surface, e.g. for carving stone or glass for cutting

Definitions

  • the present invention generally relates to abrasive jet cutting. More specifically, the invention relates to an abrasive suspension jet cutting system having reduced cutting head and system component wear, and process materials reclamation system.
  • the conventional method of cutting with abrasive is to create an abrasive jet by injecting a very-high-velocity water jet (pressurized from 20-90kpsi and traveling at up to l,200m/s) into a chamber where abrasive grit has been blown by compressed air, transferred using a vacuum, or introduced via the Venturi effect.
  • the water, air and abrasive flows are mixed in a refractory -material tube and then ejected through a small opening to create an abrasive jet for cutting.
  • AWJ Abrasive Water Jet
  • Abrasive jet cutting system is an Abrasive Suspension Jet (ASJ) cutter.
  • ASJ Abrasive Suspension Jet
  • the grit is instead mixed with water at ambient pressure to form the abrasive suspension.
  • the abrasive suspension is then pumped up to very-high pressure (e.g. 30kpsi) to form a suspension jet having a very high velocity (e.g. 650m/s) and a diameter of about 0.5mm.
  • an ASJ can be formed by diverting all or a portion of the high pressure liquid flow through an abrasive filled chamber where particles are entrained into the flow, forming the abrasive suspension that is delivered to the cutting jet. Because of the higher velocity and no air in the cutting jet, ASJ cuts much faster than the AWJ does.
  • the ASJ has been known for decades to be a more efficient form of abrasive jet generation, but has been used very little because the abrasive slurry jet erodes the jet nozzle so quickly that it is not practical.
  • Liwsyzc does this by introducing two independently operable energizing means to control the two fluid streams independently.
  • One of the energizing means starts and stops the flow of slurry prior to operating any valves in the slurry flow path which would otherwise be subject to extreme wear.
  • the second energizing means moves the second drive fluid to maintain system pressure.
  • abrasive jet cutting systems in general lies in the cost associated with abrasive particle usage.
  • Abrasive particles make up approximately 50% of the operating costs of an AWJ system and are typically discarded after only one use, adding an additional cost of disposal.
  • the currently available reclamations systems for AWJ are expensive to purchase and operate due to the high energy costs of drying the used abrasive particles making them economically viable in only a small number of shops.
  • ASJ systems have even higher abrasive costs as they typically consume even larger amounts of abrasive than AWJ systems and there are no commercially available abrasive recycling systems.
  • the main objective of the present invention is therefore to provide an ASJ system that both improves nozzle and system component wear, and reduces operational costs by providing an abrasive particle reclamation system.
  • the present disclosure is directed to a system for abrasive suspension jet cutting using an abrasive slurry and shielding fluid.
  • the system comprises a feed assembly having a slurry orifice and a shielding fluid orifice, a nozzle, and an acceleration cavity between the feed assembly and the nozzle.
  • the abrasive slurry and shielding fluid are accelerated together from the slurry orifice to the nozzle while maintaining a shielding fluid barrier substantially unmixed within abrasive slurry around the abrasive slurry. Both the slurry and shielding fluid further pass substantially unmixed through the nozzle.
  • the present disclosure is directed to a system for abrasive suspension jet cutting using abrasive slurry having abrasive particles contained within a fluid.
  • the system comprises a cutting head having a nozzle to eject a jet of slurry at high speed.
  • the system further comprises a reclamation system that collects used abrasive particles and fluid and then returns reclaimed abrasive particles and fluid to the cutting head.
  • the present disclosure is directed to a reclamation system having a feed assembly.
  • the reclamation system comprises a collection system to collect slurry and shielding fluid, a separator to separate out reusable abrasive particles from used slurry and shielding fluid to produce reclaimed slurry and reclaimed shielding fluid.
  • the reclamation system further has a recirculation system to reintroduce the reclaimed slurry and the reclaimed shielding fluid to the feed assembly.
  • the present disclosure is directed to a reclamation system having a separator system.
  • the separator system includes a filter housing having a dilute slurry inlet, a first shielding fluid outlet, a second shielding fluid outlet, a concentrated slurry outlet, a stationary filter, a movable filter and movable shuttle puck.
  • the stationary filter is located between the dilute slurry inlet and the second shielding fluid outlet.
  • the movable filter is between the dilute slurry inlet and the first shielding fluid outlet.
  • the movable filter and movable shuttle puck can move together to act as plunger and can move independently to back-purge the movable filter.
  • the present disclosure is directed to an abrasive wear control system for regulating movement of pressurized abrasive slurry and shielding fluid through a suspension jet cutting head.
  • the system comprises a slurry to shielding fluid volume flow regulator and a valve system that is operable to provide reverse flow of abrasive slurry through the cutting head while maintaining positive shielding fluid flow during stopping to reduce nozzle wear.
  • the slurry to shielding fluid volume flow regulator establishes a jet of shielding fluid prior to starting the flow of slurry to the cutting head in order to minimize slurry mixing with the shielding fluid when starting slurry flow.
  • the vent valve is opened temporarily allowing shielding fluid to flow in in reverse from the cutting head and through the slurry valve prior to closing the slurry valve and vent valve in order to minimize nozzle wear during nozzle depressurization.
  • the present disclosure is directed to a method of reducing abrasive wear of a suspension jet cutting head nozzle.
  • the method comprises providing a cutting head with a nozzle, a slurry to shielding fluid volume control flow regulator, a slurry valve and a slurry vent valve.
  • the method then involves energizing the shielding fluid and slurry.
  • the method then involves reversing flow of the abrasive slurry through the nozzle while maintaining positive shielding fluid flow during stopping operation to reduce nozzle wear.
  • the present disclosure is directed to a method of reducing abrasive wear of a suspension jet cutting head nozzle.
