Waterjet Cutting System Liquid Level Control
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Solution Overview
Problem
Waterjet cutting systems face challenges in maintaining the integrity of abrasive flow during submerged cutting operations, as the abrasive can become wet and clump or stick together due to contact with liquid, disrupting the cutting stream.
Innovation Solution
A waterjet system with a submerged nozzle in a cutting tank, where the liquid level is controlled using a level sensor and liquid level assembly to keep the liquid below the abrasive supply fitting, and a sealing assembly is used to prevent wetting of the abrasive, ensuring consistent abrasive delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the nozzle is submerged in liquid to perform submerged cutting operation, then the cutting process can be performed underwater to reduce noise and contain debris, but the abrasive becomes wet and clumps together disrupting the cutting stream
Solution Approach 1:
The system divides the cutting tank into distinct zones: an upper dry zone for abrasive storage and a lower wet zone for cutting operations. The abrasive supply fitting is positioned in the upper dry zone while the nozzle operates in the lower wet zone, separating the abrasive from the liquid environment.
Solution Approach 2:
The patent introduces a baffle as an intermediary structure between the abrasive supply fitting and the liquid. The baffle acts as a physical barrier that prevents liquid from reaching the abrasive supply fitting, allowing the abrasive to remain dry while still enabling submerged cutting operations.
2Productivity
If the liquid level is raised to submerge the nozzle for cutting operation, then submerged cutting can be achieved, but the abrasive supply fitting may be exposed to liquid causing clumping
Solution Approach 1:
The system dynamically adjusts the liquid level in the cutting tank based on the operational requirements. The liquid level is raised high enough to submerge the nozzle for effective cutting, but controlled to remain below the abrasive supply fitting level, preventing abrasive wetting while maintaining cutting capability.
Solution Approach 2:
The patent resolves the contradiction by moving to a vertical dimension solution. Instead of horizontally separating components, it uses vertical positioning - placing the abrasive supply fitting at a higher elevation than the nozzle, allowing liquid level to be controlled between these two levels.
3Reliability
If the liquid level is controlled to prevent abrasive wetting, then abrasive flow integrity is maintained, but the system complexity increases with level sensors and control assemblies
Solution Approach 1:
The system employs self-service mechanisms where the liquid level control assembly automatically adjusts the liquid level based on feedback from level sensors. The controller autonomously operates the liquid level control assembly to maintain the liquid level below the abrasive supply fitting, reducing the need for manual intervention.
Solution Approach 2:
The patent implements a feedback control system where level sensors continuously monitor the liquid level and provide feedback to the controller. The controller uses this feedback information to adjust the liquid level control assembly, maintaining the optimal liquid level to prevent abrasive wetting.
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
The controlled liquid level and sealing assembly prevent abrasive clumping, maintaining a stable cutting stream and improving the efficiency of the submerged cutting process by reducing disruptions and maintaining the abrasive's flow integrity.
Implementation Method 1
a level sensor in sensing communication with the liquid in the cutting tank to measure a liquid level within the cutting tank
Implementation Method 2
a high pressure fluid supply selectively fluidly connected to the nozzle to produce a cutting stream
Implementation Method 3
the nozzle is submersible within the liquid to perform a submerged cutting operation
Data Source
AI summary
A waterjet system comprising a nozzle supported within a cutting tank, the cutting tank having a floor and at least one upstanding wall defining a cutting volume, wherein the cutting volume is at least partially filled with a liquid, and wherein the nozzle is submersible within the liquid to perform a submerged cutting operation; a high pressure fluid supply selectively fluidly connected to the nozzle to produce a cutting stream; a controller; a level sensor in sensing communication with the liquid in the cutting tank to measure a liquid height within the cutting tank, the level sensor being in communication with the controller to provide the liquid height to the controller; a liquid level assembly in communication with the controller and adapted to maintain a selected liquid level within the cutting tank.