The present invention relates to cooling tubes, electrode holders and electrodes for an arc plasma torch. The invention further relates to arrangements thereof and an arc plasma torch with such tubes, holders, electrodes, and arrangements.
A plasma is an electrically conductive gas consisting of positive and negative ions, electrons and excited and neutral atoms, and molecules, which is heated thermally to a high temperature. Various gases are used as plasma gases, such as mono-atomic argon and/or the diatomic gases hydrogen, nitrogen, oxygen or air. These gases are ionised and dissociated by the energy of an electric arc. The electric arc is constricted by a nozzle and is then referred to as a plasma jet.
The parameters of a plasma jet can be heavily influenced by the design of a nozzle and electrode. Such parameters of the plasma jet are, for example, the diameter of the jet, temperature, energy density, and the flow rate of the gas. In plasma cutting, for example, the plasma is constricted by a nozzle, which can be cooled by gas or water. In this way, energy densities of up to 2×106 W/cm2 can be achieved. Temperatures of up to 30,000° C. arise in the plasma jet, which, in combination with the high flow rate of the gas, make it possible to achieve very high cutting speeds on materials.
Because of the high thermal stress level on nozzles, nozzles are usually made from a metallic material, preferably copper, because of copper's high electrical conductivity and thermal conductivity. The same is true of electrodes, though electrodes are also commonly made of silver. A nozzle is often inserted into an arc plasma torch, called a plasma torch for short. The main elements of a plasma torch include a plasma torch head, a nozzle cap, a plasma gas conducting member, a nozzle, a nozzle holder, an electrode with an electrode insert, and, in modern plasma torches, a holder for a nozzle protection cap, and a nozzle protection cap. Inside the electrode, there is, for example, a pointed electrode insert made from tungsten, which is suitable when non-oxidising gases are used as the plasma gas, such as a mixture of argon and hydrogen. A flat-tip electrode, the electrode insert of which is made of hafnium, is also suitable when oxidising gases are used as the plasma gas, such as air or oxygen.
In order to improve the service life for a nozzle and an electrode, a cooling fluid is often used, such as water, though cooling may also be effected with a gas. For this reason, a distinction is made between liquid-cooled and gas-cooled plasma torches.
Electrodes are often made from a material with good electric and thermal conductivity, e.g. copper and silver or their alloys, and an electrode insert consisting of a temperature-resistant material, e.g. tungsten, zirconium or hafnium. For plasma gases containing oxygen, zirconium may be used. Because of its superior thermal properties, hafnium is, however, better suited, since its oxide is more temperature-resistant.
In order to improve the service life for an electrode, a refractory material is often introduced into the holder as an emission insert, which is then cooled. The most effective form of cooling is liquid cooling.
A plasma torch, can be configured with an electrode that is hollow in the interior and with a cooling tube inside. In Former East Germany Document DD 87 361, for example, water flows through the interior of the cooling tube, streams against the bottom of the electrode, and then flows back between the interior surface of the electrode and the exterior surface of the cooling tube.
The electrode often has a cylindrical or conical region extending inwards, with the cooling tube projecting beyond it. The coolant flows around this region and is intended to ensure a better exchange of heat between the electrode and the coolant.
Nevertheless, it is common for heating to occur at the electrode. This, when the apparatus is switched on for a long time, becomes apparent in the form of considerable discoloration of the electrode holder and rapid burn-back of the electrode insert.
The invention addresses the problem of preventing, or at least reducing, overheating of electrodes of arc plasma torches. According to the invention, this problem is solved by a cooling tube for an arc plasma torch, comprising an elongate body with an end that can be disposed in the open end of an electrode and with a coolant duct extending therethrough with a bead-like thickening of the wall of the cooling tube pointing inwards and/or outwards.
The invention also addresses this problem further with an arrangement of a cooling tube and an electrode having a hollow elongate body with an open end for arranging the front end of a cooling tube and a closed end, the bottom surface of the open end having a projecting region, over which the end of the cooling tube extends, and the thickening extending in the longitudinal direction over at least the projecting region.
