Plasma Torch Head Receptacle Alignment for Faster Lead Connection
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Solution Overview
Problem
Conventional plasma arc torch systems require complex and time-consuming processes for installation and maintenance due to multiple discrete connections, necessitating experienced technicians for disconnection and reconnection of torch leads.
Innovation Solution
The plasma torch head features a set of ports with multi-stage alignment capabilities, including coarse and fine radial and rotational alignments, and a multi-start threaded connector for faster and easier engagement with the torch receptacle, facilitating quicker and more efficient connection and disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple discrete threaded connectors are used for each connection (gas, coolant, etc.), 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 threaded connectors (gas, coolant, electrical connections) into a single integrated torch receptacle assembly. This merging allows all connections to be made simultaneously through one receptacle rather than requiring separate screwing and fastening of each connection independently, thereby maintaining reliable connections while significantly improving ease of installation and maintenance
Solution Approach 2:
The torch receptacle is designed as a universal connector that handles multiple functions (fluid sealing, electrical connection, mechanical securing) in a single component. This multi-functional design eliminates the need for multiple specialized connectors, making the system easier to operate while maintaining all necessary connection reliability
2Reliability
If experienced technicians are required to disconnect and reconnect torch leads, then proper connection quality is ensured, but productivity decreases due to skill requirements and time consumption
Solution Approach 1:
The integrated torch receptacle design enables operators to perform torch lead connections without requiring specialized knowledge or skills. The self-explanatory, simplified connection mechanism allows any operator to properly connect and disconnect torch leads quickly, eliminating the need for experienced technicians and significantly improving productivity
3Reliability
If distinct threaded connectors are used for each connection type, then secure and sealed connections are achieved, but the number of components and assembly steps increases
Solution Approach 1:
The patent merges multiple distinct threaded connectors into a single integrated torch receptacle that provides all necessary connections (gas, coolant, electrical) through one unified component. This reduces the total number of parts and assembly steps while maintaining secure and sealed connections through the integrated design
Data Source
AI summary
In some aspects, a plasma torch head for a plasma arc torch can include ports disposed within a base portion that are configured to receive fluids and electrical signals from a plasma torch lead via a plasma torch receptacle, the ports being shaped to align the torch head and the plasma torch receptacle during connection and including: a central coolant supply port to convey a liquid coolant to the torch head, the central coolant supply port extending a length to primarily align the plasma torch head with the torch receptacle, the central coolant supply port further including a flat surface shaped to secondarily align the torch head with the torch receptacle upon mating engagement, and an ohmic contact connector defining a tertiary alignment feature; and a connector disposed about the base portion shaped to engage with and couple to the torch receptacle.