Cathode head and new plasma generator

Abstract

A cathode head and a new plasma generator are provided. [Solution] The cathode head (1) includes a base (11) and a reflector. The reflector has a rotating structure, with the surface of the reflector that interfaces with the base designated as a first surface (121), and the end surface of the reflector opposite the base designated as a second surface (122). The cross-sectional path from the first surface to the second surface forms a gradually narrowing circle. By simplifying the cathode head structure, the cathode head is made smaller and lighter, improving maintainability. Furthermore, the reflector optimizes the electric field distribution, enabling stable arc formation under different output conditions and reducing arc oscillation and arc interruption. At the same time, precise control of the cathode head's threads ensures a reliable threaded connection between the cathode head and the conduit, preventing gap variations due to thread length errors during manual adjustment. This significantly improves the adjustment tolerance of the anode-cathode gap and reduces the difficulty and workload of generator maintenance.

Description

[Technical Field]

[0001] The present invention relates to the technical field of plasma generators, and more particularly to cathode heads and new plasma generators. [Background technology]

[0002] Plasma generators play an extremely important role in the industrial field, particularly in boiler ignition systems at thermal power plants, as highly efficient ignition and combustion auxiliary devices. The basic principle is to ionize gas using a high-temperature arc formed between electrodes, generating plasma with high conductivity and high-temperature properties, thereby achieving ignition function.

[0003] The increased size of the cathode head in conventional plasma generators increases the overall device structure and weight, driving up manufacturing costs and hindering the widespread adoption and widespread use of plasma generators. Furthermore, material and structural limitations can impede arc formation and maintenance during high-power operation due to factors such as uneven electric field distribution and uneven electrode wear, leading to arc instability and arc interruption. This results in reduced ignition reliability, accelerated electrode wear, a shorter service life, increased maintenance frequency, and increased costs. Furthermore, installation or replacement requires repeated adjustment of the connecting screw engagement, a time-consuming and tedious process that requires highly skilled personnel. This increases the risk of equipment damage due to improper operation, resulting in increased maintenance costs and extended downtime.

[0004] Based on the above problems, a cathode head and a new type of plasma generator are proposed. Summary of the Invention

[0005] Therefore, the technical problem to be solved by this invention is to extend the service life of the cathode, ensure stable arc generation, and prevent uneven electrode wear, arc oscillation, and even arc interruption during high-power operation.

[0006] The above technical problem is solved by the following technical solution: the cathode head includes a base and a reflector, the reflector has a rotating structure, the surface of the reflector that joins with the base is a first surface, the end surface of the reflector opposite to the base is a second surface, and the cross-sectional path from the first surface to the second surface presents a gradually narrowing circle.

[0007] In a preferred embodiment of the cathode head of the present invention, an inclined surface is provided between the first surface and the second surface, and the angle A formed between the flat surface at one end of the base close to the reflecting portion and the inclined surface is 120°.

[0008] In a preferred embodiment of the cathode head according to the present invention, the outer wall of the second surface is formed with a silver ion plating layer.

[0009] In a preferred embodiment of the cathode head according to the present invention, the cathode head further comprises a connecting member provided at an end of the base opposite to the reflecting portion.

[0010] In a preferred embodiment of the cathode head of the present invention, the connecting member comprises a fixed block mounted on the outer wall of the base, the fixed block having a groove formed on the outer wall thereof, and an O-ring mounted inside the groove.

[0011] In a preferred embodiment of the cathode head according to the present invention, the fixed block is provided with a threaded block at one end opposite to the base.

[0012] In a preferred embodiment of the cathode head according to the present invention, the base has a cylindrical structure, and the outer wall of the base has a plurality of circular holes.

[0013] The present invention further provides a new type of plasma generator including an ignition assembly, the ignition assembly including a generation chamber, a sleeve disposed inside the generation chamber and extending to the outside, and an anode head disposed on the outer wall of the sleeve.

