Devices, systems, and methods consistent with the invention relate to cutting, and more specifically to devices, systems and methods for aligning and securing components of a plasma arc torch.
In many cutting, spraying and welding operations, plasma arc torches are utilized. With these torches, a plasma gas jet is emitted into the ambient atmosphere at a high temperature. The jets are emitted from a nozzle and, as they leave the nozzle, the jets are highly under-expanded and very focused. However, as the jet leaves the nozzle it begins to expand rapidly. This expansion can greatly reduce the efficiency of the nozzle as the jet energy is lost in the jet expansion, and thus there is a loss of jet thrust and focus. In applications, such as cutting and welding, this expansion can diminish the quality and process speeds, especially in cutting operations. Further, the shape of the nozzle throat can cause arc instability, which further diminishes performance. Therefore, improved nozzle performance is desirable.
Further limitations and disadvantages of conventional, traditional, and proposed approaches will become apparent to one of skill in the art, through comparison of such approaches with embodiments of the present invention as set forth in the remainder of the present application with reference to the drawings.
An exemplary embodiment of the present invention is a plasma torch nozzle and torch utilizing the nozzle, where the nozzle has a configuration which stabilizes and optimizes the plasma arc for improved performance.
In an exemplary embodiment of the invention, a nozzle assembly includes an upper portion defining an opening for receiving a gas and a longitudinally extending cylindrical body portion adjacent to the upper portion and defining a passageway for the gas. The nozzle assembly also includes a tip portion adjacent to the body portion, with the tip portion defining a throat channel. The throat channel includes a throat inlet region that focuses a flow of the gas. The throat inlet region is fluidly connected to the passageway via a throat inlet opening. The throat channel also includes an acceleration region that is disposed downstream of the throat inlet region and fluidly connected to the throat inlet region to compress the gas and accelerate the flow of the gas. The throat channel further includes an expansion region disposed downstream of the acceleration region and fluidly connected to the acceleration region to allow the gas to expand. The expansion region includes a throat outlet opening through which the gas exits the nozzle assembly.
In another exemplary embodiment a torch assembly used in cutting, spraying and/or welding operations includes an electrode and a swirl ring for receiving a gas. The torch assembly also includes a nozzle. The nozzle includes an upper portion defining an opening for receiving a portion of the electrode and a portion of the swirl ring such that an annular channel is formed to receive the gas. The nozzle also includes a longitudinally extending cylindrical body portion adjacent to the upper portion that extends the annular channel for the gas and a tip portion adjacent to the body portion that defines a throat channel. The throat channel includes a throat inlet region to focus a flow of the gas, the throat inlet region being fluidly connected to the passageway via a throat inlet opening. The throat channel also includes an acceleration region disposed downstream of the throat inlet region and fluidly connected to the throat inlet region to compress the gas and accelerate the flow of the gas. The throat channel further includes an expansion region disposed downstream of the acceleration region and fluidly connected to the acceleration region to allow the gas to expand. The expansion region includes a throat outlet opening through which the gas exits the nozzle assembly.
The above and/or other aspects of the invention will be more apparent by describing in detail exemplary embodiments of the invention with reference to the accompanying drawings, in which:
Reference will now be made in detail to various and alternative exemplary embodiments and to the accompanying drawings, with like numerals representing substantially identical structural elements. Each example is provided by way of explanation, and not as a limitation. In fact, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the scope or spirit of the disclosure and claims. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure includes modifications and variations as come within the scope of the appended claims and their equivalents.
The present disclosure is generally directed to nozzle and nozzle throat configurations for a plasma arc torch that can be useful in various cutting, welding and spraying operations. It should be noted that for purposes of brevity and clarity, the following discussion will be directed to exemplary embodiments of the present invention which are primarily directed to a plasma torch for cutting. However, embodiments of the present invention are not limited in this regard and embodiments of the present invention can be used in welding and spraying torches without departing from the spirit or scope of the present invention. The application of the present invention can include use in either mechanized torch assemblies or hand-held torch assemblies. Various types and sizes of torches are possible at varying voltages if desired. Further, the torches using the disclosed nozzles could be used for marking, cutting or metal removal. Additionally, exemplary embodiments of the present invention, can be used with varying currents and varying power levels. Of course, it should also be noted that embodiments of the present invention can be used in torches which are cooled with a torch coolant. The construction and utilization of such coolant systems are known and need not be discussed in detail herein.