The invention further addresses this problem with a cooling tube for an arc plasma torch, comprising an elongate body with a rear end that can be releasably connected to an electrode holder of an arc plasma torch and a coolant duct extending therethrough, an external thread being provided for releasably connecting the rear end to an electrode holder, with a cylindrical outer surface adjoining this for centring the cooling tube relative to the electrode holder.
Furthermore, the invention also addresses this problem with an electrode holder for an arc plasma torch, comprising an elongate body with an end for receiving an electrode and with a hollow interior, wherein an internal thread is provided in the hollow interior for screwing in a rear end of a cooling tube, with a cylindrical inner surface adjoining this for centring the cooling tube relative to the electrode holder.
The invention contemplates in some embodiments an arrangement with a cooling tube and an electrode holder wherein the cooling tube is screwed together with the electrode holder by means of the external thread and the internal thread.
The invention contemplates some embodiments that include an arrangement of a cooling tube for an arc plasma torch, comprising an elongate body with a rear end that can be releasably connected to an electrode holder of an arc plasma torch and a coolant duct extending therethrough, and with an electrode holder for an arc plasma torch, comprising an elongate body with an end for receiving an electrode and with a hollow interior in which on the outer surface of the cooling tube at least one projection is provided for centring the cooling tube in the electrode holder.
In some contemplated embodiments, an electrode for an arc plasma torch, comprises a hollow elongate body with an open end for arranging the front end of a cooling tube therein and a closed end, the open end having an external thread for screwing together with the internal thread of an electrode holder, wherein adjoining the external thread, towards the closed end, there is a cylindrical outer surface for centring the electrode relative to the electrode holder.
In other contemplated embodiments, an electrode holder for an arc plasma torch is provided, comprising an elongate body with an end having an internal thread for receiving an electrode and with a hollow interior, wherein adjoining the internal thread, there is a cylindrical inner surface for centring the electrode relative to the electrode holder.
In some contemplated embodiments, an arrangement is provided with an electrode and an electrode holder wherein the electrode is screwed together with the electrode holder by means of the external thread and the internal thread.
In some contemplated embodiments, the thickening extends over at least one millimeter in the longitudinal direction of the cooling tube. In some embodiments, this thickening can lead to an increase in the external diameter by at least 0.2 millimeters and/or to a reduction of the internal diameter by at least 0.2 millimeters.
In some contemplated arrangements according to the invention, an electrode holder can be provided having an elongate body with an end for receiving the electrode and with a hollow interior, wherein the cooling tube projects into the hollow interior and at least one projection is provided on the outer surface of the cooling tube for centring the cooling tube in the electrode holder.
It is contemplated that in some embodiments, a first group of projections can be arranged peripherally and spaced apart from one another. In particular, in such arrangements, this connection can be arranged so that the projections are positioned peripherally and spaced apart from one another, with the second group offset axially from the first group. Some embodiments further contemplate the second group of projections to be offset peripherally relative to the first group of projections.
In some more specific embodiments, cooling tube can be provided with a stop face for fixing the cooling tube axially in the electrode holder. Other embodiments may allow the cylindrical outer surface to have a peripheral groove. In some particular embodiments, an O-ring may be disposed in the groove for sealing purposes.
According to some contemplated embodiments of the invention, the cylindrical outer surface can include an external diameter that is exactly the same size as or larger than the external diameter of the external thread. In some embodiments a stop face can be provided for fixing the cooling tube axially in the electrode holder.
In further contemplated embodiments, the cylindrical inner surface can have an internal diameter which is exactly the same size as or larger than the internal diameter of the internal thread. The principle applicable here is D6.1=(D.61a−D6.1i)/2 (“a” indicating external and “i” indicating internal).
