Cutting Nozzle Air Mixing Reduces Oxygen Use
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Solution Overview
Problem
Postmixed oxy-fuel gas cutting torches consume high volumes of pure oxygen, leading to increased costs and inefficiencies, while existing nozzles lack a solution to maintain flame temperature and nozzle durability against heat stress.
Innovation Solution
A cutting nozzle design that incorporates air bores to mix with preheat oxygen, reducing the need for pure oxygen and enhancing flame temperature, combined with a shroud to protect against molten metal splash and improve nozzle longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If pure oxygen is discharged in sizable volume to ensure high flame temperature, then flame temperature is maintained, but pure oxygen consumption increases leading to higher costs
Solution Approach 1:
The patent changes the composition parameter of the preheat oxygen stream by introducing ambient air through air bores. This dilutes the pure oxygen concentration while maintaining sufficient oxygen content for combustion, thereby reducing pure oxygen consumption while preserving flame temperature requirements
Solution Approach 2:
Ambient air acts as an intermediary substance that mixes with preheat oxygen in the air bores. This intermediary introduces additional oxygen from the environment while diluting the pure oxygen stream, reducing the need for high volumes of pure oxygen discharge
2Length of moving object
If postmixed nozzles are used to produce longer and wider heat zone, then operating distance from workpiece increases, but heat stress on torch and nozzle increases
Solution Approach 1:
The patent applies local quality by creating a protected zone around the nozzle tip using the shroud. This local protective structure shields specific areas of the nozzle from direct heat exposure and molten metal splash, allowing the nozzle to operate farther from the workpiece without suffering excessive heat stress
3Productivity
If pure oxygen is discharged in sizable volume, then cutting efficiency is maintained, but operational costs increase
Solution Approach 1:
The patent enables the system to utilize ambient air as a free oxygen source. By drawing in surrounding air through the air bores, the system supplements its oxygen supply without requiring additional pure oxygen consumption, thereby maintaining cutting efficiency while reducing operational costs
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 nozzle design reduces pure oxygen consumption, maintains flame temperature, and increases nozzle service life by using ambient air to mix with preheat oxygen, resulting in a cleaner, more efficient cut with reduced material and energy usage.
Implementation Method 1
Turbulence in the discharged streams mixes the oxygen and fuel gas before ignition occurs
Implementation Method 2
The metal is thus heated to its ignition temperature, at which point a stream of cutting oxygen directed at the surface oxidizes the heated metal to effect the cut
Implementation Method 3
a stream of cutting oxygen directed at the surface oxidizes the heated metal to effect the cut
Data Source
AI summary
A cutting nozzle for a gas torch, such as a postmixed oxy-fuel gas torch, comprising a body with a torch end adapted to engage the gas torch, a discharge end, and a peripheral surface between the torch end and the discharge end. The body has a plurality of bores for respectively conducting fuel gas, preheat oxygen and cutting oxygen through the nozzle, each of the plurality of bores extending from the torch end and terminating in a respective discharge orifice at the discharge end of the body. A set of the plurality of bores are preheat oxygen bores connected to an oxygen source at the torch end for discharging the preheat oxygen at the discharge end. A plurality of air bores each have an inlet orifice located on the peripheral surface of the body and open to an air source, and a discharge orifice in or proximal to the discharge end.