It should be understood that the housing 12 illustrated in
As shown in
As shown, nozzle 32 includes an upper annular seating section 46 with an annular inner opening 48 for receiving a portion of swirl ring 30 and an outer annular shoulder 49 for contacting an inner portion of retaining cap 34 (not shown in
Electrode 28 is a substantially cylindrical body. Flange 64 is provided to position electrode 28 for mounting in torch body 26 and to position the electrode relative to swirl ring 30 and nozzle 32 once all are assembled together, and threads (not shown) may be provided to assist in assembly of electrode 28 to torch body 26. A central cylindrical portion 66 of electrode 28 ends at a tapered portion 68, which faces tapered portion 58 of nozzle 32 once assembled together. A distal end face 70 of electrode 28 is located opposite outlet passage 62. A small curved portion 67 may be present between cylindrical portion 66 and tapered portion 68 as a smoothing transition, if desired.
In use, gas flows inwardly through passages 72 within swirl ring 30, down the passageway formed between cylindrical portion 56 of nozzle 32 and cylindrical portion 66 of electrode 28 and the two tapered portions 58 and 68 to and through outlet passage 62. Suitable conventional seal members (not shown) may be provided as desired between torch body 26, electrode 28, swirl ring 30, nozzle 32, retaining cap 34, and/or shield cap 36, etc. to confine gas flow to desired passageways and prevent leakage through interfaces, threaded areas, etc.
End face 70 of electrode 28 has a discontinuous surface. Tapered portion 68 includes a discontinuity, in this case an annular edge 74. In the embodiment as shown in
Nozzle tapered portion 58 may be at the same angle or a different angle than tapered portion 68 with reference to longitudinal axis 82. As shown, tapered portion 68 is at a slightly different angle than tapered portion 58, so that the space between electrode 28 and nozzle 32 decreases slightly in the distal direction (toward outlet passage 62).
A number of variations to the above elements are possible, in particular to electrode 28. In the additional embodiments below, like or similar reference numerals refer to like or similar parts.
Turning now to
In exemplary embodiments, the length of the inlet region 101 is in the range of 5 to 30% of the thickness of the nozzle 32 at the throat. The acceleration region 103 is in the range of 30 to 85% of the thickness of the nozzle 32 at the throat and the expansion region 105 is in the range of 5 to 85% of the thickness of the nozzle 32 at the throat.
With this configuration, the inlet region 101 stabilizes the plasma jet as it enters the throat 100 from the electrode 28. This aids in preventing the plasma from inadvertently contacting the side walls of the throat and helps to focus the plasma jet. As the jet enters the acceleration region 103 the jet is compressed by the side walls and the flow of the jet is accelerated. When the jet passes from the acceleration region 103 to the expansion region 105, the plasma jet is allowed to expand. However, the expansion is controlled by the sidewalls of the expansion region 105 such that as the jet leaves the outlet 106 it does not rapidly expand like when using prior known nozzles. The expansion is less drastic and thus provides a more focused and controller plasma jet. Thus, embodiments of the present result in the creation of more accurate cuts (when used in a cutting application).
