The present invention relates to the field of plasma cutting torches, and in particular, consumables for plasma cutting torches.
When cutting heavy materials, such as a 4-inch thick steel plate, using a plasma cutting process/operation, a torch is exposed to a high heat environment for an extended period of time. The exposure to the high heat can cause damage to the plasma torch and its parts (e.g., a consumable stack including a cartridge, an electrode, nozzle or tip, shield cup, etc.), resulting in premature failure and poor cut quality. When premature failure occurs, the torch may need costly repairs and/or replacement of consumables (e.g., if the consumables are destroyed or damaged), both of which require a shutdown of a plasma cutting operation. Consequently, it may be difficult to cut heavy materials with high levels of efficiency and/or productivity and, moreover, cutting heavy materials may drastically shorten the lifespan of consumables. Further, poor cut quality may require additional processing of the workpiece (e.g., with milling).
The present invention relates to techniques for dissipating heat from a cutting torch during a plasma cutting process/operation, including a piercing stage. In accordance with at least one embodiment of the present invention, an outer shield assembly (also called a “shield club,” secondary shield, secondary shield assembly, or the like) absorbs and dissipates heat from a cutting torch including consumable components disposed therein. The outer shield surrounds and protects the outermost consumable(s) (e.g., nozzle/tip, shield, shield cup etc.) and dissipates heat from the plasma cutting operation. In some implementations, a flow of cooling water flows between and cools the outermost consumable(s) and the outer shield. In some implementations, the outer shield includes a deflector ring for deflecting spatter ejected during a plasma cutting operation and/or for increasing a surface area of a heat dissipation area of a consumable stack.
To complete the description and in order to provide for a better understanding of the present invention, a set of drawings is provided. The drawings form an integral part of the description and illustrate an embodiment of the present invention, which should not be interpreted as restricting the scope of the invention, but just as an example of how the invention can be carried out. The drawings comprise the following figures:
Like reference numerals have been used to identify like elements throughout this disclosure.
The following description is not to be taken in a limiting sense but is given solely for the purpose of describing the broad principles of the invention. Embodiments of the invention will be described by way of example, with reference to the above-mentioned drawings showing elements and results according to the present invention.
Generally, the techniques for dissipating heat from a cutting torch include an outer shield assembly (sometimes referred to herein as a “shield club,” “shield club assembly,” “secondary shield,” “outer shield assembly,” “secondary shield assembly,” etc.) surrounding a consumable stack of a cutting torch. The outer shield club assembly protects the consumable stack by absorbing and dissipating heat from a plasma cutting process/operation. In particular, the cutting operation may be a high-amp operation (e.g., about 400 Amps or more, such as approximately 800 Amps or more) for piercing and cutting thick materials, such as a 4-inch thick stainless steel plate. For simplicity, the consumables of a consumable stack disposed interiorly of the outer shield are referred to herein as “consumable stack 20.” However, such terminology in no way implies that the outer shield is not a consumable component and/or is not part of a consumable stack. Instead, such terminology is only used for clarity and simplicity in the present application.
In some implementations, a cooling fluid (e.g., water) may flow between the outer shield club assembly and an outermost consumable(s) of the consumable stack. The heat absorbed by the shield club assembly may be received and removed by the cooling fluid. The shield club assembly may receive the flow of cooling fluid from the consumable stack, and/or from a separate inlet channel extending radially through the outer shield club assembly. The flow of cooling fluid may exit the outer shield club assembly through the consumable stack, through an outlet channel extending radially through the outer shield club assembly, and/or through an orifice disposed at a distal end of the shield club assembly. In some implementations, the shield club assembly may further include a deflector ring for deflecting spatter from the cutting operation. The deflector ring may receive and remove (i.e., dissipate) heat from any portion of the consumable stack (or the shield club assembly alone), either in combination with water cooling or independent of water cooling. Generally, the deflector ring increases a surface area of a heat dissipation area of a consumable stack and/or outer shield club assembly and thus, improves cooling for the consumable stack and/or outer shield assembly.
