Post-Mix Cutting Nozzle Layout for Lower-Pressure Flame Mixing
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Solution Overview
Problem
Prior post-mixed oxygen-fuel cutting nozzles have suboptimal pre-heat gas ratios and dimensions, leading to inefficient combustion and increased gas pressures, resulting in higher consumption and waste.
Innovation Solution
The design features a post-mixed cutting nozzle with a balanced ratio of 20 oxygen bore holes of 0.0595″ diameter and 10 fuel gas bore holes of the same diameter, along with an angled shroud and wider flange to enhance gas flow and mixing efficiency, allowing for lower gas pressure settings and improved combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If prior post-mixed cutting nozzle designs are used, then the structure is simpler, but the pre-heat gas ratio is suboptimal leading to inefficient combustion and increased gas pressures
Solution Approach 1:
The patent applies parameter changes by optimizing the ratio of pre-heat gas holes to fuel gas holes (specifically 2:1), adjusting hole diameters (0.0595 inches), and modifying the number of holes in each pattern. These parameter adjustments achieve optimal combustion efficiency while maintaining reasonable manufacturing complexity.
2Temperature
If prior nozzle designs with higher gas pressures are used, then the flame intensity may be sufficient, but gas consumption increases and waste is generated
Solution Approach 1:
The patent changes pressure parameters by designing a system that achieves optimal combustion at lower gas pressures. The optimized hole configuration and 2:1 pre-heat to fuel gas ratio enable efficient combustion without requiring high pressure, thereby reducing gas consumption and waste while maintaining adequate flame intensity.
3Quantity of substance
If the number of pre-heat gas holes is increased, then the volume of pre-heat gases increases improving combustion, but the device complexity increases
Solution Approach 1:
The patent applies parameter changes by establishing a specific 2:1 ratio between pre-heat gas holes and fuel gas holes, with predetermined hole counts (20 pre-heat holes, 10 fuel holes) and standardized diameters (0.0595 inches). This parameter optimization increases pre-heat gas volume for improved combustion while avoiding excessive complexity through systematic design.
4Loss of substance
If gas pressures are minimized to reduce consumption, then gas waste is reduced, but flame focus and definition may be compromised
Solution Approach 1:
The patent simultaneously optimizes multiple parameters including hole diameter (0.0595 inches), hole ratio (2:1), and hole distribution patterns to achieve a balance where lower gas pressures reduce waste while the precise geometric parameters maintain flame focus and definition through optimized gas flow characteristics.
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 configuration results in a more focused, efficient flame with reduced gas consumption and waste, enabling better flame adjustment and cost savings while promoting thorough mixing and combustion.
Implementation Method 1
a more focused, well-defined flame... thorough mixing and combustion
Data Source
AI summary
A cutting nozzle assembly and associated method of making same includes a nozzle having a central bore extending therethrough along a longitudinal axis through which an associated cutting gas is discharged. A plurality of spaced fuel gas bores are arranged around the central bore, and preheat passages are arranged around both the central bore and the fuel gas bores. A retaining nut receives at least a portion of the nozzle therein, and the retaining nut includes a shroud extending axially outward from a discharge end of the nozzle. At least one of an inner surface of the shroud and the additional preheat passages are angled inwardly toward the longitudinal axis. The fuel gas bores and the preheat passages each have the same cross-sectional dimension, and twice the number of preheat passages as fuel gas bores are provided.