• 专利附录
  • 专利说明
  • 权利要求
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    • 专利摘要:
    OPTIMIZATION AND CONTROL OF PROCESSING MATERIAL USING A THERMAL PROCESSING TORCH The present invention provides a consumable component by a thermal processing torch. The consumable component includes a consumable component body and a signaling device located on or within the consumable component body for transmitting a signal related to the consumable component. The signal may be independent of a detectable physical characteristic of the consumable component.
    公开号:BR112014024906B1
    申请号:R112014024906-7
    申请日:2013-01-14
    公开日:2021-05-18
    发明作者:Michael E. Shipulski；Richard Anderson；Peter Brahan；Wayne Chin；Stephen Liebold；Guy Best；Jon Lindsay
    申请人:Hypertherm, Inc；
    IPC主号:
    专利说明:

    FIELD OF TECHNIQUE
    [0001] The present invention relates generally to the control and optimization of material processing through signals associated with consumable materials from a thermal processing torch. BACKGROUND OF THE INVENTION
    [0002] Thermal processing torches, such as plasma arc torches, are widely used in heating, cutting, chamfering and marking materials. The plasma arc torch generally includes an electrode, a nozzle with a central outlet mounted within a torch body, electrical connections, passages for refrigeration and passages for the arc control fluids (eg, plasma gas) . Optionally, a gas diffuser is used to control fluid flow patterns in the plasma chamber formed between the electrode and the nozzle. On some torches, a retaining cap can be used to hold the nozzle and/or gas diffuser on the plasma arc torch. In operation, the torch produces a plasma arc, which is a compressed jet of an ionized gas with a high enough temperature and strength to help remove the molten metal.
    [0003] Typically, a plasma arc torch includes several consumables. Each consumable can be selected to achieve optimal performance (eg, optimal current level, maximum lifetime, etc.), taking into account specific processing constraints such as the type of material to be cut and/or the desired cut shape. Improper installation of consumables on a torch can result in poor cutting quality and decreased cutting speed. In addition, the incorrect consumable can reduce the useful life of consumables and anticipate the insufficiency of consumables. Even when consumables are correctly installed on a torch, it can be difficult for an operator to manually configure and optimize the torch operating parameters corresponding to the set of selected consumables. In addition, it can be difficult for a torch component manufacturer to ensure good performance if replacement consumables are used in a torch system. SUMMARY OF THE INVENTION
    [0004] Thus, systems and methods are needed for the detection of incompatible consumables in a plasma arc torch. In addition, systems and methods are required to automatically adjust torch operating parameters to improve cut quality and extend consumable life. Specifically, systems and methods are needed to transport information between the various components of a torch system to facilitate efficient control and optimization operation.
    [0005] In one aspect, a consumable component of a thermal processing torch is provided. The consumable component includes a consumable component body and a signaling device located on or within the consumable component body for transmitting a signal related to the consumable component. The signal is independent of a detectable physical characteristic of the consumable component.
    [0006] In another aspect, a method for transmitting information about a consumable component of a thermal processing torch that includes a signal receiver is provided. The method includes installing the signal receiver and the consumable component on the torch. The consumable component has a signal component connected to it. The signal component is adapted to generate a signal which conveys information about the consumable component. The method also includes passing the signal from the signal component to the signal receiver.
    [0007] In another aspect, a system for transmitting information about a thermal processing torch is provided. The system includes a signal detector and at least one consumable selected from a group that includes an electrode, a nozzle, a shield, a retaining cap, a solder tip, and a gas diffuser. The system also includes at least one signaling device connected to at least one consumable for transmitting information about the at least one consumable to the signal detector. The system further includes a controller coupled to the signal detector for i) receiving information from at least one signaling device, and ii) transmitting at least a portion of the information to at least one processor, a gas console, a software of cutting plane, a height controller, and a drive motor, wherein at least one of the processor, gas console, cutting plane software, height controller, and drive motor adjusts the operation of the torch based on at the value of at least one operating parameter.
