Liquid-Cooled Plasma Burner Nozzle Deflection Sections
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Solution Overview
Problem
Existing plasma burners experience overheating issues near the nozzle channel due to inadequate coolant flow distribution, leading to reduced service life and potential leaks.
Innovation Solution
The design incorporates deflection sections on the nozzle with tapered cone angles to enhance coolant flow uniformity and increase the flow rate around the nozzle bore, eliminating the need for additional components and maintaining an acute angle for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional nozzle design with uniform cooling is used, then the manufacturing is simple, but the coolant flow distribution is inadequate causing overheating near the nozzle channel
Solution Approach 1:
The nozzle incorporates deflection sections with different geometries at specific locations to create localized variations in coolant flow distribution. These deflection sections are positioned to redirect coolant flow toward regions experiencing higher thermal loads, such as near the nozzle channel, ensuring more uniform cooling without requiring a completely redesigned nozzle structure
Solution Approach 2:
The nozzle is divided into multiple sections including a first section, a second section, and deflection sections. This segmentation allows each section to be optimized for its specific function: the first section for overall cooling, the second section for structural integrity, and the deflection sections for redirecting coolant flow to critical areas, thereby solving the overheating problem while maintaining manufacturing simplicity
2Reliability
If additional cooling components are added to improve coolant flow distribution, then the cooling efficiency increases, but the device complexity increases
Solution Approach 1:
The deflection sections serve multiple functions simultaneously: they redirect coolant flow to improve distribution, maintain the structural integrity of the nozzle, and preserve the acute angle geometry required for efficient plasma cutting and welding. This multi-functionality eliminates the need for separate additional cooling components, thereby improving cooling reliability without increasing device complexity
3Productivity
If the nozzle angle is optimized for cutting efficiency, then the cutting performance improves, but the coolant flow distribution becomes inadequate
Solution Approach 1:
The nozzle design incorporates deflection sections that dynamically redirect coolant flow based on the thermal load distribution. The deflection sections are positioned and angled to redirect coolant toward hotter regions while maintaining the overall acute angle geometry of the nozzle that is optimized for cutting efficiency. This dynamic flow redirection ensures adequate cooling without compromising cutting performance
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
This design effectively prevents overheating, extends nozzle service life, and ensures reliable coolant distribution without additional components, while maintaining the plasma burner's acute angle for efficient operation.
Implementation Method 1
The same is true of the electrode holder, though it may also be made of silver. The nozzle is then inserted in a plasma burner, the main elements of which are a plasma burner head, a nozzle cap, a plasma gas conducting member, a nozzle, a nozzle holder, an electrode quill, an electrode holder with an electrode insert and, in modern plasma burners, a bracket for a nozzle protection cap and a nozzle protection cap.
Implementation Method 2
The coolant is delivered to the nozzle via a water supply line and removed from the nozzle via a water return line and in the process flows through a coolant chamber, which is delimited by the nozzle and the nozzle cap.
Data Source
AI summary
The invention relates to a liquid-cooled plasma burner, comprising a nozzle bore for the plasma gas jet to exit at a nozzle tip and a first section whose outer surface gradually tapers in the shape of a cone at an angle α in the direction of the nozzle tip, except for at least one deflection section that extends in the shape of a cone at an angle β in the direction of the nozzle tip. The invention also relates to an arrangement thereof with a nozzle cap and to a plasma burner comprising such an arrangement.