In some additional contemplated embodiments, the cooling tube and the electrode holder are designed such that towards the front end, there is an annular gap between them. It is further contemplated that in some embodiments, the cylindrical outer surface of the cooling tube and the cylindrical inner surface of the electrode holder have narrow tolerances relative to one another.
In other contemplated embodiments, a first group of projections can be arranged peripherally and spaced apart from one another. In more specific embodiments, exactly three projections can be provided, which can be arranged to be offset from one another by 120°. In addition, a second group of projections can be provided, arranged peripherally and spaced apart from one another, with the second group offset axially relative to the first group. The second group of projections can likewise consist of exactly three projections, which can be arranged to be offset from one another by 120°. In some cases, the second group of projections can be advantageously offset peripherally relative to the first group of projections. The offset can be 60°, for example.
It is further contemplated that a stop face for fixing the electrode axially in the electrode holder can be provided. In particular, the cylindrical outer surface can have a peripheral groove with an O-ring disposed in it for sealing purposes.
According to some contemplated and advantageous embodiments, the cylindrical outer surface can have an external diameter which is exactly the same size as or larger than the external diameter of the external thread.
In some embodiments it is advantageous for the cylindrical inner surface to have an internal diameter that is exactly the same size as or larger than the internal diameter of the internal thread, such that D6.4=(D6.4a−D6.4i)/2.
In some contemplated embodiment it is advantageous for the cylindrical outer surface of the electrode and the cylindrical inner surface of the electrode holder to have narrow tolerances relative to one another. It is customary here to use a so-called transition fit, meaning, for example, an outer tolerance: 0 to −0.01 mm, and an inner tolerance: 0 to +0.01 mm.
The invention recognizes the surprising finding that thickening causes gaps between a cooling tube and an electrode to become narrower, but without reducing the cross-section in the rear region of an arc plasma torch head. In this way, a high flow speed of coolant is achieved at the front, between the cooling tube and the electrode, which improves heat transfer. Heat transfer is additionally or alternatively improved by suitably centring components of the plasma torch head.
The invention further recognizes that heat transfer between an electrode and coolant is not ideal. In this connection, pressure, flow speed, volume flow and/or pressure differential of the coolant in the flow path may not be adequate in the front region, in which the cooling tube projects beyond the inwardly extending region of the electrode. In addition, the problem has been recognised that an annular gap between the electrode and cooling tube may differ in size on its circumference if not centrally positioned. This results in an uneven distribution of coolant around the inwardly extending region of the electrode, impairing further cooling.
Further features and advantages of the invention will become clear from the enclosed claims the following description, in which several embodiments are illustrated in detail with reference to the schematic drawings, wherein:
The cooling tube 10 (see also
The plasma jet (not shown) has its point of attack on the outer surface of an electrode insert 7.8. That is where the most heat arises, which has to be dissipated in order to ensure a long service life of the electrode 7. The heat is conducted via the electrode 7 made from copper or silver to the coolant in the interior of the electrode.
In the region in which the cooling tube 10 projects beyond the inwardly extending region 7.5 of the electrode 7, the gap between the opposing surfaces of the front internal portion 10.8 of the cooling tube and the electrode region 7.5 of the electrode 7 and of the front external portion 10.10 and the inner surface 7.10 of the electrode is very small. It is in the region of 0.1 to 0.5 mm.
In addition, coolant flows in the space between the nozzle 4 and the nozzle cap 2 via a flow path WV2 (water supply line 2) and WR2 (water return line 2).
As is also illustrated in
The external diameter D10.3 of the cylindrical outer surface 10.3 of the cooling tube 10 is at least the same size as or larger than the external diameter D10.1 of the external thread 10.1. The internal diameter D6.3 of the cylindrical inner surface 6.3 of the electrode holder 6 is larger than the minimum internal diameter D6.1 of the internal thread 6.1, where D6.1=(D6.1a−D6.1i)/2.