    [0008] In other examples, any of the above aspects may include one or more of the following features. In some embodiments, the signaling device is a radio frequency identification (RFID) tag for storing information assigned to the consumable component. In some embodiments, the signal is a radio signal, a pneumatic signal, a magnetic signal, an optical signal, or a hydraulic signal. In some embodiments, the torch is a plasma arc torch.
    [0009] In some embodiments, the signal transmitted by the signaling device identifies at least one unique characteristic for a type of consumable component. The type of consumable component may include a nozzle, shield, electrode, internal retaining cap, external retaining cap, gas diffuser, solder tip, or replaceable torch body. The signal transmitted by the signaling device can also identify at least one characteristic unique to the consumable component.
    [0010] In some embodiments, the signaling device is located on a surface of the body, to minimize exposure to heat during torch operation. This surface may be adjacent to a torch cooling mechanism, and away from the torch's plasma arc, or in a torch seal ring channel, or a combination of these. The signaling device may be protected by another torch component to minimize exposure of the signaling device to at least thermal energy, radiation, noxious gases, or high frequency energy.
    [0011] In some embodiments, the signaling device is adapted to transmit the signal before, during or after ignition of the plasma arc, or a combination thereof. In some embodiments, the signal transmitted by the signaling device can be read from inside the torch after the consumable component is installed in the torch. The signal transmitted by the signaling device can also be read from the outside of the torch, after the consumable component is installed in the torch.
    [0012] In some embodiments, the signal component includes a sensor for measuring a physical change of the consumable component. Physical alteration may include physical alteration of the consumable component to restrict the flow rate of gas therethrough.
    [0013] In another aspect, a method is provided to identify consumable products, in a thermal processing system, including a torch. The method includes providing a first consumable having a first and a second consumable characteristic having a second characteristic, wherein the second characteristic is different from the first characteristic and at least one of the first or second characteristic is independent of a measured physical property of the consumable corresponding. The method also includes installing the first and second consumable on the torch. The method further includes communicating information about at least one of the first characteristic of the first consumable or the second characteristic of the second consumable to a controller by a first methodology.
    [0014] In some embodiments, the method includes communicating information about the first characteristic of the first consumable and the second characteristic of the consumable to the controller of the first methodology.
    [0015] In some embodiments, the method also includes communicating information about the first characteristic of the first consumable to the controller by the first methodology and communicating information about the second characteristic of the second consumable to the controller by a second methodology. The second methodology is different from the first methodology. The first methodology may include using a first signaling device coupled to the first consumable to transmit the first characteristic as a first signal, the second methodology comprises using a second signaling device coupled to the second consumable to transmit the second characteristic as a second signal. The first or second signal comprises a pneumatic signal, a radio signal, a light signal, a magnetic signal or a hydraulic signal.
    [0016] In some embodiments, the first consumable and the second consumable are substantially the same. In some embodiments, the first methodology includes using a signaling device coupled to at least one of the first consumable or the second consumable to communicate the information as a signal. The signal can be a pneumatic signal, a radio signal, a light signal, a magnetic signal or a hydraulic signal.
    [0017] It is also to be understood that the various aspects and embodiments of the invention may be combined in various ways. Based on the teachings of this report, a person of ordinary skill in the art can readily determine how to combine these various modalities. For example, in some embodiments, any of the above aspects may include one or more of the above features. An embodiment of the invention can provide all of the above features and advantages. BRIEF DESCRIPTION OF THE DRAWINGS
    [0018] The above described advantages of the invention, together with additional advantages, may be better understood by referring to the following description taken in conjunction with the accompanying drawings. The drawings are not necessarily to scale, rather the general emphasis is placed on illustrating the principles of the invention.
    [0019] Figure 1 shows a cross-sectional view of an exemplary plasma arc torch.
    [0020] Figure 2 shows an example communication network.
    [0021] Figure 3 shows the altered geometry of several consumables.
