Water-Jet Cutting Head Ring Sensor for Tilted Distance Control
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Solution Overview
Problem
High-pressure water jet cutting devices face challenges in achieving precise cutting edge angles and preventing damage to the cutting head and focusing tube due to the need for accurate distance measurement and control between the cutting nozzle and the workpiece, especially when dealing with flat materials and complex geometries, which affects cutting quality and operational safety.
Innovation Solution
A sensor system with a movable ring element and switching means is integrated into the cutting head, allowing for precise distance measurement and automatic adjustment or shutdown of the cutting head movement to prevent collisions and maintain optimal cutting conditions, enabling efficient cutting of flat workpieces with varying edge angles and complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor with a closed ring element is used for distance measurement, then measurement precision is improved, but the cutting head cannot be tilted at large angles and the sensing element may collide with workpiece protrusions
Solution Approach 1:
The closed ring sensing element is segmented by introducing recesses (60° to 80° openings) that divide the ring into separate sections. This segmentation allows the cutting head to tilt at large angles (up to 68°) without the sensing element colliding with workpiece protrusions, while still maintaining accurate distance measurement through the remaining ring portions.
Solution Approach 2:
The ring element is designed with asymmetric recesses positioned specifically to avoid interference with the cutting head's tilting motion. The recesses are strategically placed to allow the cutting head to tilt within a wide angle range while maintaining measurement capability in the critical measurement zones.
2Manufacturing precision
If the sensing element is positioned close to the workpiece surface for accurate measurement, then cutting quality is improved, but the risk of collision with protrusions increases
Solution Approach 1:
The segmented ring structure with recesses creates gaps that prevent continuous contact with workpiece protrusions. The sensing element can maintain close proximity to the workpiece surface for accurate distance measurement and high cut quality, while the recesses provide escape paths that prevent collisions and enhance operational reliability.
3Adaptability or versatility
If the cutting head is tilted at large angles for complex geometries, then adaptability is improved, but the sensing element may collide with protrusions
Solution Approach 1:
The recesses in the ring element create discontinuities that allow the cutting head to tilt at large angles (up to 68°) without the sensing element colliding with workpiece protrusions. This segmentation enables handling of complex geometries while maintaining operational reliability.
Solution Approach 2:
The cutting head's tilting capability is dynamically adjusted based on the workpiece geometry. The recessed ring design allows the system to adaptively change the cutting angle as needed while the sensing element automatically avoids collision through its segmented structure.
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 sensor system ensures precise distance measurement and automatic adjustment, enhancing cutting quality and preventing damage to the cutting head and focusing tube, allowing for efficient cutting of flat workpieces with small or large edge angles and complex geometries, thereby optimizing cut production and operational safety.
Implementation Method 1
a sensing element opposite the mounting is a movable ring element for determining the distance between the focusing tube and the workpiece surface
Implementation Method 2
water is forced through a nozzle at a pressure of up to 6000 bar and higher, creating a focused, supersonic water jet capable of cutting through considerable thicknesses
Implementation Method 3
Hard, flat materials such as glass, metal, composites, stone slabs, and the like can be cut using an abrasive water jet, according to current technology. In this process, abrasive material is added to the water jet after the nozzle to increase its kinetic energy
Data Source
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AI summary
The invention relates to a sensor (1) with a sensing element (2) and a switching means (3) in a control system for a directed movement of a focusing tube (4) in a cutting head (5) of a high-pressure water jet cutting device.To optimize the cutting quality during ongoing cutting operations and to prevent damage to parts of the device, the invention provides that the sensing element (2) is formed as a movable ring element (21) around a bundled cutting jet emerging from a focusing tube (4) of a cutting head (5), this ring element (21) is positioned parallel to the workpiece surface and can be adjusted at least temporarily to control the distance between the focusing tube (4) and the workpiece, and that a lateral load on the sensing element (2) directed essentially parallel to the workpiece surface by the switching means (3) of the sensor (1) can trigger a shutdown of the cutting head movement and, if necessary, the formation of the cutting jet.