The centring described above ensures the parallel alignment of the cooling tube 10 to the axis M of the plasma torch head 1, a uniform annular gap between the cooling tube 10 and the electrode region 7.5 and thus a uniform distribution of the coolant flow in the electrode interior, especially in the region of the front portion 10.8 of the cooling tube 20 and of the inwardly extending electrode region 7.5. When screwed in tightly, the stop faces 10.2 and 6.2 rest on one another. This causes the cooling tube 10 to be fixed axially in the electrode holder 6.
As is also illustrated in
The external diameter D7.6 of the cylindrical outer surface 7.6 of the electrode 7 is at least the same size as or larger than the maximum external diameter D7.4 of the external thread 7.4 (see
The centring described above is necessary for the parallel alignment of the electrode 6 to the axis M of the plasma torch head 1, which in turn ensures a uniform distribution of the coolant flow in the electrode interior, especially in the region of the front internal portion 10.8 of the cooling tube 10 and of the inwardly extending region 7.5 of the electrode 7. The purpose of centring the electrode 7 relative to the electrode holder 6 is to secure the centricity relative to the other components of the plasma torch head, especially the nozzle 4. The latter serves to form a uniform plasma jet, which is partly determined by the positioning of the electrode insert 7.8 of the electrode 7 relative to the nozzle bore 4.1 of the nozzle 4. In addition, the cylindrical outer surface 7.6 has a groove 7.3 with an O-ring 7.2 disposed in it for sealing purposes. When screwed in tightly, the stop faces 7.7 and 6.7 rest on one another. This causes the electrode 7 to be fixed axially in the electrode holder 6.
A further improvement in the radial centring of the cooling tube 10 relative to the electrode holder 6 is obtained by means of a group of projections 10.6 and a group of projections 10.7, which are located on the outer surface of the cooling tube 10. The projections fix the distance from the inner surface of the electrode holder 6. In this embodiment, there are three projections 10.6 and 10.7 per group distributed offset by 120° on the periphery of the outer surface of the cooling tube and also with an offset L10a in the longitudinal direction of the cooling tube 1 relative to one another (see
The centring between the cooling tube 10 and the electrode holder 6 is likewise achieved by means of a cylindrical inner surface 6.3 and a cylindrical outer surface 10.3. These are, however, arranged differently from what is shown in
Centring between the cooling tube 10 and the electrode holder 6 is achieved as in
The features of the invention disclosed in the present description, in the drawings and in the claims can be essential to implementing the invention in its various embodiments both individually and in any combinations. It is contemplated that several modifications can be made to the embodiments described herein within the spirit and scope of the invention without departing from the anticipated scope of the claims.
Number | Date | Country | Kind |
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10 2009 016 932 | Apr 2009 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/DE2010/000325 | 3/24/2010 | WO | 00 | 2/9/2012 |
Publishing Document | Publishing Date | Country | Kind |
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WO2010/115397 | 10/14/2010 | WO | A |
Number | Name | Date | Kind |
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3408518 | Strupczewski | Oct 1968 | A |
4625094 | Marhic et al. | Nov 1986 | A |
4954688 | Winterfeldt | Sep 1990 | A |
5278387 | Borne | Jan 1994 | A |
6147318 | Marhic | Nov 2000 | A |
6252194 | Marhic | Jun 2001 | B1 |
7019255 | Brandt et al. | Mar 2006 | B2 |
20060049150 | Severance, Jr. | Mar 2006 | A1 |
Number | Date | Country |
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87361 | Jan 1972 | DE |
2544402 | Apr 1976 | DE |
3840485 | Jun 1990 | DE |
4018423 | Dec 1991 | DE |
698 02 062 | Jun 2002 | DE |
202004021644 | Sep 2009 | DE |
WO 9010366 | Sep 1990 | WO |
WO 02098190 | Dec 2002 | WO |
WO 2008067285 | Jun 2008 | WO |
WO 2010115397 | Oct 2010 | WO |
Entry |
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International Search Report—PCT/WO 2010/115397 A3. |
Number | Date | Country | |
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20120132626 A1 | May 2012 | US |