Torch and Forward Spray Layout for Dross-Free Thermal Grooving
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Solution Overview
Problem
Dross deposition on workpieces during thermal processing, such as plasma processing, leads to reduced productivity and hindered stable processing due to adhesion, despite existing methods like spraying a dross adhesion inhibitor.
Innovation Solution
A processing machine with a torch and a spray system that tilts the torch and positions the spray outlet ahead of the torch tip, ejecting a spray material forward to remove dross from a predetermined zone on the workpiece surface during thermal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a dross adhesion inhibitor is sprayed toward the workpiece before thermal processing, then adhesion of dross to the workpiece is reduced, but dross deposition on the front or back side of the workpiece remains unsolved
Solution Approach 1:
The spray ejects spray material toward the workpiece surface before dross can deposit and adhere. The outlet is positioned ahead of the torch tip in the movement direction, creating a protective spray barrier in advance of where dross will be generated and deposited during thermal processing
Solution Approach 2:
A spray material is introduced as an intermediary substance between the thermal processing zone and the workpiece surface. This spray material intercepts and removes dross particles before they can adhere to the workpiece, acting as a mediating layer that prevents direct contact between dross and the workpiece surface
2Productivity
If the spray outlet is positioned ahead of the torch tip in the movement direction, then dross removal is effective, but the spray may interfere with the thermal processing operation
Solution Approach 1:
The spray is directed toward a specific predetermined zone on the workpiece surface rather than the entire surface. The outlet faces the first surface and targets areas where dross is most likely to deposit, concentrating the spray effect in the critical zone while avoiding interference with the plasma arc and thermal processing zone
Solution Approach 2:
The spray outlet is positioned in space ahead of the torch tip in the movement direction, utilizing the temporal and spatial dimension of the moving processing system. This positioning allows the spray to cover the workpiece surface in the path of motion without physically interfering with the torch or plasma arc, resolving the conflict between spray coverage and processing stability
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
Prevents dross deposition, ensuring stable and automated thermal processing by effectively removing dross without interfering with the processing operation.
Implementation Method 1
the workpiece is subjected to thermal processing such as plasma processing... generating a heat source such as plasma between the tip of a torch and the portion of the workpiece that is to be processed
Implementation Method 2
a spray that ejects a spray material toward a first surface of the workpiece that faces the torch to remove dross deposited on a predetermined zone
Data Source
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AI summary
A processing machine includes: a processing machine main body movable relative to a workpiece; a torch that is secured to the processing machine main body and that generates a heat source between a tip of the torch and a portion of the workpiece that is to be processed; and a spray that ejects a spray material toward a first surface of the workpiece that faces the torch to remove dross deposited on a predetermined zone due to the thermal processing. The torch is tilted such that the tip of the torch is located ahead of an opposite end of the torch in a movement direction in which the processing machine main body moves relative to the workpiece during the thermal processing. An outlet of the spray is located in a direction in which the first surface of the workpiece faces, and is located ahead of the tip of the torch in the movement direction. The spray ejects the spray material forward in the movement direction. The processing machine forms a groove on the first surface of the workpiece by performing the thermal processing while moving the processing machine main body.