Portable Plasma Torch Segmentation for Mobility
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Solution Overview
Problem
Plasma arc torch systems are not portable due to high power requirements and large gas consumption, limiting their use to fixed locations with continuous power and gas supply, making them unsuitable for applications where mobility and self-sufficiency are needed.
Innovation Solution
A portable plasma arc torch system with a wearable assembly that includes a replaceable or rechargeable power source and gas source, allowing for operation without a continuous gas supply and electrical connection, featuring a plasma delivery device powered by a polymer lithium ion battery and a compressor for gas delivery, along with a docking station for recharging, and a contact start plasma arc torch with a passive pilot arc circuit for reduced size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plasma arc torch system uses traditional fixed gas source and continuous power supply, then cutting performance and reliability are improved, but portability and system mobility deteriorate
Solution Approach 1:
The system is divided into separable components: a handheld plasma torch assembly and a wearable backpack assembly. The backpack contains the power source (battery) and gas source (compressed gas tank), while the torch contains only the plasma delivery device. This segmentation allows the torch to be lightweight and portable while the backpack provides sustained power and gas supply, resolving the contradiction between portability and reliable performance.
Solution Approach 2:
The solution moves from a single-location fixed system to a distributed wearable system. The power and gas sources are relocated from a fixed stationary position to a wearable backpack that moves with the operator, enabling portable operation while maintaining continuous supply capability through the wearable configuration.
2Productivity
If plasma arc torch system uses large gas source and high power supply, then cutting capability and performance are improved, but system size and weight increase
Solution Approach 1:
The system separates the high-power plasma generation components (electrode, nozzle, arc channel) into a lightweight handheld torch, while placing the heavy power source (battery) and gas source (compressed tank) in a wearable backpack. This segmentation allows the torch to remain lightweight for easy handling while the backpack accommodates the heavier components that enable sustained high-performance cutting.
Solution Approach 2:
The system uses periodic recharging and refilling cycles. The battery and gas tank in the backpack are recharged and refilled periodically at base stations, allowing the handheld torch to maintain high cutting capability during operation without carrying excessive weight of power and gas reserves. This periodic replenishment enables sustained productivity without permanently increasing system weight.
3Reliability
If plasma arc torch system operates with continuous gas flow, then arc stability and cutting quality are improved, but gas consumption increases
Solution Approach 1:
The compressed gas tank in the backpack provides continuous gas supply to the handheld torch, enabling sustained arc operation without interruption. This continuous supply maintains arc stability and cutting quality throughout the operation, while the efficient compression and delivery system minimizes overall gas consumption compared to traditional systems.
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
Enables portable and efficient material processing in various locations, including remote sites, with reduced gas consumption and power usage, providing a self-contained solution for cutting, piercing, and marking metallic workpieces, while minimizing system size and production costs.
Implementation Method 1
The plasma arc torch system includes a plasma delivery device receiving current from the power source and gas from the gas source to generate a plasma arc
Implementation Method 2
The torch produces a plasma arc, which is a constricted ionized jet of a plasma gas with high temperature and high momentum
Implementation Method 3
The portable plasma arc torch system includes a battery for providing DC power to the plasma arc torch assembly
Implementation Method 4
The portable plasma arc torch system includes a compressor for providing gas to the plasma arc torch assembly
Data Source
AI summary
A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces. The plasma arc torch can include a wearable portable assembly which includes the replaceable or rechargeable power and gas source. A plasma delivery device receives current from the power source in the assembly and gas from the gas source in the assembly to generate a plasma arc.