Plasma Torch Jet Angle Adjustment for Edge Cutting
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Solution Overview
Problem
Plasma cutting technologies face challenges in achieving smooth, burr-free edges and minimizing material waste, particularly when cutting corners and edges, leading to the need for reworking, due to the plasma jet's behavior when transitioning across workpiece edges.
Innovation Solution
Inclining or deflecting the plasma jet by an angle of at least 5° to 45° in the feed movement direction before traversing workpiece edges or corners, and maintaining this alignment until the cut is complete, to ensure the plasma jet's emission position is adjusted relative to the workpiece surface, reducing burr formation and material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the plasma jet is directed perpendicular to the workpiece surface, then the cutting process is simple and productive, but burr formation and poor edge quality occur at workpiece edges and corners
Solution Approach 1:
The plasma jet direction is made dynamically adjustable rather than fixed perpendicular. The system changes the jet angle adaptively based on the workpiece geometry, using at least two different angles (first angle for normal cutting, second angle for edge/corner cutting) to optimize both productivity and edge quality across different cutting scenarios
Solution Approach 2:
The cutting parameters are changed by varying the plasma jet angle. By adjusting the angle of the plasma jet relative to the workpiece surface, the system optimizes the cutting process for different geometries, reducing burr formation at edges and corners while maintaining efficient cutting elsewhere
2Manufacturing precision
If the plasma jet angle is adjusted to reduce burr formation at edges, then edge quality improves, but the cutting process becomes more complex
Solution Approach 1:
The system uses the workpiece geometry itself to trigger the angle change. By detecting features such as edges and corners through the cutting process, the system automatically adjusts the plasma jet angle without requiring external intervention or complex manual alignment procedures
Solution Approach 2:
The torch assembly incorporates dynamic positioning capabilities that allow real-time adjustment of the plasma jet angle during cutting, enabling the system to adapt to different workpiece geometries while maintaining operational simplicity through automated control
3Productivity
If the plasma jet traverses workpiece edges quickly, then productivity is maintained, but material waste and reworking increase due to poor cut quality
Solution Approach 1:
The system changes the plasma jet angle parameter when approaching edges and corners, which improves cut quality and reduces burr formation. This parameter adjustment prevents material waste from poor cuts while maintaining overall productivity by quickly transitioning between different angle settings
Solution Approach 2:
The system proactively adjusts the plasma jet angle before reaching critical edge and corner regions, preparing the cutting conditions in advance to ensure high-quality cuts and prevent burr formation, thereby reducing the need for reworking and material waste
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 results in improved cutting surfaces that require minimal reworking, maintaining high productivity and reducing burr formation, especially at edges and corners, by optimizing the plasma jet's interaction with the workpiece surface.
Implementation Method 1
These gases ionize and dissociate by the energy of the plasma arc
Implementation Method 2
A plasma is a thermally highly heated electrically conductive gas which is composed of positive and negative ions, electrons and excited and neutral atoms and molecules
Implementation Method 3
The workpiece is exposed to the thermal, kinetic and electrical effect of the plasma jet
Implementation Method 4
Temperatures arise in the plasma jet of up to 30,000° C.
Implementation Method 5
The workpiece is exposed to the thermal, kinetic and electrical effect of the plasma jet
Implementation Method 6
the electrical cutting current flows from the current source to the plasma cutting torch via its electrode, the plasma jet constricted by the nozzle
Implementation Method 7
a pilot arc which burns with a small electrical current and thus with a small power between the electrode and the nozzle
Data Source
AI summary
The invention relates to a method for the plasma cutting of workpieces. It is the object of the invention to provide possibilities with which improved cutting surfaces can be achieved in plasma cutting which do not require any reworking, or at least only a reduced reworking. In the method in accordance with the invention, a plasma cutting torch having at least one torch body, an electrode and a nozzle is used and the plasma jet is inclined or deflected at least before the traveling over of a workpiece edge at an angle δ with respect to the axis aligned perpendicular to the workpiece surface such that the emission position of the plasma jet from the workpiece is arranged at a spacing in the feed movement direction which is at most half the amount than is the case with a plasma jet incident perpendicular on the workpiece surface.