    [0022] Figure 4 shows an exemplary thermal processing system using the communications network of Figure 2 to control the operation of a plasma arc torch. DETAILED DESCRIPTION OF THE INVENTION
    [0023] Figure 1 is a cross-sectional view of an exemplary plasma arc torch 100 includes a torch body 102 and a torch tip 104. The torch tip 104 includes various consumables, for example, an electrode 105, a nozzle 110, a retaining cap 115, a gas diffuser 120, and a shield 125. The torch body 102, which is generally cylindrical in shape, supports the electrode 105 and the nozzle 110. The nozzle 110 is spaced apart from the electrode 105 and has a central outlet port mounted within the torch body 102. The gas diffuser 120 is mounted to the torch body 102 and has a radially inclined or offset set of gas distribution ports 127 which provides a component. of tangential velocity to the plasma gas flow, causing the plasma gas flow to rotate. The shield 125, which also includes an exit hole, is attached (e.g., threaded) to the retaining cap 115. The retaining cap 115 as shown is on an inner retaining cap firmly attached (e.g., threaded) to the nozzle 110. In some embodiments, an outer retaining cap (not shown) is secured relative to shield 125. Torch 100 may additionally include electrical connections, cooling passages, passages for arc control fluids (e.g., plasma gas), and a power supply. In some embodiments, consumables include a solder tip, which is a nozzle for passing a ignited soldering gas.
    [0024] During operation, the plasma gas flows through a gas inlet tube (not shown) and the gas distribution holes 127 in the gas diffuser 120. From there, the plasma gas flows into a plasma chamber. 128 and out of torch 100, through nozzle outlet port 110 and shield 125. A pilot arc is first generated between electrode 105 and nozzle 110. The pilot arc ionizes the gas passing through the nozzle outlet port. nozzle and the output orifice of the shield. The arc then transfers from the nozzle 110 to a workpiece (not shown) for thermal processing (eg cutting or welding) the workpiece. Note that the illustrated details of the torch 100, including the arrangement of components, the direction of gas and coolant flows, and electrical connections, can take many forms.
    [0025] Different operational processes generally require different shielding and/or plasma gas flow rates, which require different sets of consumables. This leads to a variety of consumables being used in the field. The use of correct consumables and their combinations properly are necessary to achieve optimal cutting performance. Misuse of consumables (for example, using a consumable designed to operate at 65 amps on a torch that is being operated at 105 amps) can result in reduced consumable life and/or poor arc torch performance of plasma.
    [0026] Figure 2 shows an exemplary communication network 200 of the present invention. The communication network 200 includes one or more signaling devices 202, each assigned to a consumable of a thermal processing torch, such as the plasma arc torch 100 of Figure 1. Exemplary consumables include the electrode 105, the nozzle 110, retaining cap 115, gas diffuser 120, and shield 125. In some embodiments, a signaling device 202 is an electrically writable device configured to transmit information about a consumable in the form of one or more signals. For example, the signaling device 202 may be a radio frequency identification (RFID) card or tag, integrated circuit board (CI), or the like. In some embodiments, a signaling device 202 is a detector (e.g., a sensor) for detecting a physical characteristic of the consumable and transmitting the detected information in the form of one or more signals. The communication network 200 also includes at least one receiver 204 for i) receiving the signals transmitted by the signaling devices 202, ii) extracting the data transmitted by the signals, and iii) providing the extracted data to a processor 206 for analysis. and other actions. Processor 206 may be a digital signal processor (DSP), microprocessor, microcontroller, computer, machine tool computer numerical control (CNC), programmable logic controller (PLC), application specific integrated circuit (ASIC), or the like. .
    [0027] In some embodiments, each signaling device 202 is encoded with information relating to the consumable to which the signaling device 202 is assigned. The encoded information can be generic or fixed, such as the name, trademark, manufacturer, serial number and/or type of consumable. Coded information, for example, may include a model number to generally indicate that the consumable is a tip. In some embodiments, encoded information is unique to the consumable, such as the metal composition of the consumable, weight of the consumable, date, time and/or location the consumable was manufactured, the person responsible for the consumable, and the like. As an example, coded information can provide a serial number, which is unique for each torch component manufactured, to distinguish, for example, Type A Nozzle Series #1 from Type A Nozzle Series #2.