[0014] In a preferred embodiment of the novel plasma generator according to the present invention, the sleeve has a seat inside, the seat has an outer wall with a conduit, and the conduit is threadedly connected to the cathode head.

[0015] In a preferred embodiment of the novel plasma generator of the present invention, the anode head is connected to the sleeve via a bolt, and the gap between the anode head and the cathode head is controlled to be 0.9mm to 1mm.

[0016] The beneficial effects of this invention are as follows: By simplifying the cathode head structure, the cathode head can be made smaller and lighter, improving maintainability. Furthermore, the provision of a reflector optimizes the electric field distribution, enabling stable arc formation under different output conditions and reducing arc oscillation and arc interruption. At the same time, precise control of the cathode head threads ensures a reliable threaded connection between the cathode head and the conduit, preventing gap variations due to thread length errors during manual adjustment. This significantly improves the anode-cathode gap adjustment tolerance and reduces the difficulty and workload of generator maintenance. [Brief explanation of the drawings]

[0017] In order to more clearly explain the technical solutions in the embodiments of the present invention, the following briefly introduces drawings related to the embodiments of the present invention. Obviously, the drawings used in the following description only relate to some embodiments of the present invention and are not intended to limit the present invention. In the drawings, [Figure 1] FIG. 2 is an axonometric view showing the connection structure of the cathode head. [Figure 2] FIG. 2 is a side view showing the cathode head. [Figure 3] FIG. 2 is a schematic diagram showing a connection structure of an ignition assembly. [Figure 4] FIG. 2 is a cross-sectional view showing the internal structure of the ignition assembly. DETAILED DESCRIPTION OF THE INVENTION

[0018] In order to enable those skilled in the art to better understand the present invention, the following will describe the present invention in more detail in combination with specific embodiments and drawings.

[0019] The terms used in this invention are general terms currently widely used in the art, taking into consideration the function of the invention. However, these terms may be changed according to the intentions of those skilled in the art, prior art, or the development of new technology in the art. Furthermore, specific terms may be selected by the applicant, and in this case, their detailed meanings will be described in the detailed description of the invention. Therefore, the terms used in this specification should not be understood as simple names, but should be understood based on the meaning of the terms and the overall description of the invention.

[0020] 1 and 2, this embodiment provides a cathode head, the cathode head 1 including a base 11 and a reflector 12, the base 11 and the reflector 12 being fixedly connected by welding, and the cathode head 1 having a hollow structure inside, which reduces the amount of material used, reduces the weight of the cathode head 1, and facilitates installation and maintenance. Furthermore, the hollow structure increases the heat dissipation area, thereby contributing to improved heat dissipation efficiency and effectively suppressing the temperature of the cathode head, especially during high-power operation.

[0021] The reflector 12 has a rotating structure and is shaped like a truncated cone. The truncated cone is hollow, which increases the contact area between the cathode head and the anode, expanding the arc formation area and improving arc stability. A more stable arc enhances the reliability of the plasma generator's ignition process and reduces ignition failures caused by arc fluctuations or arc interruptions. The surface of the reflector 12 that interfaces with the base 11 is called the first surface 121, and the reflector 12 and base 11 form a fixed connection. The end surface of the reflector 12 opposite the base 11 is called the second surface 122. The second surface 122 is the tip of the reflector 12 and is the key area for arc formation. This allows the electric field intensity to be concentrated in this area, more easily inducing the ionization process and forming high-temperature plasma. The cross-sectional path from the first surface 121 to the second surface 122 is a gradually shrinking circle, which allows the arc to be stably formed even under different power conditions and reduces arc fluctuations and arc interruption phenomena.

[0022] In one alternative embodiment, an inclined surface 123 is provided between the first surface 121 and the second surface 122, which allows the arc to be distributed evenly around the tip of the cathode head, preventing local overheating and rapid material consumption, and extending the service life of the cathode head. Furthermore, the design of the inclined surface 123 increases the contact area between the cathode head and the anode, expanding the area where the arc is formed and improving the stability of the arc.