Also, as shown in
In the inlet region 101, the inlet portion 111 has a tapered wall surface as shown. This surface aids in ensure that the plasma jet properly enters the throat and begins to focus the jet to the center of the throat. In exemplary embodiments, the inlet portion 111 has an angled wall surface that is angled (α1) in the range of 45 to 75 degrees, with respect to the centerline of the throat 100. Further, the length of the inlet portion 111 (along the centerline) is in the range of 10 to 60% of the length of the inlet region 101. Following the inlet portion 111 is the transition portion 113 which permits the jet to stabilize briefly after it enters throat 100. In exemplary embodiments of the present invention, the angling of the inlet portion 111 is not steeper than that of the focus portion 115 (i.e., α2 value is lower than α1 value), and thus the transition portion 113 aids in stabilizing the plasma prior to be more fully focused in the focus portion 115. In the embodiment shown, the transition portion 113 has a constant diameter along its length. However, in other exemplary embodiments, the transition portion 113 can also have an angled or an arcuate surface to allow for a transition from the inlet portion to the focus portion 115 of the inlet region 101. In exemplary embodiments, the transition portion 113 has a length in the range of 20 to 80% of the length of the inlet region 101. The focus portion 115 focuses and compresses the plasma jet before it enters the acceleration portion 103 of the throat 100. As shown, in exemplary embodiments the focus portion 115 is the longest portion of the inlet region 101 and has an angled surface. The angle (α2) of the surface is in the range of 30 to 55 degrees with respect to the centerline of the throat and typically has a shallower angle than inlet portion 111. Further, in some embodiments, the length of the focus portion 115 is in the range of 5 to 95% of the length of the inlet region 101. In some embodiments, the length of the focus portion 115 is in the range of 10 to 90% of the length of the inlet region 101. In the embodiment shown, the angle of the surface of the focus portion 115 is constant from the transition portion 113 to the transition 114. However, in other exemplary embodiments, the focus portion 115 can use at least two different angles between the transition portion 113 and the transition 114.
Also as shown in
In further exemplary embodiments, the nozzle 32 can be constructed from a plurality of components that—when coupled together—created a nozzle assembly similar in construction to the nozzle 32 described above and shown in the Figures. In such embodiments, each of the separate nozzle components include portions of the throat 100, such that when the components are assembled they formed a completed throat 100. For example, in some embodiments, the nozzle 32 can be made of three separate components, such that when they are coupled together they form the throat 100. In such an embodiment, an inner nozzle portion contains only the inlet region 101, an intermediate nozzle portion contains only the acceleration region 103, and an outer nozzle portion contains only the expansion region 105. When these separate and distinct nozzle components are assembled, they form the completed nozzle assembly (similar to 32) and have the entire throat 100. They can be assembled via any known methodology, including screwing each of the nozzle portions to each other via threads. Other connection means can also be used. When assembled there gaps between the separate components should be small so as to ensure optimum performance of the throat 100. Such embodiments allow a user to only replace a portion of the nozzle assembly that may be damaged, without having to replace the other nozzle components. Further, embodiments such as these allow a user to couple different throat geometries as needed. That is, a user can have a plurality of each of the inner, intermediate and outer nozzle portions—each having differing dimensions for their respect throat regions. With this, a user can assemble a custom nozzle assembly having an optimized throat configuration for a given cutting operation. That is, a user can create a custom nozzle and throat for a given operation. Further, in other exemplary embodiments, the nozzle 32 can be made from two separate and distinct components where one of the nozzle components contains two out of the three regions described above, while the other contains the other region. For example, a first nozzle portion contains the inlet and acceleration regions 101/103, and the other nozzle portion contains the expansion region 105. This configuration can allow a user to, again, assembly various nozzle components to achieve a customized throat 100 for a desired plasma jet configuration. Further, this can allow a user to replace only a portion of the nozzle, if only that portion was damaged.
It should be noted that in some exemplary embodiments of the present invention, the torch, nozzle and electrode are constructed such that the distance or gap between electrode and nozzle can be adjusted. This adjustment allows a user to obtain a desired plasma jet performance and configuration. For example, a screw type connection can be used to adjust the distance between these components. Thus, in use a user can adjust this distance prior to cutting.
With the embodiments described herein an optimized nozzle and throat configuration can be attained for a particular function. That is, with embodiments of the present invention, a plasma jet can be created at a desired velocity and focus for a particular operation. Because of this, performance and precision levels can be achieved that cannot be achieved by known nozzle configurations.
While the claimed subject matter of the present application has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the claimed subject matter. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the claimed subject matter without departing from its scope. Therefore, it is intended that the claimed subject matter not be limited to the particular embodiment disclosed, but that the claimed subject matter will include all embodiments falling within the scope of the appended claims.
The present application claims priority to U.S. Provisional Patent Application No. 61/943,594, which is incorporated herein by reference in its entirety.
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