    [0028] In some embodiments, the information is encoded to a signaling device 202 at the time of manufacturing the corresponding consumables. Information may also be encoded to a signaling device 202 during the life of the consumable, such as after each use of the consumable. Such information may include the date, time and place of use of the consumables, any abnormalities detected during use, and/or conditions of the consumables after use so that a record can be created to predict a failure situation or end-of-life situation associated with the consumable.
    [0029] The encoded data for a signaling device 202 can also specify operating parameters. For example, for a signaling device 202 related to shield 125, the encoded data for signaling device 202 may indicate the type of shielding gas and/or gas flow rate suitable for shield 125. In some embodiments, encoded data from a signaling device 202 provides information about other related torch components. For example, encoded data can identify other torch components that are compatible with the assigned consumable, aiding in the installation of a torch's entire consumable set to achieve certain performance metrics.
    [0030] In some embodiments, a signaling device 202 includes information about the corresponding consumable independent of a detectable physical characteristic of the consumable. Examples of detectable physical characteristics of consumables include magnetic properties, surface reflectivity, density, acoustic properties, and other tactile characteristics of the consumable measured by a detector installed in the torch. Therefore, examples of data-independent consumables of a consumable's detectable physical characteristic may include the name, type, manufacturer, date of manufacture, place of manufacture, serial number, or other non-tactile characteristics of a consumable. In some embodiments, the signaling device 202 stores the pre-collected consumption information of the consumables, including their physical characteristics, before being installed in the torch, but the signaling device 202 is not configured to actively measure or detect the physical characteristics . However, the signaling device 202 can store physical characteristics about the consumable measured or detected by another device, such as by a sensor. Generally, the signaling device 202 is primarily used for data storage purposes.
    [0031] In some embodiments, the signaling device 202 is located on or on the torch 100. For example, the signaling device 202 may be attached to a surface of a consumable that is ultimately installed within the tip of the torch 104. The signaling device 202 may also be connected to a component within the torch 100 other than the assigned consumable. For example, while a signaling device 202 is designed to store data about the electrode 105, the signaling device 202 may be attached to a surface of the retaining cap 115. In some embodiments, the signaling device 202 is coupled to a source that is not physically associated with the torch 100. For example, the signaling device 202 may be connected to a compartment used to store the consumable and is remote from the consumable as it is installed in the torch 100. If the signaling device 202 is located within torch 100, the surface to which signaling device 202 is attached may be selected to reduce or minimize exposure to heat during operation of torch 100. For example, signaling device 202 may be located close to a cooling mechanism, away from the plasma arc, and/or in a torch seal ring channel 100 to reduce or minimize the e. exposure to heat. In addition, the signaling device 202 can be coated with a heat shielding material to prevent the device from overheating during torch operation. Generally, the signaling device 202 can be located, such as being protected by another torch component, to minimize exposure to thermal energy, radiation, harmful gases (e.g., ozone), and/or high frequency energy.
    [0032] In some embodiments, a signaling device 202 is designed to be durable, that is, functional during and after one or more torch ignitions. In some embodiments, a signaling device 202 is disposable after each use or after several uses of the torch. In some embodiments, a signaling device 202 is writeable once, for example, to encode information about a consumable when the consumable is first manufactured. In some embodiments, a signaling device 202 is multiple times writable, such as for the lifetime of the corresponding consumable.
    [0033] In the communication network 200, the signaling device 202 can wirelessly transmit its stored information to the receiver 204 in the form of one or more signals. Receiver 204 is adapted to process these signals to extract pertinent data about the consumable and transmit the data to processor 206 for analysis. In some embodiments, receiver 204 is located on or on plasma arc torch 100. For example, receiver 204 may be located on torch body 102. In some embodiments, receiver 204 is located at an external location on the torch 100, such as connected to a power supply module, a gas console, processor 206, etc.