[0023] As shown in Figure 2, the angle A between the flat surface at one end of base 11 closest to reflector 12 and inclined surface 123 is 120°. The 120° angle design allows the arc to form more easily at the tip, reducing the energy required to start the arc and improving the success rate of arc initiation. Furthermore, a more stable arc improves the reliability of the plasma generator's ignition process and reduces ignition failures caused by arc fluctuations and arc interruptions, thereby improving the performance and reliability of the overall device.

[0024] As an alternative embodiment, since the silver ion plating layer has extremely high conductivity, applying a silver ion plating layer to the outer wall of the second surface 122 can significantly reduce the resistance of the cathode head 1, reduce energy loss during the arc formation process, and improve power conversion efficiency. Furthermore, the oxidation and corrosion resistance of the silver ion plating layer can protect the surface of the cathode head 1 even in high temperature and strong electric field environments, improving the performance and reliability of the plasma generator and extending the service life of the cathode head 1.

[0025] In one alternative embodiment, the base 11 has a hollow cylindrical structure, and a plurality of circular holes 111 are provided on its outer wall. The circular holes 111 do not penetrate the outer wall of the base 11, and preferably there are four of them, which are uniformly distributed on the side wall of the base 11. The design of the circular holes 111 increases the surface area of ​​the base 11, which contributes to improving heat dissipation efficiency. When the plasma generator operates at high power, the circular holes 111 can effectively reduce the temperature of the base 11.

[0026] As one optional embodiment, the cathode head 1 further includes a connecting member 13 provided at one end of the base 11 opposite the reflecting portion 12, the base 11 and the connecting member 13 forming a fixed connecting structure, and the connecting member 13 is used to attach the cathode head 1.

[0027] In one alternative embodiment, the connecting member 13 comprises a fixing block 131 provided on the outer wall of the base 11, the interior of the fixing block 131 being hollow, and the fixing block 131 being fixedly installed on the outer wall of the base 11 opposite the reflecting part 12 by welding, a groove 132 being opened on the outer wall of the fixing block 131, and an O-ring 133 being provided inside the groove 132, the sealing property of the O-ring 133 preventing leakage of cooling water, compressed air or other media and ensuring the sealing property and reliability of the device.

[0028] In one possible embodiment, a threaded block 134 is provided on one end of the fixed block 131 opposite the base 11, and the thread amount of the threaded block 134 is precisely controlled during the manufacturing process, thereby ensuring that the gap between the cathode head 1 and the anode head 23 automatically meets the design requirement of 0.9 mm to 1 mm, improving installation accuracy and reliability. The threaded block 134 has a hollow cylindrical structure, and one end of it is fixedly connected to the fixed block 131 by welding.

[0029] Referring to Figures 1 to 4, this embodiment provides a new plasma generator equipped with an ignition assembly 2. The ignition assembly 2 includes a generation chamber 21, which is equipped with a cooling water system, an electrical assembly, and an air system. The cooling water system dynamically adjusts the flow rate and pressure of the cooling water in response to fluctuations in the power of the plasma generator, thereby maintaining an optimal operating temperature under different power conditions. The electrical assembly rectifies AC power to DC power via a three-phase full-wave controlled bridge thyristor rectifier circuit, and adjusts the output power using a large-capacity DC speed regulator and a control PLC, ensuring that the plasma generator operates within the desired power range. The air system uses stable, clean, and dry air as the plasma carrier and supplies instrument compressed air as the carrier gas for the plasma generator. When the plasma generator is shut down, it automatically switches to fire detection cooling air and supplies purge gas. This signal is sent to the DCS (since the control of the cooling water system, electrical assembly, and air system is based on existing mature technology, it will not be described in further detail in this application).

[0030] It also comprises a sleeve 22 that is provided inside the generating chamber 21 and extends to the outside, and an anode head 23 that is provided on the outer wall of the sleeve 22, and the sleeve 22 functions as a support structure, being fixed inside the generating chamber 21 and extending to the outside, providing a stable mounting position for the anode head 23.

