Cutting Torch Ignition Mixer for Automated Gas 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 gas pressure and flow rate control, resulting in suboptimal cutting performance and higher costs.
Innovation Solution
A cutting torch system with integrated ignition and cleaning capabilities, equipped with sensors for real-time gas pressure and flow rate measurement, and an automated control system that adjusts parameters based on sensor data, allowing for precise control and reduced operator dependency, and featuring an electronic nozzle identifier for automatic setup adjustments.
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 operator can control the cutting process, but the setup time increases and operator skill dependency increases
Solution Approach 1:
The cutting torch system automatically adjusts oxygen and fuel gas pressure and flow rates using electronic control valves and sensors, eliminating the need for manual operator intervention during start-up and operation. The system self-regulates gas parameters based on pre-stored optimal values, reducing setup time and operator skill dependency while maintaining precise control capability.
2Reliability
If external ignition device is used, then ignition can be achieved, but the machine becomes more complicated and requires additional fuel gas supply and space
Solution Approach 1:
The ignition device is integrated directly into the cutting torch body, merging the ignition function with the main torch structure. This eliminates the need for separate external ignition devices, reducing machine complexity, removing additional fuel gas supply requirements, and eliminating the need for extra adjustment mechanisms while maintaining reliable ignition capability.
3Ease of repair
If nozzle is changed manually due to maintenance requirements or setup changes, then the nozzle can be replaced, but the cutting machine has to be stopped and the system has to be set up again
Solution Approach 1:
Optimal gas pressure and flow rate parameters for different nozzle configurations are pre-stored in the system's memory. When a nozzle is replaced, the operator simply selects the appropriate nozzle type, and the system automatically retrieves and applies the pre-stored optimal parameters, eliminating the need for manual re-setup and minimizing machine downtime while maintaining ease of nozzle replacement.
4Device complexity
If cutting oxygen pressure is not measured at the cutting torch, then the system is simpler, but exact information about an important process parameter is missing
Solution Approach 1:
Traditional mechanical pressure gauges are replaced with electronic pressure sensors and digital measurement systems at the cutting torch. This substitution provides exact real-time pressure information while maintaining relatively simple system architecture through electronic integration, enabling precise monitoring of cutting oxygen pressure without significantly increasing overall system complexity.
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 provides reliable, efficient, and safe flame ignition, reduces maintenance needs, improves cutting performance, and lowers operational costs by automating adjustments and monitoring conditions, ensuring consistent gas supply and minimizing manual intervention.
Implementation Method 1
an ignition mixer (7) for mixing heating oxygen and fuel gas into an ignition gas
Implementation Method 2
The cutting torch requires manual adjustment of oxygen and fuel gas pressure and flow rates during start-up. On each use, the flame of the cutting torch is ignited using an ignition device.
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The present invention relates to a cutting torch system having an ignition mode and a cooling and cleaning mode. The cutting torch system comprises a cutting torch (1) having a cutting oxygen channel (4), a heating oxygen channel (5), and a fuel gas channel (6) The heating oxygen channel (5) and the fuel gas channel (6) are connected to an ignition mixer (7) and a fuel gas shut-off valve (8) is arranged upstream of the ignition mixer (7). The fuel gas shut-off valve (8) is configured to be open in the ignition mode and closed in the cleaning and cooling mode. The ignition mixer (7) is adapted for mixing heating oxygen and fuel gas into an ignition gas and communicating the ignition gas into the cutting oxygen channel (4) in the ignition mode, and for communicating heating oxygen into the cutting oxygen channel (4) in the cleaning and cooling mode.