Cutting Torch Ignition Mixer for Automated Gas and Nozzle Setup
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Solution Overview
Problem
Current automated machine cutting torch systems require significant operator intervention for setup and adjustments, leading to inefficiencies, increased maintenance, and potential safety issues due to manual handling and lack of precise control over gas parameters and nozzle alignment.
Innovation Solution
A cutting torch system with integrated ignition and cleaning modes, featuring an ignition mixer, fuel gas shut-off valve, cutting oxygen sensor, and control system for automatic adjustment of gas flow and pressure, along with a nozzle with an integrated height sensor and electronic identifier for automated setup and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of oxygen and fuel gas pressure and flow rates is used during start-up and operation, then the cutting torch can be operated, but significant operator skill and intervention are required, leading to inefficiency and inconsistency
Solution Approach 1:
The control system automatically adjusts oxygen and fuel gas pressure and flow rates based on sensor feedback, enabling the cutting torch to self-regulate without operator intervention. The system monitors parameters such as gas consumption, pressure, and flow rate, and automatically makes adjustments to maintain optimal cutting conditions, eliminating the need for manual tuning during operation.
Solution Approach 2:
The system incorporates sensors that continuously monitor gas consumption, pressure, and flow rate, providing real-time feedback to the control system. This feedback loop enables automatic adjustment of operating parameters to maintain optimal cutting conditions, replacing manual operator adjustments with automated closed-loop control.
2Reliability
If external ignition device is used, then ignition can be achieved, but sufficient free space is required, additional fuel gas supply is needed, and the device is frequently damaged by the cutting process
Solution Approach 1:
The ignition device is integrated into the cutting torch body, merging the ignition function with the main torch structure. This eliminates the need for separate external ignition devices and their associated fuel gas supplies, reducing overall system complexity and improving reliability by protecting the ignition component from damage during the cutting process.
Solution Approach 2:
The integrated ignition system serves multiple functions within a single component structure, combining ignition capability with the torch body. This multi-functional design reduces the number of separate components needed, simplifies the system, and ensures the ignition device is positioned and protected appropriately during operation.
3Ease of repair
If nozzle is changed manually due to maintenance requirements or setup changes, then nozzle replacement can be performed, but the cutting machine has to be stopped, special wrenches are required, and significant time is lost
Solution Approach 1:
The nozzle is designed with a dynamic quick-change mechanism that allows for rapid replacement without tools. The nozzle can be quickly detached and reattached by the operator without requiring the machine to stop completely or using special wrenches, significantly reducing nozzle change time and improving maintenance efficiency.
Solution Approach 2:
The quick-change nozzle design incorporates pre-positioned locking and unlocking mechanisms that are prepared in advance, allowing for tool-free replacement. The nozzle connection system is designed with preliminary alignment features that guide the nozzle into place during replacement, eliminating the need for manual alignment and reducing change time.
4Measurement precision
If pressure gauge is arranged externally between hose and cutting torch to measure cutting oxygen pressure, then pressure measurement is possible, but accuracy and life-time are too low and complexity is too high
Solution Approach 1:
The pressure sensor is integrated directly into the cutting torch body, nested within the existing structure. This internal placement eliminates the need for external gauges and connecting hoses, reducing system complexity while improving measurement accuracy by measuring pressure at the exact point where it is needed, without additional pressure drops in external components.
Solution Approach 2:
The integrated pressure sensor acts as an intermediary element within the torch structure, directly measuring cutting oxygen pressure at the source. This eliminates the need for external measurement devices and the associated hoses and connections, reducing complexity and improving accuracy by removing intermediate pressure-dropping components.
5Productivity
If automated machine cutting torch system is used, then cutting operation can be performed, but significant operator intervention is still required for setup and adjustments
Solution Approach 1:
The control system automatically adjusts oxygen and fuel gas pressure and flow rates based on sensor feedback, enabling the cutting torch to self-regulate without operator intervention. The system monitors parameters such as gas consumption, pressure, and flow rate, and automatically makes adjustments to maintain optimal cutting conditions, eliminating the need for manual tuning during operation.
Solution Approach 2:
The system incorporates sensors that continuously monitor gas consumption, pressure, and flow rate, providing real-time feedback to the control system. This feedback loop enables automatic adjustment of operating parameters to maintain optimal cutting conditions, replacing manual operator adjustments with automated closed-loop control.
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 system reduces operator dependency, enhances cutting performance, extends equipment lifetime, and automates nozzle changes and cleaning, resulting in improved cut quality, reduced maintenance needs, and cost savings.
Implementation Method 1
an ignition mixer (7) arranged in the body (2), a fuel gas shut-off valve (8) arranged upstream of the ignition mixer (7), wherein the heating oxygen channel (5) and the fuel gas channel (6) are connected to the ignition mixer (7), and the ignition mixer (7) is adapted for mixing heating oxygen and fuel gas into an ignition gas
Implementation Method 2
a head (3) comprising an ignition plug (9)
Implementation Method 3
a channel (4) for cutting oxygen, wherein the channel (4) for cutting oxygen is connected to the inlet side of the body (2)
Data Source
AI summary
A cutting torch comprises a cutting oxygen channel for supplying cutting oxygen, a heating oxygen channel for supplying heating oxygen, a fuel gas channel for supplying fuel gas, an ignition mixer configured to generate ignition gas from heating oxygen and fuel gas, a heating oxygen bypass channel originating from the heating oxygen channel and coupled to the ignition mixer, the heating oxygen bypass channel configured to supply heating oxygen to the ignition mixer, a fuel gas bypass channel originating from the fuel gas channel and coupled to the ignition mixer, the fuel gas bypass channel configured to supply fuel gas to the ignition mixer, and a fuel gas shut-off valve located on the fuel gas bypass channel. The shut-off valve is configured to turn off the supply of the fuel gas to the ignition mixer, and the ignition mixer supplies only heating oxygen to the cutting oxygen channel.