Plasma Coating Lance Eccentric Head for Reduced Centrifugal Force
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Solution Overview
Problem
Conventional manufacturing methods for plasma lances, especially for extended and thin internal coating tools, face physical limitations and inefficiencies, particularly in drilling and assembly, leading to complex and inaccurate production processes and increased centrifugal forces during rotation, which affect coating quality and balance.
Innovation Solution
The use of additive manufacturing for the plasma head and deep-hole drilling for the shaft, allowing for complex geometries and reduced centrifugal forces by maintaining the lance coaxial to the rotating shaft, along with active cooling of the cathode to manage thermal loads and precise balancing for consistent production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing methods (drilling, bending, soldering) are used for extended and thin internal coating tools, then the lance can be manufactured with simple geometry, but the manufacturing process becomes laborious, complex, and reaches physical load limits
Solution Approach 1:
The lance is divided into modular segments that can be manufactured separately using additive manufacturing and then assembled. This allows complex geometries to be created in manageable sections, reducing the overall manufacturing complexity while maintaining the ability to create extended and thin internal coating tools.
Solution Approach 2:
The manufacturing process transitions from conventional subtractive methods (drilling, bending, soldering) to additive manufacturing, fundamentally changing the manufacturing parameters and capabilities. This enables the creation of complex geometries that were previously impossible or extremely difficult to manufacture.
2Adaptability or versatility
If the entire lance is deflected laterally to coat larger drillings, then larger surfaces can be coated, but centrifugal forces increase causing vibrations and loads on the drive system
Solution Approach 1:
Only the plasma head is deflected laterally while the main lance body remains coaxial with the rotating shaft. This localized deflection allows the plasma head to reach larger drilling surfaces while minimizing the mass at a distance from the rotation axis, thereby reducing centrifugal forces and vibrations.
Solution Approach 2:
The solution moves from a two-dimensional lateral deflection of the entire lance to a three-dimensional configuration where only the plasma head is offset. This dimensional change allows adaptability for larger surfaces while maintaining balance.
3Manufacturing precision
If manual work and countless processing steps are used, then complex geometries can be attempted, but production time increases and accuracy decreases
Solution Approach 1:
Manual mechanical processing steps are replaced with automated additive manufacturing processes. This substitution eliminates laborious manual work and countless processing steps while simultaneously improving manufacturing precision and increasing productivity through automation.
Solution Approach 2:
Complex geometries are pre-programmed into the additive manufacturing process rather than being created through sequential manual operations. This preliminary digital preparation ensures high precision and consistency while dramatically reducing production time compared to manual methods.
4Ease of manufacture
If non-detachable connection (soldering) is used, then assembly is simple, but revision and maintenance become difficult or very complex
Solution Approach 1:
The connection between lance segments and the plasma head transitions from a static, permanent soldered joint to a dynamic, detachable connection. This allows the system to adapt between easy assembly/disassembly for maintenance while maintaining structural integrity during operation.
Solution Approach 2:
The lance is designed as segmented modular components with detachable connections, allowing individual segments to be removed and replaced without affecting the entire system. This segmentation enables easy revision and maintenance while keeping the overall assembly process simple.
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 approach enables precise, efficient, and consistent manufacturing of plasma lances with reduced centrifugal forces and improved coating quality by allowing for complex geometries and precise balancing, while minimizing manual labor and assembly complexities.
Implementation Method 1
By the thermal energy of the plasma, the supplied material is partially melted or completely melted
Implementation Method 2
deflected away from the coating lance in the direction of the surface to be coated by the kinetic energy of the plasma
Implementation Method 3
a plasma 5 is generated via an arc with the aid of a gas mixture
Implementation Method 4
the cooling medium is led through a cooling conductor in order to remove thermal energy from the cathode
Data Source
AI summary
The invention relates to a coating lance for a plasma process, the lance comprising a plasma shaft, a plasma neck, and a plasma head, the plasma shaft comprising a longitudinal channel, which extends in an axial direction along an axis from a first shaft end to a second shaft end, the plasma neck comprising a shaft boss and a head boss and at least one neck channel, which extends from the shaft boss to the head boss, and the shaft boss being arranged on the second shaft end in such a way that the longitudinal channel leads into the at least one neck channel, the plasma head comprising a neck boss, a plasma opening, and at least one head channel, which extends from the neck boss to the plasma opening, and the neck boss of the plasma head being arranged on the head boss of the plasma neck in such a way that the at least one neck channel leads into the head channel. The course of the plasma channel deviates from the axis in such a way that the neck channel leads into the head channel eccentrically with respect to the axis, i.e. at an offset to the axis.