Angled Plasma Nozzle for Flush Bevel Cutting
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Solution Overview
Problem
Conventional plasma arc torches face difficulties in performing flush cuts near internal corners and bevel cuts, requiring secondary operations and lacking reproducibility, due to their axial configuration and lack of positioning mechanisms.
Innovation Solution
A consumable set for plasma arc torches featuring a nozzle with a non-zero angled exit orifice and alignment surfaces that allow the plasma arc to impinge orthogonally on the workpiece, enabling flush and bevel cuts while maintaining the torch perpendicular to the surface, and optionally using templates for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional axial plasma arc torch is used, then the torch structure is simple and easy to operate, but the torch cannot make flush cuts near internal corners and requires secondary operations
Solution Approach 1:
The patent applies asymmetry by positioning the plasma arc exit at an offset location rather than at the axial center of the torch. This asymmetric configuration allows the plasma arc to impinge on the workpiece at an angle, enabling flush cuts near internal corners while maintaining a simple torch structure without requiring complex positioning mechanisms
2Adaptability or versatility
If the plasma arc torch is tilted to achieve bevel cuts, then bevel cutting capability is obtained, but the operator skill requirement increases and cut consistency decreases
Solution Approach 1:
Instead of tilting the entire torch to achieve bevel cuts, the patent inverts the approach by keeping the torch body vertical and offsetting the plasma arc exit position. This allows the plasma arc to strike the workpiece at the desired bevel angle while the torch remains in a stable, easy-to-control vertical position, ensuring consistent cut angles without requiring operator skill for angle maintenance
3Manufacturing precision
If the plasma arc torch is positioned close to workpiece corners, then flush cut quality improves, but the risk of damaging the base increases
Solution Approach 1:
The patent applies local quality by concentrating the cutting function at the offset plasma arc exit position while keeping the torch body structure separate. This allows the plasma arc to be precisely positioned for flush cuts near corners without requiring the entire torch to be in a vulnerable position, reducing the risk of base damage while maintaining cut quality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables consistent, high-quality bevel cuts over distances without requiring skilled operators or costly accessories, reducing the need for secondary refinement and ensuring reproducibility of cuts.
Implementation Method 1
the torch produces a plasma arc, which is a constricted jet of an ionized gas with high temperature and sufficient momentum to assist with removal of molten metal
Implementation Method 2
a constricted jet of an ionized gas with high temperature
Data Source
AI summary
A consumable set is provided that is usable in a plasma arc torch to direct a plasma arc to a processing surface of a workpiece. The consumable set comprises a nozzle and an alignment surface. The nozzle includes: 1) a nozzle body defining a longitudinal axis extending therethrough, and 2) a nozzle exit orifice disposed in the nozzle body for constricting the plasma arc. The nozzle exit orifice defines an exit orifice axis oriented at a non-zero bevel angle relative to the longitudinal axis. The alignment surface is generally parallel to the longitudinal axis and substantially planar. The alignment surface is dimensioned to orient the nozzle exit orifice such that the plasma arc impinges on the processing surface of the workpiece at the bevel angle while the plasma arc torch is substantially perpendicular to the processing surface.