  • the method comprises providing a cutting head with a nozzle, a slurry to shielding fluid volume control flow regulator, a slurry valve and a vent valve.
  • the method then involves energizing the shielding fluid and slurry.
  • the method then involves starting flow of abrasive slurry through the nozzle only after shielding fluid is flowing through the nozzle at pressure during starting operation to reduce nozzle wear.
  • the present disclosure is directed to a cutting head for abrasive suspension jet cutting using an abrasive slurry and a shielding fluid.
  • the cutting head comprises a feed assembly having a slurry orifice and a shielding fluid orifice.
  • the cutting head further has a nozzle having a nozzle entrance orifice, a nozzle exit orifice and a nozzle orifice length therebetween.
  • the cutting head still further has an acceleration cavity between the slurry orifice and the nozzle entrance orifice, the acceleration cavity narrows from the slurry orifice to the nozzle orifice to provide hydrodynamic focusing within the acceleration cavity.
  • the abrasive slurry and shielding fluid are accelerated together from the slurry orifice to the nozzle entrance orifice while maintaining a shielding fluid barrier substantially unmixed with abrasive slurry around the abrasive slurry, both the slurry and shielding fluid pass substantially unmixed through the nozzle.
  • the present disclosure is directed to a system for abrasive suspension jet cutting.
  • the system comprises a feed assembly having a slurry orifice and a shielding fluid orifice, a nozzle, and an acceleration cavity between the slurry orifice and nozzle.
  • the system further comprises abrasive slurry and shielding fluid where the abrasive slurry and shielding fluid have the same flow characteristics.
  • Within the acceleration cavity the abrasive slurry and shielding fluid are accelerated together from the slurry orifice to the nozzle as both pass through the acceleration cavity and exit the nozzle.
  • FIG. 1 is perspective view of one embodiment of a system for abrasive suspension jet cutting system in accordance with the present invention
  • FIG. 2 is an enlarged view of the dashed outline in FIG. 1 of the abrasive suspension jet cutting system highlighting the cutting head;
  • FIG. 3 is a sectional view along line 3-3 of the cutting head of the abrasive suspension jet cutting system of FIG. 2;
  • FIG. 4 is a sectional view of the cutting head and enlarged sectional views of the jet forming element and nozzle of the abrasive suspension jet cutting system of FIG. 1;
  • FIG. 5 is a schematic showing one embodiment of a fluid delivery system for the abrasive suspension jet cutting system of FIG. 1;
  • FIG. 6 is a schematic showing another embodiment of a fluid delivery system for the abrasive suspension jet cutting system of FIG. 1 without a fluid buffer tank;
  • FIG. 7 is a schematic showing another embodiment of a fluid delivery system for the abrasive suspension jet cutting system of FIG. 1 that works using a batch of prepared slurry;
  • FIG. 8 is a schematic showing an electronic control system used in conjunction with the abrasive suspension jet cutting system of FIG. 1;
  • FIG. 9 is a sectional view showing schematically the formation of the cutting jet within the cutting head of the abrasive suspension jet cutting system of FIG. 1;
  • FIG. 10a is a sectional view showing schematically the details of abrasive particle and shielding fluid interaction within a cutting head that result from long distances and low angles within an acceleration cavity;
  • FIG. 10b is a sectional view showing schematically the details of abrasive particle and shielding fluid interaction within a cutting head that result from short distances and high angles within the acceleration cavity of the abrasive suspension jet cutting system of FIG. 1;
  • FIG. 11a is a sectional view showing schematically the details of abrasive particle and shielding fluid interaction within a cutting head that result from a long nozzle orifice length;
  • FIG. lib is a sectional view showing schematically the details of abrasive particle and shielding fluid interaction within the cutting head of the abrasive suspension j et cutting system of FIG. 1 that has a short nozzle orifice length;
  • FIG. 12a is a sectional view showing schematically the details of abrasive particle and shielding fluid interaction within a cutting head that result from low slurry to shielding fluid volume percentage;
  • FIG. 12b is a sectional view showing schematically the details of abrasive particle and shielding fluid interaction within a cutting head that result from high slurry to shielding fluid volume percentage;
  • FIG. 12c is a sectional view showing schematically the details of abrasive particle and shielding fluid interaction within a cutting head that result from optimal slurry to shielding fluid volume percentage of the abrasive suspension jet cutting system of FIG. 1;
  • FIG. 13 is a schematic showing one embodiment of an abrasive wear control system used in conjunction with the suspension jet cutting system of FIG. 1;
  • FIG. 14a is a schematic showing a first step of the fluids flow for the startup procedure of the wear control system used in conjunction with the suspension j et cutting system of FIG. 1;
  • FIG. 14b is a schematic showing a second step of the fluids flow for the startup procedure of the wear control system used in conjunction with the suspension j et cutting system of FIG. 1;
  • FIG. 14c is a schematic showing a third step of the fluids flow for the startup procedure of the wear control system used in conjunction with the suspension j et cutting system of FIG. 1;
  • FIG. 15b is a schematic showing a second step of the fluids flow for the shutdown procedure of the wear control system used in conjunction with the suspension j et cutting system of FIG. 1;
  • FIG. 15c is a schematic showing a third step of the fluids flow for the shutdown procedure of the wear control system used in conjunction with the suspension j et cutting system of FIG. 1;
  • FIG. 15d is a schematic showing a fourth step of the fluids flow for the shutdown procedure of the wear control system used in conjunction with the suspension j et cutting system of FIG. 1;
  • FIG. 15e is a schematic showing a fifth step of the fluids flow for the shutdown procedure of the wear control system used in conjunction with the suspension j et cutting system of FIG. 1;
  • FIG. 15f is a schematic showing a sixth step of the fluids flow for the shutdown procedure of the wear control system used in conjunction with the suspension j et cutting system of FIG. 1;
  • FIG. 16 is a schematic showing the abrasive suspension jet cutting system of FIG. 1 including details of the abrasive particle and fluid reclamation system;
  • FIG. 17 is a schematic showing a single filter separation system that may be used in conjunction with the abrasive particle and fluid reclamation system of FIG. 16;
  • FIG. 18 is sectional view showing the details of one embodiment of a single filter separator that may be used with the single filter separation system of FIG. 17;
  • FIG. 19 is a schematic showing a dual filter separation system that may be used in conjunction with the abrasive particle and fluid reclamation system of FIG. 16;
  • FIG. 20 is sectional view showing the details of one embodiment of a dual filter separator that may be used with the dual filter separation system of FIG. 19;
  • FIG. 21 is a schematic showing a plunger separation system that may be used in conjunction with the abrasive particle and fluid reclamation system of FIG. 16;
  • FIG. 22 is a schematic showing a dual filter separation system with a shuttle puck that may be used in conjunction with the abrasive particle and fluid reclamation system of FIG. 16;
  • FIG. 23 is a sectional view showing the details of one embodiment of the filter housing used with the dual filter separation system with a shuttle puck of FIG. 22.