At a high-level, the cutting system 10 includes a table 11 configured to receive a workpiece (not shown), such as, but not limited to, sheets of metal. The automated cutting system also includes a positioning system 12 that is mounted to the table 11 and configured to translate or move along the table 11. At least one automated plasma arc torch 18 is mounted to the positioning system 12 and, in some embodiments, multiple automated plasma arc torches 18 may be mounted to the positioning system 12. The positioning system 12 may be configured to move, translate, and/or rotate the torch 18 in any direction (e.g., to provide movement in all degrees of freedom).
Additionally, at least one power supply 14 is operatively connected to the automated plasma arc torch 18 and configured to supply (or at least control the supply of) electrical power and flows of one or more fluids to the automated plasma arc torch 18 for operation. Finally, a controller or control panel 16 is operatively coupled to and in communication with the automated plasma arc torch 18, the one or more power supplies 14, and the positioning system 12. The controller 16 may be configured to control the operations of the automated plasma arc torch 18, one or more power supplies 14, and/or the positioning system 12, either alone or in combination with the one or more power supplies 14.
In at least some embodiments, the one or more power supplies 14 meter one or more flows of fluid received from one or more fluid supplies before or as the one or more power supplies 14 supply gas to the torch 18 via one or more cable conduits. Additionally or alternatively, the automated cutting system 10 may include a separate fluid supply unit (not shown) or units that can provide one or more fluids to the automated torch 18 independent of the one or more power supplies 14. To be clear, as used herein, the term “fluid” shall be construed to include a gas or a liquid. The one or more power supplies 14 may also condition, meter, and supply power to the automated torch 18 via one or more cables, which may be integrated with, bundled with, or provided separately from cable conduits for fluid flows. Additional cables for data, signals, and the like may also interconnect the controller 16, the automated plasma arc torch 18, the power supply 14, and/or the positioning system 12. Any cable or cable conduit/hose included in the automated cutting system 10 may be any length. Moreover, each end of any cable or cable conduit/hose may be connected to components of the automated cutting system 10 via any connectors now known or developed hereafter (e.g., via releasable connectors).
At the other end, the operative end 64 of the body 62 may receive interchangeable components, including consumable component stack 20 that facilitate cutting operations. For simplicity,
Now referring to
The shield club 300 is mounted to the outermost consumable(s) of the consumable stack 20. As shown in
Now referring to
In some implementations, the radial or the cross-sectional thickness T of the sidewall 305 of the shield club 300 may vary between the distal end 301 and the proximal end 303 to improve the local and overall thermal mass or heat capacity of the shield club 300. For example, a first cross-sectional thickness T1 may be greater at the distal end 301 than a second cross-sectional thickness T2 near the proximal end 303. As noted above, the thickness T impacts thermal mass. That is, the greater the thermal mass, the more heat the shield club 300 may absorb. Because the distal end 301 is exposed to more heat and spatter than the proximal end 303, the first thickness T1 (and thus thermal mass) is greater than the second thickness T2.
Additionally, the sidewall 305 includes a third cross-sectional thickness T3 where an interior surface of the shield club 300 engages, or otherwise contacts, one or more consumables (e.g., shield cup 260, shield 250, tip retainer 235, cartridge body 200, etc.). The third cross-sectional thickness T3 may be greater than each of the first thickness T1 and the second thickness T2. The one or more consumables contacting the shield club sidewall 305 may be heated during the arc processing operation, and the shield club 300 may absorb and/or dissipate at least some of the heat from these consumable(s), in addition to absorbing heat from the arc processing operation and/or spatter. Thus, the third thickness T3 is selected based on a desired local thermal mass of the shield club 300. That is, the local cross-sectional thickness T of a particular portion the sidewall 305 may be set based on the desired thermal mass of the particular portion of the sidewall 305 to withstand received heat, radiation, and/or spatter from the arc process operation. Consequently, the cross-sectional thickness T of the sidewall 305 may vary between the distal end 301 and the proximal end 303.
However, in some implementations, the cross-sectional thickness T of the sidewall 305 of the shield club 300 may be substantially constant/consistent and be selected or set based on an overall desired thermal mass of the shield club 300. That is, the thickness T of the sidewall 305 may not vary between the distal end 301 and the proximal end 303.
