The use of high velocity, liquid jets and abrasive-laden liquid jets to precisely cut a variety of materials is well known. Briefly, a high velocity liquid jet is first formed by compressing the liquid (typically water) to an operating pressure of 50,000-90,000 psi or more), and forcing the compressed liquid through an orifice having a diameter approximating that of a human hair; namely, 0.003 to 0.040 inches. The material defining the jet-forming orifice is typically a hard jewel such sapphire, ruby or diamond.
The resulting highly coherent waterjet is discharged from the orifice against a workpiece via a generally tubular cutting nozzle at a velocity which approaches or exceeds the speed of sound. Those skilled in the art will recognize, however, that numerous other liquids can be used without departing from the scope of the invention, and the recitation of the jet as comprising water should not be interpreted as a limitation. Accordingly, the term “waterjet” and “water” as used herein shall include any liquid suitable for cutting a workpiece in the manner described herein.
To enhance the cutting power of the waterjet, abrasive materials have been added to the jet stream to produce an abrasive-laden waterjet, typically called an “abrasivejet”. The abrasivejet is used to effectively cut a wide variety of materials from exceptionally hard materials (such as tool steel, aluminum, cast iron armor plate, certain ceramics and bullet-proof glass) to soft materials (such as lead). Typical abrasive materials include garnet, silica, and aluminum oxide having grit sizes of #36 through #200.
To produce the abrasivejet, the waterjet passes through a “mixing region” wherein a quantity of abrasive is enhanced with kinetic energy from the high speed waterjet, thus enabling abrasive removal of most materials through abrasion. The abrasive material, which is under atmospheric pressure in an external hopper, is drawn into the mixing region by the lower pressure region via a conduit (referred to as the “abrasive feed tube”) that communicates at one end with the interior of the hopper, and at the other end with the mixing region via an abrasive inlet hole formed in the cutting head housing that houses the jet-forming orifice jewel and mixing region.
The resulting abrasive-laden waterjet (or “abrasivejet”) is then discharged against a workpiece through an abrasivejet nozzle that is supported closely adjacent the workpiece. The spent abrasive-laden water is drained away from the workpiece in any of a number of known ways, and collected in a collection tank for recycling of the abrasive and/or proper disposal.
As used hereinafter in this specification and in the claims, and as recognized by those of ordinary skill in the art, the term “waterjet cutting systems” includes abrasivejet cutting systems, the term “waterjet” includes “abrasivejet” within its scope when referring to the jet that is discharged towards the workpiece, and the term “cutting head” refers to a unit comprising a housing that has a high pressure water inlet (and an abrasive inlet if an abrasivejet cutting head), and encloses the orifice member, a mixing region if an abrasivejet cutting head, fluid paths therebetween and required seals in the positions and spatial relationships needed for efficient cutting. The cutting head may also include an on/off actuator that controls the flow of water within the cutting head. As also known to those of ordinary skill the art, The cutting head directs the waterjet/abrasivejet to the workpiece through a discharge nozzle.
To appropriately and precisely position the cutting head with respect to a workpiece, a growing number of waterjet cutting system applications provide translation and/or rotation of the cutting head nozzle (usually referred to as the “cutting tool” or simply the “nozzle”) along and about a plurality of axes to so that the workpiece can be approached from multiple directions.
Those of ordinary skill in the art recognize that the commonly used axes are the “X”, “Y”, “Z”, “A”, “B” and “C” axes. The first three are linear axes; i.e., the cutting head and nozzle are moved linearly in the directions of the X, Y and Z axes. The X and Y axes may correspond, for example, to the length and width of a cutting table underlying the cutting nozzle, while the Z axis corresponds to the height of the cutting nozzle above the cutting table. The A, B, and C axes are axis of rotation; i.e., the cutting head and nozzle rotate about the A, B and C axes. By convention, the C axis is parallel to the Z axis and perpendicular to the X-Y plane. The A axis is perpendicular to the C axis, with its centerline parallel to the X-axis when the C-axis position is zero. The B axis is also perpendicular to the C axis, with its centerline passing through the centerline of the C axis, but orthogonal to the A-axis; in other words, the A axis is parallel to the X-axis, and the B-axis is parallel to the Y-axis when the C-axis position is zero.
This specification will discuss the invention in terms of these standard and commonly used nomenclatures; however, it should be recognized that the invention is not limited by the use of this nomenclature, and that other axes and axis relationships can be used without departing from the scope of the invention.
Existing waterjet cutting systems employ swivels and coils to supply the high pressure cutting liquid to the nozzle. The mechanisms utilized to accommodate the rotational axes of movement have been bulky, and have restricted the positioning of the nozzle vis-à-vis the workpiece, thus limiting the application of waterjet cutting, particularly where multiple axes of rotation are employed. The use of coils that allow movement about these axes is expensive and poses a possible safety hazard due to the common fatigue failure of the coils which, as previously described, are the conduits for up to 50,000 psi or more of pressurized water. In addition, such coils reduce clearance around the cutting head of the system, limiting the orientation of the cutting tool around the workpiece at times.
