Integrated Plasma Torch Lead Connector for Fast Multi-Port Coupling
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Solution Overview
Problem
Conventional plasma arc torch systems require complex and time-consuming connections with multiple discrete connections for gas, coolant, and electrical supply, necessitating skilled technicians for installation and maintenance.
Innovation Solution
A liquid-cooled plasma cutting system with a base portion and ports for coolant supply, return, gas supply, and ohmic contact, integrated into a lead plug that simplifies connections by using a single connector for multiple functions, including electrical current transmission through the coolant return port to prevent coolant preheating, and o-ring sealing members for secure fluid and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple discrete connections are used for gas, coolant, and electrical supply, then reliable fluid and electrical connections are achieved, but installation and maintenance become difficult and time-consuming
Solution Approach 1:
The patent combines multiple discrete connections (coolant supply, coolant return, gas supply, and electrical connections) into a single integrated connector assembly. This single connector simultaneously establishes all necessary fluid and electrical connections when attached to the torch lead receptacle, eliminating the need for multiple separate connection steps while maintaining reliable connections for all functions.
Solution Approach 2:
The connector is designed as a multi-functional component that simultaneously performs multiple functions: conveying coolant supply, receiving coolant return, delivering gas supply, and establishing electrical connections. This universal connector handles all connection types through a single interface, simplifying the connection process while ensuring all necessary connections are made reliably.
2Adaptability or versatility
If multiple discrete connections are used for gas, coolant, and electrical supply, then complete functional connections are achieved, but the number of connection steps increases
Solution Approach 1:
The patent merges all connection functions into a single integrated connector that establishes complete functional connections (coolant supply, coolant return, gas supply, and electrical connections) in one attachment action. This eliminates the need for multiple sequential connection steps while ensuring all necessary connections are made completely and reliably.
Solution Approach 2:
The connector is pre-configured with all necessary connection pathways and sealing elements before installation. The internal structure is designed beforehand to automatically establish all required connections upon single attachment, eliminating the need for multiple adjustment or connection steps during installation.
3Reliability
If threaded connectors are used for each connection, then secure connections are achieved, but the complexity of the connection system increases
Solution Approach 1:
The patent combines multiple threaded connection elements into a single integrated connector assembly. Instead of requiring separate threaded connections for coolant supply, coolant return, gas supply, and electrical connections, all these connections are integrated into one connector that attaches to the torch lead receptacle as a single unit, reducing system complexity while maintaining secure connections.
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
Simplifies the connection process, reduces installation time, minimizes electrical noise, and ensures reliable connections by integrating multiple functions into a single interface, while maintaining effective cooling and plasma arc generation.
Implementation Method 1
the coolant return port... being configured to convey an operational current from the liquid-cooled plasma cutting system to the plasma arc torch
Implementation Method 2
The coolant supply port, the gas supply port, and the coolant return port can include o-ring sealing members
Data Source
AI summary
In some aspects, contact members to connect plasma torch leads to plasma cutting systems can include: a base portion; a set of ports within the base portion that include: a coolant supply port to convey a liquid coolant from the cutting system to a plasma arc torch connected to the contact member by the torch lead, a coolant return port: i) to convey return liquid coolant from the torch to the cutting system, and ii) to convey an operational current from the cutting system to the torch, at least one gas supply port to convey processing gases to the torch, and an ohmic contact connector; and a connector to couple the base portion to the cutting system and connect each of the ports and electrical connectors to respective complementary connections of the cutting system upon coupling to the cutting system.