  • FIGS. 1-23 An abrasive suspension jet cutting system 30 for cutting a part 32 is illustrated in FIGS. 1-23.
  • Cutting system 30 comprises a cutting head 34.
  • Cutting head 34 includes a feed assembly 36 having a slurry orifice 38 and a shielding fluid orifice 40.
  • Cutting head 34 further includes acceleration cavity 42 and nozzle 44. Acceleration cavity 42 is located between feed assembly 36 and nozzle 44. Acceleration cavity 42 is configured so that abrasive slurry 60 and shielding fluid 62 are accelerated together from slurry orifice 38 to nozzle 44 while maintaining a shielding fluid barrier substantially unmixed with the abrasive slurry around the abrasive slurry.
  • Cutting head 34 is further configured so that both slurry 60 and shielding fluid 62 continue to pass substantially unmixed through nozzle 44 and exit the nozzle exit orifice 41 as a high velocity cutting jet 45.
  • FIGS. 1 and 2 show the overall abrasive suspension jet cutting system 30.
  • abrasive suspension jet cutting system 30 further comprises cutting table 50 with platform 52 that supports part 32 to be cut.
  • Cutting table 50 has a positioning arm 56 that supports and moves cutting head 34 above part 32.
  • Cutting system 30 further comprises a fluid delivery system 94 (94a, 94b, 94c) that provides slurry 60 through slurry supply line 61 and shielding fluid 62 through supply lines 64 (64a and 64b) to cutting head 34.
  • Electronic control system 66 with a user interface 68 is used to operate abrasive suspension jet system 30.
  • Cutting system 30 may also include an abrasive particle and fluid reclamation system 100 for reclaiming the abrasive particles 72 and fluid needed to operate the cutting system.
  • Central core 78 may include one or more flow conditioning elements 84 that may be turbulence-reducing screens and swirl reducing elements to ensure uniform velocity fluid flow to feed assembly 36.
  • flow conditioning elements 84 may be turbulence-reducing screens and swirl reducing elements to ensure uniform velocity fluid flow to feed assembly 36.
  • slurry tube 80 At the end of slurry tube 80 is slurry orifice 38.
  • shielding fluid cavity 82 At the end of shielding fluid cavity 82 is shielding fluid orifice 40.
  • jet forming element 86 At the end of central core 78 of cutting head 34 is jet forming element 86, FIG. 4.
  • Jet forming element 86 is preferably a removable element that can be secured in to cutting head 34.
  • Jet forming element 86 includes jet forming insert 88 and jet forming insert holder 90.
  • Jet forming insert 88 is preferably press-fit into jet forming insert holder 90.
  • Jet forming element 86 may have a seal 92 sealing with the rest of the cutting head body.
  • feed assembly 36 acceleration cavity 42 and nozzle 44.
  • Nozzle 44 has a nozzle entrance orifice 43, a nozzle exit orifice 41 and a nozzle orifice length 39.
  • Nozzle 44 includes a nozzle length 39 and nozzle orifice diameter 37, wherein the nozzle length is less than the nozzle orifice diameter.
  • Acceleration cavity 42 narrows from slurry orifice 38 to the nozzle entrance orifice 43 to provide hydrodynamic focusing.
  • Fluid delivery system 94 (94a, 94b, 94c).
  • fluid delivery system 94 has a fluid energizing means 96, an abrasive slurry supply, a shielding fluid supply and a combination of valves to drive and regulate both abrasive slurry and shielding fluid through cutting system 30.
  • Fluid delivery system 94 may include abrasive wear control system 98, which is a set of regulators and valves to reduce system wear.
  • Fluid delivery system 94 may include an abrasive particle and fluid reclamation system 100.
  • fluid deliver system 94 is a continuous operation fluid delivery system 94a that includes two slurry cylinders 102 (102a and 102b) as well as two buffer tanks, slurry buffer tank 104 and shielding fluid buffer tank 106.
  • Each slurry cylinder 102 (102a and 102b) further has a fill valve 108 (108a and 108b) and an isolation valve 110 (110a and 110b).
  • Isolation valve 110 is closed as slurry 60 is pumped into each cylinder and opened when delivering slurry to cutting head 34.
  • a single pump / energizing means 96 is used to commonly energize both abrasive slurry 60 and shielding fluid 62 and move both fluids through acceleration cavity 42 and out nozzle 44.
  • Energized slurry flowing out of slurry cylinders 102 is regulated by slurry drive valves 111 (111a and 111b).