Swivels are safer but, to limit the size which can add to the bulky size of the mechanism, most manufactures use small ¼-inch high pressure swivels, which have a short mean time between failure as compared to the larger ⅜-inch high-pressure swivels.
A waterjet cutting system constructed in accordance with the invention herein eliminates high-pressure tubing coils in the area adjacent the waterjet system's cutting head and isolates critical system components from the backsplash of the cutting process. Preferably, a high-pressure swivel is combined with an on/off valve arrangement in such a way that these components are closely adjacent the cutting head but substantially shielded from waterjet back-splash, minimizing the mechanism's size while increasing waterjet back-splash safety and mean time before failure. The cutting head and the swivel/valve combination are rotated about the cutting head's final axis of rotation (described below) by a drive mechanism substantially shielded by structure associated with a prior axis of rotation . . . preferably, the cutting head's prior axis of rotation.
As used in this specification, the term “final axis of rotation” refers to the axis of rotation about which the cutting head is rotated without such rotation moving the position of another rotational axis. As used in this specification, a “prior axis rotation” refers to the axis of rotation about which the cutting head is rotated prior to its rotation about its final axis of rotation. Where the cutting head has both “A” and “B” axes of rotation, the “final axis of rotation” is whichever of the two is moved last.
By eliminating high pressure tubing coils, and thereby reducing the clearance needed to manipulate the cutting head around the workpiece, the preferred system constructed in accordance with the invention also simplifies the kinematics of the multi-axis system, making it easier to be programmed for accurate CNC control while protecting critical components from back-splash to thereby increase mean time to failure.
The five exemplary axes employed by the illustrated cutting system are the “X”, “Y”, “Z”, “A” and “C” axes. The illustrated combination in
As illustrated in
As will be apparent, rotation about the C-axis is not limited by a high pressure water conduit. In
As the C-axis structure rotates, thereby rotating the cutting head, the internal conduit 72 (
As illustrated in
As described below, the preferred A-axis swivel 18 is preferably included within a common housing 23 with a high pressure on/off valve 22. The high pressure valve/swivel combination within the common housing 23 results in the use of larger swivel within less space, permitting use of the relatively larger long-life swivel components without impinging on the positioning constraints that would be imposed by such swivels if used in known 5-axis waterjet cutting systems. This allows for long periods of operation without failure, readily available components and safety without the need of high pressure coils.
Thus, the preferred configuration provides:
The on/off valve 22 within the common housing is preferably a needle valve actuated by the on/off actuator 30. The preferred actuator comprises a pneumatically responsive needle (not shown) that selectively blocks fluid communication between the on/off valve's inlet 35 and the valve's outlet 36 in response to a signal from a CNC or other control unit or switch, to activate and deactivate the waterjet/abrasivejet.
The internal passage of the extension tube 28 conducts high pressure water from the on/off valve outlet 36 to the cutting head 26 for discharge as a waterjet or abrasivejet at the downstream end of the cutting nozzle 10. Accordingly, the entire path taken by the high-pressure water exiting from the conduit 72 is internal to the common housing 23, extension tube 28 and cutting head 26 and, therefore, within the portion of the cutting system that rotates about the A-axis (as further described below).
The common housing 23 is preferably supported by the Z-axis carriage structure for movement along the Z-axis in such a way that the actuator 30, extension tube 28 and cutting head 26 are also supported by the carriage structure for movement along the Z-axis. The preferred structure by which this support is provided is schematically illustrated in
In accordance with the preferred embodiment of the invention, the system's A-axis drive 14 is housed within the C-axis structure 16, as illustrated in
In accordance with the invention, the A-drive mechanism is substantially enclosed within the C-axis structure and thereby substantially shielded from back-splash from the waterjet cutting process.
The alternative drive mechanism schematically illustrated in
In
As described earlier, the common housing 23 is preferably supported by the Z-axis carriage structure for movement along the Z-axis in such a way that the actuator 30, extension tube 28 and cutting head 26 are also supported by the carriage structure for movement along the Z-axis. More precisely, and as further described above, the common housing, actuator, extension tube and cutting head affixed to the C-axis structure which, in turn, is supported by the Z-axis carriage. The common housing 23 is preferably supported by the strut arm 38 of the C-axis structure 16 (
While the foregoing embodiment is, for the reasons stated above, a 5-axis configuration, those skilled in the art will recognize that the invention herein is not so limited and may be applied to any number of axis having any number of orientations and relationships. Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention, which is defined by the appended claims.
Number | Date | Country | |
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62234423 | Sep 2015 | US |