In the embodiment depicted in
Additionally, generally, the deflector ring 310 expands the radial footprint of the consumable stack 20 and/or the shield club 300, which may create a larger surface area from which heat may dissipate from the consumable stack 20 and/or the shield club 300. That is, the deflector ring 310 may create a heat sink for the shield club assembly 30—with the depicted embodiment essentially providing a single, annular fin. In fact, although not shown, in some implementations, the curved surface 312 may include features to increase heat dissipation/heat transfer, such as fins, texturing, knurling, etc. Generally, at least because the deflector ring 310 is positioned at the proximal end 303 of the shield club 300, heat may tend to migrate towards the deflector ring 310 during an arc processing operation. Then, the expanded surface area of the deflector ring 310 (created by the expanded radial footprint) may provide enhanced heat dissipation from the consumable stack 20 and/or the shield club 300.
In some implementations, the shield club 300 may be omitted and the deflector ring 310 may be coupled directly to the consumable stack 20, one or more outermost components of the consumable stack 20, the cartridge body 200, and/or the torch head 60. In some implementations, the deflector ring 310 may be omitted from the shield club assembly 30. Such constructions may realize the same advantages as discussed above (e.g., spatter protection and enhanced heat dissipation).
Now referring to
From the shield cup 260, the cooling fluid 400 flows into a cavity of the shield club 300. The cooling fluid 400 flows through a radial gap or channel between the shield club 300 and the shield cup 260 before entering a radially extending return port 261 of the shield cup 260. The cooling fluid 400 flows radially from the return port 261 through a return channel 202 in the cartridge body 200. The return channel 202 guides the cooling fluid 400 radially inward and then axially upwards towards a cartridge outlet port 420 where it exits the cartridge body 200. The cooling fluid 400 flows through the torch head 60 and back to a cooling fluid reservoir. The flow of the cooling fluid 400 is depicted as a single flow path. However, the depicted single flow path is representative of multiple flow paths arranged radially about the consumable stack 20. That is, the consumable stack 20 includes a plurality of channels disposed radially about the assembly to guide the cooling fluid 400 through multiple, radially offset flow paths. While a specific flow path of the cooling fluid 400 is depicted in
Regardless of the specific flow path of the cooling fluid 400, the cooling fluid 400 cools and dissipates heat from the consumable stack 20 and shield club assembly 30. The cooling fluid 400 absorbs and carries away heat from each component that it contacts as it flows through the consumable stack 20 and shield club assembly 30. Meanwhile, a tight contact fit between the deflector ring 310 and the shield club 300 facilitates cooling the deflector ring 310. That is, the cooling fluid 400 cools the shield club 300 which in turn cools the deflector ring 310. Additionally or alternatively, the deflector ring 310 may dissipate heat to the atmosphere (i.e., dissipate heat externally, perhaps independently of cooling fluid). In any case, heat removed from the consumable stack 20 and shield club assembly 30 by the cooling fluid 400 leaves the consumable stack 20 with the cooling fluid 400 via outlet port 420. The heat is then dissipated via a heat sink disposed in or near the cooling fluid reservoir. Additionally or alternatively, in some instances, a portion of the cooling fluid 400 may flow from a radial gap between the shield club 300 and the shield cup 260 and/or the shield 250 to the distal opening 302. That is, some of the cooling fluid 400 may be discharged from the shield club 300 through the distal opening 302. the cooling fluid 400 may be discharged from the shield club 300 via the distal opening 302.
Now referring to
In the depicted embodiment, the cooling fluid 400 is discharged from a distal end opening 502 of the shield club 500. However, in other implementations, the cooling fluid 400 flows through the consumable stack 20 and the torch head, back to a cooling fluid reservoir. In other implementations, the cooling fluid exits the shield club 500 to the cooling fluid reservoir via a return line substantially parallel to and radially offset from feed line 501. In yet other implementations, the cooling fluid may be discharged from the shield club 500 in a combination of exit ports (e.g., via the distal end opening 502, via the consumable stack 20 to the torch head, and/or via an external return line).
