Integrated Plasma Torch Lead Plug for Fast Liquid-Cooled Connection
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Solution Overview
Problem
Conventional plasma arc torch systems require complex and time-consuming installation and maintenance due to multiple discrete connections for electrical and gas delivery, often leading to difficulties in connecting and disconnecting the torch leads, and can suffer from electrical noise issues.
Innovation Solution
A liquid-cooled plasma cutting system lead plug with integrated ports for coolant supply and return, plasma processing gases, and electrical connections, including a current-carrying multiple contact band, which allows for quick and easy alignment and connection to a receptacle, reducing the number of ports and minimizing preheating of coolant, and providing a grounding mechanism to reduce noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple discrete connections are used for electrical and gas delivery, then reliable electrical and fluid connections are achieved, but installation and maintenance become difficult and time-consuming
Solution Approach 1:
The patent combines multiple discrete connections (electrical contacts, gas ports, coolant connections) into a single integrated torch lead connector assembly. This merging allows all connections to be made simultaneously through one coupling action rather than requiring multiple separate connection steps, thereby maintaining connection reliability while dramatically improving ease of installation and maintenance.
Solution Approach 2:
The torch lead connector is designed as a universal multi-functional component that simultaneously handles electrical power transmission, gas delivery, and coolant flow. This single component performs multiple functions that would otherwise require separate connectors, reducing complexity and improving operational ease while maintaining all necessary connection functions.
2Adaptability or versatility
If multiple threaded connections are used to fluidly and electrically connect torch to power supply, then complete functional connections are achieved, but the system becomes complex and requires experienced technicians
Solution Approach 1:
The patent merges multiple threaded connections into a single integrated coupling mechanism. The torch lead connector assembly incorporates all necessary electrical contacts, gas ports, and coolant connections within one unified structure that attaches to the power supply through a single coupling action, thereby maintaining complete functional connections while reducing system complexity.
Solution Approach 2:
The patent segments the connection system into two main parts: an integrated torch lead connector assembly and a corresponding receptacle. This segmentation allows the complex multi-functionality to be contained within the modular connector unit, simplifying the overall system architecture and reducing the number of separate components that require assembly.
3Reliability
If conventional discrete connections are used, then individual connection functions are achieved, but connection process becomes time-consuming
Solution Approach 1:
The patent combines all connection functions (electrical, gas, coolant) into a single torch lead connector assembly that can be attached and detached in one action. This merging enables all connections to be established simultaneously during a single coupling operation, dramatically increasing connection speed while maintaining the reliability of each individual connection function.
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 coolant preheating, and decreases electrical noise by delivering power through the coolant return port, enhancing the reliability and efficiency of plasma arc torch operations.
Implementation Method 1
a liquid-cooled plasma cutting system lead plug to connect a plasma arc torch to a plasma arc processing system
Implementation Method 2
The base portion includes or defines a set of ports to convey one or more fluids, gases, or electrical currents
Implementation Method 3
providing a grounding mechanism to reduce noise
Data Source
Figure 1
Figure 2
Figure 3A~3B
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.