Automated Fluid Jet Nozzle Replacement Mechanism
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Solution Overview
Problem
Existing fluid jet cutting devices face challenges in efficiently changing cutting nozzles due to complex handling processes, requiring manual dexterity and experience, leading to unsatisfactory cut accuracy and unnecessary waste, especially when switching between different cutting methods or detecting nozzle wear.
Innovation Solution
A cutting nozzle removable mechanism with sensors for wear detection and an automated or partially automated system for nozzle exchange, allowing for manual or fully automatic changes without manual intervention, using a cutting nozzle adapter and worm drive for precise and reliable nozzle replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual nozzle replacement is used, then device complexity is reduced, but ease of operation deteriorates due to requiring manual dexterity and experience
Solution Approach 1:
The system performs nozzle replacement automatically without human intervention. The control unit detects nozzle wear through sensors and autonomously executes the replacement sequence, making the system self-servicing rather than requiring manual operator action.
Solution Approach 2:
The patent replaces manual mechanical manipulation with an automated mechanical system. A robotic arm or automated mechanism positioned by the control unit performs the nozzle extraction and insertion, substituting human dexterity with programmable mechanical motion.
2Ease of operation
If automated nozzle replacement is implemented, then ease of operation improves, but device complexity increases due to additional mechanisms
Solution Approach 1:
The control unit serves multiple functions: it controls the high-pressure pump, monitors nozzle wear through sensor data, decides when replacement is needed, and coordinates the automated replacement mechanism. This multi-functionality reduces the need for separate dedicated components.
Solution Approach 2:
The automated replacement mechanism is integrated within the existing cutting device structure. The robotic arm or replacement mechanism is positioned within or adjacent to the cutting head assembly, nesting the replacement function within the overall device footprint rather than adding external bulk.
3Measurement precision
If nozzle wear is monitored manually, then measurement precision is reduced, but device complexity is lowered
Solution Approach 1:
Sensors provide continuous feedback about nozzle condition to the control unit. The control unit evaluates sensor signals and automatically triggers replacement when wear thresholds are exceeded, creating a closed-loop monitoring system that maintains precision without complex manual inspection procedures.
Solution Approach 2:
The patent replaces manual visual inspection with sensor-based detection. Optical sensors, acoustic sensors, or other detection devices measure nozzle wear parameters objectively, substituting human sensory limitations with precise electronic measurement capabilities.
4Manufacturing precision
If frequent nozzle replacement is performed, then manufacturing precision is maintained, but productivity decreases due to downtime
Solution Approach 1:
The system performs nozzle replacement proactively based on wear detection before precision degradation occurs. By monitoring nozzle condition continuously and replacing at optimal intervals, the system prevents quality defects while minimizing unnecessary replacements that would waste time.
Solution Approach 2:
The automated replacement system minimizes operational interruption by quickly exchanging nozzles and immediately resuming cutting operations. The control unit coordinates pump pressure adjustments and positioning to maintain continuous productive action with minimal downtime between nozzle changes.
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
Enables reliable and efficient operation of fluid jet cutting devices with reduced operator expertise, increased uptime, and minimized waste by detecting nozzle wear and automatically replacing nozzles, facilitating around-the-clock operation and simplified handling.
Implementation Method 1
at least one sensor through which a wear feature of the cutting nozzle or other characterizing the cutting beam parts of the fluid jet cutting apparatus characterizing size can be detected
Implementation Method 2
worm drive for precise and reliable nozzle replacement
Data Source
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AI summary
The invention relates to a fluid jet cutting device (1) with a cutting head (2) having an interchangeable cutting nozzle (3) from which a cutting jet (4) of the fluid jet cutting device is emitted into the environment, with one or both of the following features a), b): a) the fluid jet cutting device has a cutting nozzle changing mechanism (7) by which the cutting nozzle can be removed from the cutting head and another cutting nozzle can be attached to the cutting head without manual intervention, b) the fluid jet cutting device has at least one sensor (9) by which a quantity characterizing a wear feature of the cutting nozzle or other parts of the fluid jet cutting device that guide the cutting jet can be detected.