With the consumables and/or techniques presented herein, consumables for a cutting torch head 60 will experience less wear during a cutting operation and can withstand higher temperatures from high-amp (i.e., high current) plasma cutting operations as compared to a conventional torch head. That is, when used with the club assembly 30, 50 presented herein, cutting consumables may have longer lifespans. The shield club assembly 30, 50 results in improved heat dissipation during high-amp plasma cutting operations (e.g., a cutting operation having a current of about 800 Amps for piercing and cutting 4-inch stainless steel plates). However, the techniques described herein may be used with any plasma cutting operation. The improved heat dissipation results in less wear and premature failure of consumables in the consumable stack 20. Consequently, more pierces/cuts may be performed with a desired cut quality between stoppages for replacing worn/damaged consumables as compared to conventional cutting torches.
Each example embodiment disclosed herein has been included to present one or more different features. However, all disclosed example embodiments are designed to work together as part of a single larger system or method. This disclosure explicitly envisions compound embodiments that combine multiple previously-discussed features in different example embodiments into a single system or method. While the invention has been illustrated and described in detail and with reference to specific embodiments thereof, it is nevertheless not intended to be limited to the details shown, since it will be apparent that various modifications and structural changes may be made therein without departing from the scope of the inventions and within the scope and range of equivalents of the claims. In addition, various features from one of the embodiments may be incorporated into another of the embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure as set forth in the following claims.
Reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present disclosure, the devices, components, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms such as “above,” “below,” “upper,” “lower,” “top,” “bottom,” “left,” “right,” “front,” “rear,” “side,” “height,” “length,” “width,” “interior,” “exterior,” “inner,” “outer,” or other similar terms merely describe points of reference and do not limit the present invention to any particular orientation or configuration. When used to describe a range of dimensions and/or other characteristics (e.g., time, pressure, temperature, distance, etc.) of an element, operations, conditions, etc. the phrase “between X and Y” represents a range that includes X and Y.
Further, the term “exemplary” is used herein to describe an example or illustration. Any embodiment described herein as exemplary is not to be construed as a preferred or advantageous embodiment, but rather as one example or illustration of a possible embodiment.
Further, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity, and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
When used herein, the term “comprises” and its derivations (such as “comprising”, “including,” “containing,” etc.) should not be understood in an excluding sense, that is, these terms should not be interpreted as excluding the possibility that what is described and defined may include further elements, steps, etc. Meanwhile, when used herein, the term “approximately” and terms of its family (such as “approximate,” etc.) should be understood as indicating values very near to those which accompany the aforementioned term. That is to say, a deviation within reasonable limits from an exact value should be accepted, because a skilled person in the art will understand that such a deviation from the values indicated is inevitable due to measurement inaccuracies, etc. The same applies to the similar terms, such as, but not limited to, “about,” “around,” and “substantially.”
As used herein, unless expressly stated to the contrary, use of the phrase “at least one of”, “one or more of”, “and/or”, and variations thereof are open-ended expressions that are both conjunctive and disjunctive in operation for any and all possible combination of the associated listed items. For example, each of the expressions “at least one of X, Y and Z,” “at least one of X, Y or Z,” “one or more of X, Y and Z,” “one or more of X, Y or Z,” and “X, Y and/or Z” can mean any of the following: 1) X, but not Y and not Z; 2) Y, but not X and not Z; 3) Z, but not X and not Y; 4) X and Y, but not Z; 5) X and Z, but not Y; 6) Y and Z, but not X; or 7) X, Y, and Z. Further as referred to herein, “at least one of” and “one or more of” can be represented using the “(s)” nomenclature (e.g., one or more element(s)).
Additionally, unless expressly stated to the contrary, the terms “first,” “second,” “third,” etc. are intended to distinguish the particular nouns they modify (e.g., element, condition, node, module, activity, operation, etc.). Unless expressly stated to the contrary, the use of these terms is not intended to indicate any type of order, rank, importance, temporal sequence, or hierarchy of the modified noun. For example, “first X” and “second X” are intended to designate two “X” elements that are not necessarily limited by any order, rank, importance, temporal sequence, or hierarchy of the two elements.
This application is a continuation of International App. No. PCT/US2023/015629, which was filed on Mar. 20, 2023, and which claims priority to U.S. Provisional Application No. 63/322,481, filed Mar. 22, 2022. The contents of each of these applications is incorporated herein by reference in entirety.
Number | Date | Country | |
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63322481 | Mar 2022 | US |
Number | Date | Country | |
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Parent | PCT/US2023/015629 | Mar 2023 | US |
Child | 18459574 | US |