  • An additional slurry valve 113 is included to control slurry delivery to cutting head 34.
  • FIG. 6 simplified continuous operation fluid delivery system 94b is a continuous system without buffer tanks, but contains all other elements of fluid delivery system 94a. This embodiment reduces the footprint of the system and increases simplification of fluid delivery system 94b.
  • fluid delivery system 94c is a batch system. In this batch system only one slurry cylinder 102 is used and cutting head 34 must be turned off when refilling the slurry supply.
  • Abrasive suspension j et cutting system 30 further includes electronic control system 112, FIG. 8.
  • Electronic components are contained within an electronics enclosure 116.
  • Electronic components include a computer 118, programmable logic controller 120, data acquisition/logging device 122 and a multi-axis motion control system 124 that drives multi-axis motion hardware 125.
  • a user interface 68 allows an operator to interface with electronic components and control cutting system 30.
  • Electronic control system 112 regulates fluid delivery system 94 which may include wear control system 98 and reclamation system 100.
  • Electronic control system 112 further controls the multi-axis motion control system 124 that drives positioning arm 56.
  • Shielding fluid 62 is pumped through shielding fluid cavity 82. Shielding fluid 62 enters acceleration cavity 42 as an annulus of shielding fluid 62 from shielding fluid orifice 40 and fills the acceleration cavity. Once acceleration cavity 42 is full of shielding fluid 62 flowing at working pressure, slurry 60 is then introduced into the acceleration cavity 42. Because acceleration cavity 42 narrows from slurry orifice 38 to nozzle 44, the resulting fluid flow is a cone of slurry 60 surrounded by an annular cone of shielding fluid 62 with the slurry and shielding fluid accelerating together from feed assembly to the nozzle. Slurry 60 surrounded by shielding fluid 62 then pass through nozzle 44 and out the nozzle exit orifice 41 as cutting jet 45.
  • the pressure gradient within the acceleration cavity 42 has the potential to cause mixing between the slurry having abrasive particles and shielding fluids if the two fluids do not flow in a similar manner when exposed to this pressure gradient resulting in increased nozzle wear. For this reason, it is critical for the slurry and shielding fluid to have similar rheologic parameters including viscosity and the strain rate dependence of this viscosity. A variation in these parameters between the two fluids will cause a local variation in the Reynolds number along the boundary between the two fluids resulting in the development of a shear force that can induce mixing of abrasive slurry and shielding fluid. To minimize this mixing the present invention uses the same base fluid for the shielding fluid and slurry.
  • the base fluid may be one from the group including water, water and a suspension agent, oil, and oil and a suspension agent.
  • a modifying additive may be added to the slurry and shielding fluids to give them similar flow characteristics, including viscosity and viscosity shear rate dependence, and ensure equivalent acceleration without mixing in the acceleration cavity 42 and through the nozzle exit orifice 41.
  • This additive may be a xanthan gum, guar gum, cellulose derivatives, polyacrylamide, gelatin, bentonite, another natural synthetic polymer or clay.
  • nozzle orifice length 39 effects mixing of abrasive slurry 60 and shielding fluid 62 within nozzle 44, FIGS. 11a and lib.
  • An abrasive particle within slurry 60 may follow a trajectory shown by bold line (trajectory T) in FIG. 1 la. This trajectory is a result of the momentum of the abrasive particle.
  • abrasive particle 72 enters nozzle 44, the particle wants to continue on generally the same path that the particle followed through the lower part of acceleration cavity where the velocity is high. This means particle 72 wants to move into the shielding fluid 62.
  • FIG. lib shows where when nozzle orifice length 39 is shortened to less than D, the abrasive particles will no longer make contact with the nozzle wall.
  • An optimum nozzle orifice length is generally when the nozzle orifice length 39 is shorter than the diameter of nozzle entrance orifice 43.
  • FIGS 12a-12c It has also been determined that slurry to shielding fluid volume ratio effects mixing, FIGS 12a-12c.
  • the trajectory of an abrasive particle 72 is such that the particle may move into shielding fluid 62 and contact nozzle 44 abrading the nozzle wall before the particle has exited the nozzle.
  • the trajectory of an abrasive particle 72 is such that the particle may also move into shielding fluid 62 and contact nozzle 44 abrading the nozzle wall before the particle has exited the nozzle.
  • FIG. 12c illustrates an optimal slurry to shielding fluid volume allowing abrasive particles to exit nozzle 44 before the particles have a chance to abrade the nozzle wall.
  • the abrasive slurry has an abrasive slurry volume
  • the shielding fluid has a shielding fluid volume
  • the abrasive slurry volume and shielding fluid volume define a total volume
  • the system provides that the abrasive slurry volume may be greater than 30-percent of the total volume as the abrasive slurry exits the nozzle.
  • the large slurry volume percentage allows for increased abrasive jet power and cutting efficiency while maintaining nozzle protection and is made possible by the cutting head and operational details disclosed herein.
  • an abrasive wear control system 98 may be incorporated into fluid delivery system 94, FIG. 13.
  • Abrasive wear control system 98 incudes a slurry to shielding fluid volume regulator 126 and a valve system 128.
  • Valve system 128 includes a slurry valve 113 and a slurry vent valve 132.
  • Abrasive wear control system 98 is important during the formation and shutdown of cutting jet 45.
  • Abrasive wear control system 98 works to minimize mixing of abrasive particles 72 into shielding fluid 62 and thus mitigate further wear on the cutting head components.
  • FIGS. 14a-c illustrate how abrasive wear control system 98 operates during the startup procedure.
  • no shielding fluid 62 is running through cutting head 34.
  • Flow of shielding fluid 62 is then initiated to provide clean shielding fluid at pressure within acceleration cavity 42 and nozzle 44, FIG. 14b.
