Plasma Torch Directing Component for Uniform Cooling Flow
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Solution Overview
Problem
Existing plasma torches experience non-uniform cooling, with greater cooling around a single coolant inlet and inadequate utilization of shield gas, leading to uneven heat distribution and reduced component durability.
Innovation Solution
A directing component with a cylindrical and conical portion that includes angularly spaced channels for cooling liquid and shield gas, where the axes of cooling liquid channels form an angle of 30° to 60° with the component axis, and shield gas channels are arranged to ensure uniform cooling by spreading the flow sideways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If cooling liquid is supplied through a single inlet channel, then the structure is simple, but the cooling uniformity deteriorates
Solution Approach 1:
The single cooling liquid inlet is divided into multiple inlet channels distributed around the circumference of the directing component. This segmentation allows cooling liquid to be supplied to multiple locations simultaneously, ensuring uniform cooling distribution across all torch components while maintaining structural simplicity through the modular channel design.
2Device complexity
If shield gas is supplied through a single supply channel, then the structure is simple, but the cooling function is insufficient
Solution Approach 1:
The single shield gas supply is divided into multiple gas supply channels arranged circumferentially. Each channel delivers shield gas to different regions, enabling the gas to perform its cooling function uniformly across all torch components. This segmentation maximizes the utilization of shield gas for cooling purposes.
Solution Approach 2:
The shield gas channels are designed to serve dual functions: providing shield gas for plasma arc protection and simultaneously delivering cooling gas to torch components. This multi-functionality ensures that the shield gas supply system contributes to both shielding and cooling, eliminating the need for separate cooling gas supplies.
3Device complexity
If cooling liquid flows predominantly on one side of the nozzle, then the flow path is simple, but the cooling uniformity deteriorates
Solution Approach 1:
The cooling liquid inlet channels are positioned asymmetrically at optimized angular locations around the directing component rather than being uniformly distributed. This asymmetric arrangement, with specific angular spacing, ensures that cooling liquid flows are balanced across all sides of the nozzle, preventing predominant flow on any single side while maintaining simple flow paths.
4Ease of manufacture
If torch components are made of materials with lower thermal durability, then the manufacturing cost is reduced, but the component lifetime deteriorates
Solution Approach 1:
Multiple cooling liquid inlet channels are positioned to deliver cooling liquid to critical components before they reach dangerous temperature levels. This preliminary cooling action prevents thermal damage to components made of materials with lower thermal durability, extending their operational lifetime while allowing the use of cost-effective materials.
Solution Approach 2:
The cooling liquid channels are designed to provide continuous cooling throughout the operational life of the torch components. The channels ensure that cooling liquid continuously flows over hot surfaces, maintaining components within safe temperature ranges and preventing thermal degradation, thereby extending component lifetime without requiring expensive high-thermal-durability materials.
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 solution achieves uniform cooling of plasma torch components, extending the lifetime of the torch by ensuring consistent heat management across all parts, regardless of material thermal durability.
Implementation Method 1
a set of mutually angularly spaced apart channels for cooling liquid, each of said channels for cooling liquid having an inlet located at an internal surface of the directing component and an outlet located at an external surface of the directing component and extending at least partially through the conical portion
Implementation Method 2
a set of channels for shield gas, each of said channels for shield gas having an inlet located at an internal surface of the directing component and an inlet at an external surface of the directing component and extending at least partially through the conical portion
Implementation Method 3
The solution achieves uniform cooling of plasma torch components, extending the lifetime of the torch by ensuring consistent heat management across all parts
Data Source
AI summary
Directing component (1) for a plasma torch, the directing component (1) comprising: a cylindrical portion (17), a conical portion (18), coaxially adjoining the cylindrical portion (17), wherein the cylindrical portion (17) and the conical portion (18) together define a pass-through cavity, a set of mutually angularly spaced apart channels (11) for cooling liquid, each of said channels (11) for cooling liquid having an inlet located at an internal surface of the directing component (1) and an outlet located at an external surface of the directing component (1) and extending at least partially through the conical portion (18), and a set of channels (12) for shield gas, each of said channels (12) for shield gas having an inlet located at an internal surface of the directing component (1) and an inlet at an external surface of the directing component (1) and extending at least partially through the conical portion (18), wherein the channels (11) for cooling liquid form an angle in the range of 30° to 60° with the axis of the directing component (1).