Liquid-Cooled Plasma Torch Nozzle With Clocking-Independent Cooling
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Solution Overview
Problem
Existing plasma arc torch nozzles require complex and costly clocking-dependent designs for coolant flow, increasing manufacturing complexity and supply chain costs, while also limiting the service life and cut quality due to inefficient cooling.
Innovation Solution
A clocking-independent nozzle design with axially extended coolant channels and windows, allowing coolant flow to circulate around the nozzle tip without requiring specific orientation, ensuring effective cooling and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clocking-dependent nozzle design with specific orientation is used, then coolant flow path can be optimized, but manufacturing complexity and supply chain costs increase
Solution Approach 1:
The nozzle is designed with radially extending coolant channels that allow coolant to flow from any circumferential orientation of the inlet to any circumferential orientation of the outlet. This universal flow path design eliminates the need for specific clocking or orientation during installation, making the nozzle adaptable to any rotational position while maintaining effective cooling. The channels are configured to provide substantially equal flow paths regardless of orientation, achieving both cooling efficiency and manufacturing simplicity.
2Ease of manufacture
If clocking-independent nozzle design is used, then assembly is simplified, but coolant flow path optimization may be compromised
Solution Approach 1:
The nozzle employs asymmetric coolant channel configurations within each radial sector, with supply channels and return channels having different path lengths and geometries. The supply channels extend further radially and have different cross-sectional areas compared to the return channels. This asymmetric design within a symmetric overall structure allows the coolant to follow optimized paths that maximize cooling efficiency while still permitting installation in any circumferential orientation.
3Temperature
If complex coolant channels are used to cool nozzle tip, then cooling efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The coolant cooling system is divided into multiple independent radial sectors, each containing its own supply channel, return channel, and cooling passages. Each sector operates as a独立的 cooling unit that channels coolant from the inlet through axial channels to the nozzle tip region, distributes it through radial channels, and returns it via separate return channels to the outlet. This segmentation allows each sector to be manufactured and cooled independently, simplifying the overall manufacturing process while providing comprehensive cooling coverage.
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 design enhances nozzle service life and cut quality by optimizing coolant flow, simplifying assembly, and reducing manufacturing costs through clocking-independent installation, while maintaining effective cooling and pressure management.
Implementation Method 1
The coolant flow path forces the coolant flow to cool the distal tip region of the nozzle and return the coolant flow to the torch body
Implementation Method 2
coolant flow to and from the distal tip region through a series of axial channels and circumferential channels
Data Source
AI summary
A nozzle for a liquid cooled plasma arc cutting torch is provided. The nozzle includes a hollow nozzle body and a nozzle jacket disposed about an external surface of the nozzle body. The jacket defines (i) a length along the central longitudinal axis and (ii) a diameter of a distal tip of the jacket at the distal region of the nozzle, where the length is greater than about 1.5 inches and a ratio of the length to the diameter is greater than about 1.4. The nozzle also includes a coolant inlet and a coolant outlet defined between the nozzle body and nozzle jacket at the proximal region of the nozzle. The nozzle further includes a plurality of coolant channels cooperatively defined between the nozzle body and the nozzle jacket. The plurality of coolant channels extend axially between the proximal region and the distal region of the nozzle.