Multi-Torch Plasma Unit for Single-Pass Bevel Cutting
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Solution Overview
Problem
Existing plasma torch systems require multiple passes and manual adjustments to produce contour or bevel cuts, leading to increased time and cost due to the need for a single plasma torch to be adjusted at different angles for each cut.
Innovation Solution
A multiple plasma torch unit with three simultaneously operable plasma torches, each with a hose pack held by a twistable hollow shaft along the axis of rotation, allowing for motor-driven angular adjustments and high-frequency shielding, enabling simultaneous cuts with reduced processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single plasma torch is used with manual angular adjustments, then the device complexity is reduced, but the processing time increases significantly due to multiple passes required for contour cuts
Solution Approach 1:
The single plasma torch is segmented into three separate plasma torches (first, second, and third plasma torches) with independent angular adjustment capabilities. Each torch can be positioned at different angles simultaneously, allowing contour cuts to be made in a single pass rather than requiring multiple sequential passes with manual repositioning.
Solution Approach 2:
The invention adds the angular dimension as an independent variable by providing motor-driven angular adjustment devices for each plasma torch. This allows the torches to operate at different angles (α1, α2, α3) simultaneously, transforming a one-dimensional linear cutting process into a multi-dimensional operation that can accommodate complex contours without multiple passes.
2Device complexity
If manual angular adjustment is used for each cut, then the device complexity is minimized, but the productivity decreases due to time-consuming adjustments between passes
Solution Approach 1:
Manual mechanical adjustment of torch angles is replaced with motor-driven angular adjustment devices. These motors can be controlled programmatically to position each plasma torch at the required angle automatically, eliminating the need for manual intervention and significantly reducing the time required for angle changes between passes.
Solution Approach 2:
The angular positions of all plasma torches are predetermined and programmed before the cutting operation begins. The motor-driven adjustment devices pre-position each torch at its required angle (α1, α2, α3) before the cutting process starts, allowing all torches to operate simultaneously at optimal angles without time-consuming adjustments during the process.
3Loss of time
If multiple plasma torches with independent angular adjustment are used, then the processing time is reduced, but the device complexity and cost increase
Solution Approach 1:
The three plasma torches are integrated into a single universal torch unit that can perform multiple functions. The unit can cut various contour types (K-seams, X-seams, Y-seams, V-seams) by programming different angular positions for the torches, eliminating the need for multiple specialized devices or repeated manual reconfigurations.
Solution Approach 2:
Three plasma torches with independent angular adjustment capabilities are merged into a single integrated torch unit with a common support structure and control system. This consolidation allows simultaneous operation of multiple torches while sharing common components, reducing overall system complexity compared to three separate independently adjusted torches.
4Ease of operation
If motor-driven angular adjustment devices are implemented, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The motor-driven angular adjustment devices are equipped with programmable control systems that automatically position each plasma torch at the required angle based on pre-programmed parameters. The system serves itself by autonomously adjusting torch angles without requiring manual intervention, simplifying operation while the complexity is managed through automated control logic.
Data Source
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AI summary
The invention relates to a torch assembly (10) comprising a height-adjustable boom (12) with a torch holder (14) rotatable eccentrically about a pivot axis (16) and with at least one plasma torch (32), the longitudinal axis (46) of which is adjustable at an angle α to a workpiece surface (20) of a workpiece (22). To reduce the processing time for bevel cuts, the torch assembly (10) is provided to have at least two simultaneously operable plasma torches (30, 32, 34) for producing a contour or bevel cut, each with a hose assembly (36, 38, 40), wherein the hose assemblies (36, 38, 40) are twistably received by a hollow shaft (18) extending along the pivot axis (16) in the boom (12).