  • Slurry valve 113 is then opened and slurry 60 introduced into the shielding fluid 62 that is already flowing through acceleration cavity 42, FIG. 14c.
  • slurry 60 mixing with shielding fluid 62 is minimized because the slurry is not introduced into acceleration cavity 42 when transient, nonlinear flow of shielding fluid is occurring at the beginning of shielding fluid flowing into the acceleration cavity.
  • FIGS. 15a-f illustrate how abrasive wear control system 98 operates during the shutdown procedure.
  • slurry 60 with a clear shielding fluid layer is flowing through acceleration cavity 42 and out nozzle 44.
  • Slurry valve 113 is shut off so that all slurry 60 is cleared from acceleration cavity 42 and nozzle 44, FIG. 15b.
  • Vent valve 132 (132a and 132b) and slurry valve 113 are then opened to flush all slurry through cutting head 34, through slurry valve 113 and out vent valve 132, FIG. 15c and 15d.
  • Vent valve 132 and slurry valve 113 are then shut off, FIG. 15e.
  • the slurry to shielding fluid volume flow regulator 126 is shut off to stop all fluids flowing through cutting head 34,
  • Slurry to shielding fluid volume flow regulator may include a slurry pressure regulator and a shielding fluid pressure regulator.
  • the slurry to shielding fluid volume flow regulator may be a shielding fluid flow control valve. Shielding fluid volume flow regulator 126 and the rest of the valve system may allow reverse flow of abrasive slurry through the cutting head to reduce nozzle wear.
  • the starting and stopping of the slurry flow requires the operation of a valve or valves on the abrasive slurry, which leads to significant wear of the internal valve components.
  • the present invention alleviates this wear by purging abrasive from any valve located in the slurry flow path with clean shielding fluid before operating the valve. This allows for the frequent starting and stopping of jet 45, which is required during typical operation, without producing significant valve wear.
  • Abrasive suspension jet cutting system 30, FIG. 16 may include an abrasive particle and fluid reclamation system 100 (a.k.a. reclamation system, abrasive slurry reclamation system) to reduce costs of abrasive particle 72 and shielding fluid 62.
  • Reclamation system 100 includes jet catch tank 134, which in combination with catch tank agitator 136 creates collection system 135.
  • Reclamation system 100 also includes a separator system 160, where separator system 160 may be any of the separator systems 160a, 160b 160c and 160d.
  • Abrasive particles 72 and shielding fluid 62 are collected in jet catch tank 134 after being in jet 45 to cut a part 32.
  • Separator system 160 contains separator 146 (146a, 146b, 146c and 146d), fluid flow meter 195, and fluid properties controller 152. Within separator system 160, reusable abrasive particles 72 and a portion of the base fluid are separated from used fluid to produce reclaimed slurry and reclaimed shielding fluid. Separator 146 may be a settling tank, hydrocyclone, centrifuge, mechanical filter, tangential flow filter, or a combination thereof. Reclaimed shielding fluid is then pumped by shielding fluid boost pump 148 through a fines filter 150 to remove waste particles from shielding fluid. Clean, reclaimed shielding fluid is then returned through fluid delivery system 94 to be reused by cutting head 34 to form cutting jet 45.
  • fluid property controller 152 Separated abrasive particles suspended in fluid as a concentrated slurry is processed through fluid property controller 152.
  • the fluid properties of density or viscosity may be measured by fluid property sensor 153 and processed by density logic 155 or viscosity logic 157.
  • the density information generated by density logic 155 is used to concentrate or dilute the slurry being processed in separator 146.
  • the viscosity information generated by viscosity logic 157 is used to monitor the relative changes in fluid viscosity over time. When sufficiently large changes in viscosity have occurred, viscosity logic 157 will indicate that the fluid’s viscosity needs to be adjusted, which may include adding polymer concentrate 145 to jet catch tank 134.
  • Fluid flow meter 195 may be installed on the dilute slurry inlet 192, the reclaimed shielding fluid outlet(s) 194a 194b or both. Together dilute slurry pump 142, separator system 160, slurry boost pump 156, shielding fluid boost pump 148 and associated valves create a recirculation system.
  • Reclamation system 100 further may further include a conditioner system to maintain rheological and biological properties of the base fluid. Rheological properties may include viscosity and shear thinning rate.
  • Conditioner system may include a biocide system.
  • Rheological test system includes a rheological test system and a rheological modifier system. Associated with these systems are polymer concentrate 145 and slurry concentrate 147 that are available to adjust viscosity and slurry density.
  • separator system 160 (single filter 160a, dual filter 160b, plunger 160c and dual filter with shuttle puck 160d) is to re-use the abrasive used in Abrasive Suspension Jet (ASJ) cutters.
  • Separator system 160 has one input feed line and two output lines.
  • the input feed is dilute slurry from collection system 135.
  • the output lines are derived from the same input fluid to make this a closed-loop abrasive recovery and filtration system for abrasive suspension jet cutting systems.
  • One output line is a concentrated abrasive suspension (a.k.a. slurry) to be reused in the ASJ cutter.
  • the other output feed is an abrasive-free shielding fluid to be reused in the ASJ cutter.
  • Filter 170 moves within filter housing 158 between the dilute slurry inlet 192 and the reclaimed shielding fluid outlet 194.
  • Moveable filter plate 168 are designed to be easily removed from the system and replaced with fresh filter plates.
  • Separator agitator 172 mixes the slurry within the separator.
  • separator system 146, 146a Operation of separator system 146, 146a is as follows. With dilute slurry valve 162 and reclaimed shielding fluid valve 178 open and concentrated slurry valve 182 closed, dilute slurry pump 142 transports diluted slurry from catch tank 134 into filter housing 158 and through moveable filter plate 168.
