Plasma Spray Torch Anode Neutrode Gap Segmentation
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Solution Overview
Problem
Plasma spraying devices face high thermal stress and wear in the area between the anode and the adjacent neutrode, leading to reduced service life and efficiency.
Innovation Solution
The gap between the foremost neutrode and the anode is divided into multiple sections with radial and axial distances, each equipped with insulating disks, and a sealing ring is placed outside the thermally less stressed area, enhancing thermal insulation and hydraulic sealing, while the neutrodes are designed with annular collars and slots for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the gap between the foremost neutrode and the anode is equipped with only one insulating washer, then the device complexity is reduced, but the service life of the thermally stressed parts is reduced
Solution Approach 1:
The gap between the foremost neutrode and the anode is divided into multiple sections, with insulating washers arranged in at least two of these sections. This segmentation distributes the thermal and electrical stress across multiple insulation points, extending the service life of the thermally stressed components without creating excessive complexity.
2Temperature
If cooling water flows around the anode and foremost neutrode only on their outer surfaces, then the manufacturing precision is simplified, but the thermal stress on the insulating components is increased
Solution Approach 1:
The cooling system is segmented into multiple channels: outer surface cooling for the anode and foremost neutrode, and an additional inner surface cooling channel for the anode. This segmentation allows targeted cooling of the inner anode surface, reducing thermal stress on insulating components while maintaining manufacturing feasibility.
Solution Approach 2:
A cooling channel arranged on the inner surface of the anode acts as an intermediary cooling path, providing direct cooling to the thermally stressed inner surface. This intermediary cooling mechanism reduces thermal stress on insulating components without requiring complete redesign of the manufacturing process.
3Reliability
If the gap between the foremost neutrode and the anode is divided into multiple sections with insulating washers, then the service life is extended, but the device complexity increases
Solution Approach 1:
The gap is divided into multiple sections with insulating washers placed in at least two sections, creating distributed electrical insulation points. This segmentation improves reliability by providing multiple insulation barriers, while the modular nature of the sections keeps the overall device complexity manageable.
Solution Approach 2:
Different sections of the gap are provided with insulating washers based on local thermal and electrical stress requirements. This local quality approach ensures reliable insulation where needed most, while avoiding unnecessary insulation components in lower-stress areas, thus balancing reliability with device complexity.
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 extends the service life of the anode and neutrodes, allowing increased nominal power with the same service life or maintaining service life with higher power output, while ensuring stable electrical insulation and efficient cooling.
Implementation Method 1
During operation, an electric arc is generated between the cathode and the anode. The arc is applied to the anode at the inlet side, i.e., the area facing the inside of the burner head. Very high temperatures prevail in this area, which can easily reach 10,000 Kelvin and more.
Implementation Method 2
To cool the anode and the neutrodes, a cooling channel (cavity) is arranged on their outer surface, through which cooling water flows.
Data Source
Figure 1~1a
Figure 2~8
AI summary
The invention relates to a plasma spraying device, the torch head of which has a plasma channel (10) that extends between a cathode (3) and an anode (7). The plasma channel (10) is bounded by a plurality of neutrodes (4, 5, 6), which are electrically insulated from each other. A gap (26) extends between the frontmost neutrode (6) and the anode (7), which gap is divided into at least two sections (27, 29). There is a radial distance and an axial distance between the two sections (27, 29). An insulating disk (30, 31) is arranged in each of the two sections (27, 29).