Bevel Head Apparatus for Plasma Torch Tilt Control
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Solution Overview
Problem
Conventional plate cutting machines using plasma torches for weld preparation are expensive, inaccurate, and difficult to program, with issues such as cable twisting, limited torch tilt angles, and excessive material waste, leading to increased costs and labor in manual or semi-manual processes.
Innovation Solution
A bevel head apparatus with independent XY and AC axes, allowing for synchronous movement and tilt up to 60 degrees, featuring a drive box with integrated motors and a pantograph mechanism for precise control of the cutting torch, reducing the need for separate amplifiers and cables, and utilizing a laser for height control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional plasma torches are used for weld preparation, then cutting capability is maintained, but torch tilt angle is limited and cable twisting occurs
Solution Approach 1:
The patent introduces a pantograph mechanism that adds a second rotational dimension to the torch holder assembly. The primary arm rotates about a first axis while the pantograph rotates about a second axis that is perpendicular to the first axis, enabling the torch to achieve tilt angles up to 60 degrees without cable twisting by changing the dimensional space in which the torch operates.
2Ease of operation
If separate amplifiers and cables are used for each motor, then motor control is achieved, but device complexity and cost increase
Solution Approach 1:
The patent integrates multiple motor control functions into a single amplifier unit. The controller is coupled to a single amplifier that simultaneously controls the first motor driving the primary arm and the second motor driving the pantograph, eliminating the need for separate amplifiers and cables for each motor, thereby reducing device complexity and cost.
3Manufacturing precision
If conventional cutting machines are used, then cutting function is provided, but weld preparation accuracy and efficiency are insufficient
Solution Approach 1:
The patent transforms a conventional single-function cutting machine into a multi-functional system by adding the bevel head apparatus with dual-axis rotation capability. This enables the machine to perform both cutting operations and precise weld preparation operations with varying bevel angles, thereby improving both accuracy and efficiency of weld preparation without requiring separate equipment.
4Manufacturing precision
If manual or semi-manual grinding is used for weld preparation, then weld faces are created, but labor cost and processing time increase
Solution Approach 1:
The patent replaces manual or semi-manual mechanical grinding operations with an automated plasma torch system controlled by a controller. The controller coordinates the motion of the gantry, torch lifter, and bevel head apparatus to automatically create precise weld faces, eliminating the need for manual grinding and significantly reducing both labor cost and processing time while maintaining or improving weld face quality.
Data Source
AI summary
A bevel head apparatus includes tilt, rotation, and vertical positioning with a cutting torch of a numerically controlled plate cutting machine. The apparatus has a back panel that attaches to the cutting machine and provides vertical movement of the cutting torch, a drive box coupled with the back panel houses electronics and mechanical components, an arm coupled to the drive box provides rotational movement of the cutting torch, and a pantograph coupled with the arm provides tilt movement to the cutting torch attached to the pantograph. Tilt, rotation, and vertical positioning of the cutting torch is controlled by the electronics and mechanical components. The bevel head apparatus also include a laser for measuring distance to determine and control a height of the cutting torch above the flat plate.