  • Moveable filter plate 168 is connected to filter plate actuation system 159 which allows the filter plate to move linearly within the filter housing.
  • Moveable filter plate 168 includes a mesh or porous material (a.k.a. filter 170) that allows the base fluid to pass through but restricts abrasive.
  • the diluted slurry begins to separate into shielding fluid that passes through the filter, and concentrated slurry that does not flow through the filter.
  • Pressure transducers (dilute slurry pressure sensor 164 and reclaimed shielding fluid pressure sensor 180) continuously monitor the pressure on both sides of the filter plate.
  • An increasing pressure differential across the filter plate corresponds to the abrasive particles clogging the filter media and reduced filtration throughput.
  • Separator agitator 172 which may be a propeller, is designed to unclog abrasive from the filter plate to reduce this pressure differential as well as to ensure a homogenous mixture of slurry. Further increases in a pressure differential indicate the separator agitator 172 is becoming ineffective.
  • dilute slurry pump 142 will then stop, dilute slurry valve 162 will close, reclaimed shielding fluid valve 178 will close and the filter plate linear actuator 176 will move moveable filter plate 168 away from the input feed line.
  • This motion creates a higher pressure on the lower side of filter 170 relative to the upper side of the filter 170 that forces fluid through filter 170 in the opposite direction of filtration.
  • Substantially all abrasive trapped in the filter media and the abrasive cake on the surface of the filter is removed during this process. This process is called a “back-purge” and both restores filter throughput and greatly extends the usable filter life.
  • Separator agitator motor 174 will drive separator agitator 172 to uniformly distribute abrasive within the filter housing 158.
  • Dilute slurry valve 162 and reclaimed shielding fluid valve 178 then open; dilute slurry pump 142 turns on, and the filtering process resumes.
  • Fluid flow meter 195 and fluid property controller 152 monitor and provide feedback to the filtration system. When the slurry in the filter housing matches the desired slurry density, concentrated slurry valve 182 opens, dilute slurry valve 162 closes, and the filter plate linear actuator 176 moves moveable filter plate 168 towards the slurry output line. This discharges the concentrated slurry out of filter housing 158.
  • Fluid flow meter 195 and fluid property controller 152 provide feedback to reclamation system 100.
  • the density of the dilute slurry being input into filter housing 158 is determined using the following equation:
  • Fluid flow meter 195 which may be measuring reclaimed shielding fluid output flow from filter housing or dilute slurry input flow to filter housing, records the fluid flow during the filtration cycle.
  • separation system 160 can have two filters, a first filter 170a located in stationary filter plate 184 and a second filter 170b located in moveable filter plate 168, making the separation system a dual filter separation system 160b.
  • Stationary filter plate 184 is located between the dilute slurry inlet 192 and second shielding fluid outlet 194b. This additional stationary filter plate 184 provides more filter surface area for increased filtration throughput.
  • Moveable filter plate 168 moves between the dilute slurry inlet 192 and first shielding fluid outlet 194b.
  • First shielding fluid outlet 194a and second shielding fluid outlet 194b are hydrodynamically connected. Operation is the same as described above for the single filter separation system 160a, but whenever base fluid is flowing through movable filter plate 168, the base fluid is also flowing through stationary filter plate 184.
  • separation system 160 can have two filters and a plunger 186 making the separation system a plunger separation system 160c.
  • Two stationary filter plates 184 with an additional shielding fluid output line can be fashioned to the dilute slurry input side of filter housing 158. Having two stationary filter plates 184 (top stationary slurry plate 184a and bottom stationary slurry plate 184b) provides more filter surface area for increased filtration throughput.
  • the separator system 160c includes a filter housing 158 having first dilute slurry inlet 192a, second dilute slurry inlet 192b, first stationary filter 170a, second filter 170b, plunger 186, first reclaimed shielding fluid outlet 194a, second reclaimed shielding fluid outlet 194b, first concentrated slurry outlet 193a, and second concentrated slurry outlet 193b.
  • First filter 170a is located between first dilute slurry inlet 192a and first reclaimed shielding fluid outlet 194a.
  • Second filter 170b is located between second dilute slurry inlet 192b and second reclaimed shielding fluid outlet 194b.
  • Plunger 186 is located between first filter 170a and second filter 170b.
  • plunger separation system 160c Operation of plunger separation system 160c is as follows. With dilute slurry valve 162a open, dilute slurry valve 162b closed, concentrated slurry valves 182a and 182b closed, reclaimed shielding fluid valve 178b open, and reclaimed shielding fluid valve 178a closed, dilute slurry pump 142 transports diluted slurry from catch tank 134 into filter housing 158. Fluid pressure then drives plunger 186 towards the bottom stationary filter plate 184b.
  • Bottom stationary filter plate 184b includes a mesh or porous material that allows the base fluid to pass through, but restricts abrasive.
  • the diluted slurry begins to separate into shielding fluid that passes through bottom stationary filter plate 184b, and concentrated slurry that does not flow through the bottom stationary filter plate.
  • Pressure transducers dilute slurry pressure sensors 164a and 164b, and reclaimed shielding fluid pressure sensor 180 continuously monitor the pressure on both sides of the filter plate. An increasing pressure differential across the filter plate corresponds to the abrasive particles clogging the filter media and reduced filtration throughput.
  • Separator agitator motors 174a and 174b drive separator agitators 172a and 172b, respectively.
  • Separator agitators 172a and 172b which may be propellers, are designed to unclog abrasive from the filter plate to reduce this pressure differential as well as to ensure a homogenous mixture of slurry.
  • Fluid flow meter 195 and fluid property controller 152 provide feedback to the filtration system.
  • reclaimed shielding fluid valve 178b will close, and concentrated slurry valve 182b will open.