[0031] As shown in FIG. 3, in one alternative embodiment, a base 221 is provided inside the sleeve 22, and a conduit 222 is provided on the outer wall of the base 221. The base 221 and the conduit 222 are fixedly connected, and the conduit 222 is threadedly connected to the cathode head 1 to ensure secure attachment of the cathode head. A threaded hole is provided inside the conduit 222 to engage with the screw block 134, and the thread depth of the screw block 134 and the screw hole is precisely controlled during manufacturing, thereby reliably controlling the gap between the anode head 23 and the cathode head 1 to 0.9 mm to 1 mm, eliminating the need for repeated adjustments. The conduit 222 not only enables the attachment and fixation of the cathode head 1, but also functions as an arc conduction.

[0032] In one alternative embodiment, the anode head 23 is connected to the sleeve 22 via a bolt, allowing for easy and quick installation and disassembly of the anode head 23 without the need for complex tools or operations. The gap between the anode head 23 and the cathode head 1 is controlled to 0.9 mm to 1 mm, and this precise gap ensures that the arc is formed under optimal conditions and burns stably, contributing to a reduction in the arc starting voltage, making it easier to ignite the arc, and suppressing arc fluctuations and arc interruption.

[0033] During installation, the screw block 134 simply needs to be tightened directly onto the conduit 22, and since the spacing is already precisely controlled during the manufacturing process, there is no need to adjust the thread length. This avoids the tedious task of repeatedly adjusting the thread length required in conventional installation processes, and also reduces the requirements for the skill level of the installation worker and the risk of damage to the device due to operating errors.

[0034] Finally, it should be pointed out that the methods and apparatus described in detail above are merely examples, and that those skilled in the art can make various modifications to these examples without departing from the scope of the present invention.

Claims

1. A cathode head (1) comprising a base (11) and a reflector (12); The cathode head is characterized in that the reflecting portion (12) has a rotating body structure, the surface of the reflecting portion (12) that joins with the base (11) is a first surface (121), the end surface of the reflecting portion (12) opposite the base (11) is a second surface (122), and the cross-sectional path from the first surface (121) to the second surface (122) presents a gradually narrowing circle.

2. 2. The cathode head according to claim 1, wherein an inclined surface (123) is provided between the first surface (121) and the second surface (122), and the angle A formed between the flat surface at one end of the base (11) close to the reflecting portion (12) and the inclined surface (123) is 120°.

3. 3. The cathode head according to claim 2, wherein a silver ion plating layer is formed on the outer wall of the second surface (122).

4. 4. The cathode head according to claim 3, further comprising a connecting member (13) provided at one end of the base (11) opposite to the reflecting portion (12).

5. The cathode head of claim 4, characterized in that the connecting member (13) comprises a fixed block (131) provided on the outer wall of the base (11), a groove (132) is provided on the outer wall of the fixed block (131), and an O-ring (133) is provided inside the groove (132).

6. 6. A cathode head according to claim 5, characterized in that the fixed block (131) is provided with a threaded block (134) at one end opposite to the base (11).

7. 7. The cathode head according to claim 6, wherein the base (11) has a cylindrical structure, and the outer wall of the base (11) is provided with a plurality of circular holes (111).

8. A cathode head according to claim 7, The new plasma generator further comprises an ignition assembly (2), the ignition assembly (2) comprising a generation chamber (21), a sleeve (22) disposed inside the generation chamber (21) and extending to the outside, and an anode head (23) disposed on the outer wall of the sleeve (22).

9. 9. The novel plasma generator according to claim 8, characterized in that a seat (221) is provided inside the sleeve (22), a conduit (222) is provided on the outer wall of the seat (221), and the conduit (222) is screw-connected to the cathode head (1).

10. The new plasma generator according to claim 9, characterized in that the anode head (23) is connected to the sleeve (22) via a bolt, and the gap between the anode head (23) and the cathode head (1) is controlled to be 0.9 mm to 1 mm.

Images