  • Dilute slurry pump 142 will continue to fill the filter housing above plunger 186 with dilute slurry, and the now concentrated slurry will flow out of concentrated slurry valve 182b, through fluid property controller 152, and to slurry conditioning tank 154.
  • Fluid flow meter 195 and fluid property controller 152 provide feedback to the filtration system.
  • reclaimed shielding valve 178a closes, and concentrated slurry valve 182a opens.
  • Dilute slurry pump 142 will continue to transport dilute slurry into the filter housing between plunger 186 and bottom stationary filter plate 184b.
  • dilute slurry valve 162 opens, dilute slurry valve 162b closes, shielding fluid valves 178a and 178b open, and concentrated slurry valve 182a closes.
  • Dilute slurry pump 142 then fills the top part of filter housing 158 between top stationary filter plate 184a and plunger 186 with dilute slurry, repeating the filtration cycle.
  • separation system 160 can have two filters 170, first filter 170a located in stationary filter plate 184 and second filter 170b located in movable filter plate 168, and movable shuttle puck 188 located downstream of movable filter plate 168, making the separation system a dual filter separation system with shuttle puck 160d.
  • Moveable shuttle puck 188 has a moveable shuttle puck collar 190.
  • Dual filter separation system with shuttle puck 160d further includes dilute slurry valve 162 for introducing dilute slurry, at dilute slurry inlet 192, into dual filter separation system with shuttle puck 160d from collection system 135.
  • Dilute slurry pressure sensor 164 senses dilute slurry pressure coming into separator 146d.
  • a movable filter plate 168 having second filter 170b, stationary filter plate 184 having first filter 170a, and movable shuttle puck 188.
  • First filter 170a does not move and is located hydrodynamically between the dilute slurry inlet 192 and second reclaimed shielding fluid outlet 194b.
  • Second filter 170b moves within filter housing 158 between the dilute slurry inlet 192 and the first reclaimed shielding fluid outlet 194a.
  • Movable shuttle puck 188 is located between the first reclaimed shielding fluid outlet 194a and the second reclaimed shielding fluid outlet 194b.
  • Movable shuttle puck 188 can move with movable filter plate 168 when filling filter housing 158 with dilute slurry and when purging the concentrated slurry out of the housing. Movable shuttle puck 188 also moves with movable filter plate 168 when back purging first filter 170a. Movable shuttle puck 188 moves independently of movable filter plate 168 when back purging second filter 170b. Movable filter plate 168 and stationary filter plate 184 are designed to be easily removed from the system and replaced with fresh filter plates.
  • Separator agitator 172 mixes the slurry within the separator 146d.
  • Separator Agitator motor 174 drives the agitator.
  • Filter plate and shuttle puck linear actuator 177 moves movable filter plate 168 and movable shuttle puck 188 back and forth within separator 146d.
  • Reclaimed shielding fluid exits separator 146d through reclaimed shielding fluid valves 178a and 178b and then in some instances, through fluid flow meter 195 to shielding fluid boost pump 148.
  • Reclaimed shielding fluid pressure sensors 180a and 180b sense the pressure of reclaimed shielding fluid exiting dual filter with shuttle puck separator 146d.
  • Concentrated slurry exits dual filter with shuttle puck separator 146d through concentrated slurry valve 182.
  • the concentrated slurry enters fluid property controller 152 having fluid property sensor 153 and density logic 155 and/or viscosity logic 157. Fluid property controller 152 monitors density and viscosity of concentrated slurry.
  • Slurry concentrated within filter housing 158 exits the filter housing and is transported to slurry conditioning tank 154.
  • separator system 146, 146d Operation of separator system 146, 146d is as follows. With dilute slurry valve 162, reclaimed shielding fluid valves 178a and 178b, and reclaimed shielding fluid purge control valves 202a and 202b open, and concentrated slurry valve 182 closed, dilute slurry pump 142 transports dilute slurry from catch tank 134 into filter housing 158 and through movable filter plate 168 and stationary filter plate 184. Movable filter plate 168 and stationary filter plate 184 are hydrodynamically connected when reclaimed shielding fluid purge control vales 202a and 202b are open.
  • Pressure transducers continuously monitor the pressure on both sides of both filter plates.
  • An increasing pressure differential across the individual filter plates corresponds to the abrasive particles clogging the filter media and a reduced filtration throughput.
  • Separator agitator 172 may be a propeller, pump, acoustic vibrator, mechanical vibrator or brushes. Separator agitator 172 is designed to unclog abrasive from the filter plates to reduce this pressure differential as well as to ensure a homogenous mixture of slurry. Further increases in a pressure differential indicate the separator agitator 172 is becoming ineffective.
  • dilute slurry pump 142 will then stop, dilute slurry valve 162 will close, reclaimed shielding fluid valves 178a and 178b will close and the filter plate linear actuator 176 will move movable filter plate 168 and movable shuttle puck 188 away from dilute slurry inlet 192.
  • movable shuttle puck 188 and movable filter plate 168 move together at the same speed. This motion creates a lower pressure on the lower side of stationary filter plate 184a relative to the upper side of stationary filter plate 184a that forces fluid through stationary filter plate 184a in the opposite direction of filtration.
  • moveable shuttle puck 188 reaches movable shuttle puck backstop 198, the movable shuttle puck no longer moves together with movable filter plate 168.
  • moveable shuttle puck 188 stops moving, and movable filter plate 168 continues to move downwards as movable shuttle puck back-purge spring 196 begins to compress.
  • This relative motion between movable filter plate 168 and movable shuttle puck 188 changes the volume of fluid between movable filter plate and movable shuttle puck due to fluid being forced through the movable filter plate in the opposite direction of filtration.
  • Substantially all abrasive trapped in both the filter’s media and the abrasive cake on the surface of the filters are removed during this process. This process is called a “back-purge” and both restores filter throughput and greatly extends the usable filter life.
  • the movable shuttle puck back-purge spring 196 and movable shuttle puck backstop 198 ensure that both filters 170a and 170b can be back-purged independently.
  • Separator agitator 172 mixes the abrasive cake that was removed from the filters to make a homogenous slurry.
  • Dilute slurry valve 162 and reclaimed shielding fluid valves 178a and 178b then open; dilute slurry pump 142 turns on, and the filtering process resumes.
  • Fluid flow meter 195 and fluid property controller 152 provide feedback to the filtration system
  • concentrated slurry valve 182 opens, dilute slurry valve 162 closes, reclaimed shielding fluid valve 178a closes, reclaimed shielding fluid valve 178b remains open, and reclaimed shielding fluid purge control valves 202a and 202b close.
  • the filter plate and shuttle puck linear actuator 177 moves movable filter plate 168 and movable shuttle puck 188 towards concentrated slurry outlet 193. This discharges the concentrated slurry out of filter housing 158.
  • the unchanging volumes of fluid between movable filter plate 168 and movable shuttle puck 188, and between stationary filter plate 184 and reclaimed shielding fluid purge control valves (202a, 202b), ensures that no unwarranted filtration occurs as concentrated slurry is being discharged from filter housing 158.
  • concentrated slurry valve 182 closes, dilute slurry valve 162 opens, reclaimed shielding fluid purge control valves (202a, 202b) open, reclaimed shielding fluid valves 178a opens, 178b remains open, and then dilute slurry pump 142 begins pumping more diluted slurry into filter housing 158 as movable filter plate 168 and movable shuttle puck 188 move back towards their original starting positions, restarting the filtration cycle.
  • abrasive particle and fluid reclamation system 100 can be used with traditional ASJ system that does not use a shielding fluid.
  • a reclamation system would include the collection system and recirculation system but may not include a conditioner system or separator.
  • Fluid and slurry properties may be obtained by monitoring by density and/or viscosity.
  • density logic 155 is measuring density.
  • viscosity logic is measuring viscosity.
  • fluid property sensor 153 may be comprised of a vertical section of pipe, with a pressure transducer near the bottom of the pipe, and another pressure transducer near the top of the pipe.
  • the pipe may be filled with concentrated slurry.
  • the static pressure head equation is:
  • the viscosity of a non-Newtonian fluid can be determined over multiple rates of shear by also knowing Pi, P 2 and h.
  • shear stress, T, and shear rate, g can be determined using the equations above, and can be used to determine the flow consistency index, K, and flow behavior index, n, as described in a fluid model such as the Ostwald-de Waele power law:
  • Operation of abrasive suspension jet cutting system 30 includes three general tasks; software programming, cutting and material handling.
  • the operator powers on cutting system 30 and through the user interface generates a cutting file that describes the material, thickness and shape or shapes to be cut.
  • a pre-programmed file can be loaded into the system.
  • the operator then lowers the fluid level in the catch tank 134 to expose the material support slats and affixes the material to be cut to platform 52 (a.k.a. slats) with clamping hardware.
  • the cutting head 34 is then aligned to the material to ensure cutting will be performed in the desired location on the material to be cut.
  • the fluid level in the catch tank 134 is then raised to submerge the material to be cut and nozzle 44. All cutting is performed below the fluid surface to ensure no air is entrained in the fluid during operation, which would otherwise complicate the fluid re-use process.
  • the operator then returns to the user interface to start the cutting program.
  • the electronic controls operate multi-axis motion control system 124 and fluid delivery system 94, including abrasive particle and fluid reclamation system 100, in concert in order to start and stop cutting jet 45 in concert with the prescribed cutting head motion, and to return the reclaimed slurry and shielding fluid to the system.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
  • Processing Of Stones Or Stones Resemblance Materials (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)

Abstract

L'invention concerne un système de coupe à jet de suspension abrasive, le système comprenant une tête de coupe. La tête de coupe a un ensemble d'alimentation, une buse et une cavité d'accélération entre ceux-ci. L'ensemble d'alimentation comporte un orifice à boue et un orifice à fluide de protection. Dans la cavité d'accélération, une boue abrasive et le fluide de protection sont accélérés ensemble de l'orifice à boue à la buse tout en maintenant une barrière de fluide de protection sensiblement non mélangée avec la boue abrasive autour de la boue abrasive. La tête de coupe est en outre conçue de sorte qu'à la fois la boue et le fluide de protection traversent la buse sensiblement sans être mélangés, limitant ainsi l'usure de la buse. Un système de régulation d'usure est prévu pour réduire l'usure de la buse et d'autres composants du système au démarrage et à l'arrêt. Le système peut en outre comprendre un système de récupération qui collecte et récupère des particules abrasives utilisées et un fluide et les renvoie à la tête de coupe en vue d'une réutilisation, ce qui permet de réduire les coûts de fonctionnement du système.
PCT/US2020/061780 2019-11-25 2020-11-23 Système de coupe à jet de suspension abrasive à usure réduite de système et récupération de matériaux de traitement WO2021108304A1 (fr)

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US11577366B2 (en) 2016-12-12 2023-02-14 Omax Corporation Recirculation of wet abrasive material in abrasive waterjet systems and related technology
CN115698507A (zh) 2020-03-30 2023-02-03 海别得公司 用于具有多功能接口纵向端的液体喷射泵的气缸
US20230056508A1 (en) * 2021-08-19 2023-02-23 Raytheon Technologies Corporation Method and system for drilling ceramic

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US20030027100A1 (en) * 2001-08-01 2003-02-06 Sidney Grant Dental tool
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