    [0034] In some embodiments, at least one of the signaling devices 202 is an RFID tag; and receiver 204 is a reader used to interrogate the RFID tag. In such embodiments, the RFID tag includes an integrated circuit to store the information and an antenna to receive and transmit the RF signals. The reader may include 1) an antenna to transmit the RF signals to the RFID tag to interrogate the tag and 2) components to decode a response transmitted by the RFID tag before forwarding the response to processor 206. The RFID tag may be active or passive. An active RFID tag includes a battery to produce a stronger electromagnetic feedback signal to the reader, thus increasing the possible transmission distance between the RFID tag and the reader. The distance between the RFID tag and a reader can be between about 2.5 cm to 30 meters or more, depending on the output power, the radio frequency used and the type of material the RF signals need to travel through. . In one example, the distance between the RFID tag and an antenna of a corresponding reader can be about 2 to 4 cm. The antenna of the player and the remaining components of the player do not need to be in the same compartment. For example, the reader antenna can be placed on or on the body of torch 102, while the remaining components of the reader are on the outside of torch 100. Using an RFID tag is advantageous because it does not require direct contact (eg, through wire) or direct line of sight (eg via optical signals) to the reader and is well suited for use in harsh environments.
    [0035] In some embodiments, a signaling device 202 is a detector (e.g., a sensor) for detecting at least one physical marker of the consumable to uniquely identify the consumable, by its type or individually. The physical marker can be a physical alteration of the consumable, for example. As shown in Figure 3, identification of a consumable is achieved by modifying the geometry of the consumable in such a way that, when installed on torch 100, it affects the wall of an adjacent refrigerant passage 402, which in turn changes the speed of a coolant that flows through it. Specifically, the altered section of the coolant passage 402 can limit the coolant flow rate. A signaling device 202 can be used to measure the change in pressure as a function of the flow rate of the coolant. Therefore, the measured refrigerant pressure change serves as an identification of the consumable. In another example, as shown in Figure 3, an auxiliary vent duct 404 is connected to a valve and a flow meter is connected to the nozzle 110 to identify the nozzle 110. The valve is opened prior to ignition of the plasma arc and the flow rate in the auxiliary vent duct is measured by a signaling device 202 as a function of plasma pressure during a purge cycle. Therefore, the measured flow rate serves as an identification of the nozzle 110. In another example, one or more uniquely sized measurement holes (not shown) may be drilled into the outer retaining cap to identify the cap, as it is installed on torch 100. The size of each metering hole is configured to exclusively affect the valve pressure and/or shielding gas flow rate. Therefore, these measurements, taken by a signaling device 202 in a routine pre-flow before ignition of the pilot arc, serve to identify the external retaining cap.
    [0036] In yet another example, the shield 125 can be identified by measuring the length of the consumable in relation to a torch data. In an exemplary measurement process, a torch height controller is used to determine the height at which a known torch burns and begins to cut the workpiece. This height can serve as the torch's reference datum. Then, after installing an unidentified consumable for the torch, the height relative to the reference datum is determined. Therefore, simple calculations involving the two heights can be used to determine the relative length of the unidentified consumable. In turn, the relative length of the consumable can be used to identify the consumable, for example by referencing a comparison table that correlates consumable lengths against consumable parts.
    [0037] In some embodiments, a signaling device 202 is a bar code that provides an optical representation of data about the corresponding consumable. A barcode can be read by the receiver 204 in the form of a barcode reader. Generally, a signaling device 202 can transmit data on a consumable in the form of any machine readable signals, including radio signals, optical signals or other light-based signals (e.g., infrared or ultraviolet signals), signals magnetic, pneumatic signals, or hydraulic signals.
    [0038] In some embodiments, a single signaling device 202 is assigned to each consumable of a torch to transmit pertinent information about the corresponding consumable. In some embodiments, two or more signaling devices 202 are assigned to the same consumable to convey different information about that consumable. For example, one signal from device 202 may transmit information unique to the consumable type, such as the model number and operating parameters for the consumable type, while another signaling device 202 may transmit information unique to the consumable itself, such as such as weight and usage history of the consumable. In some embodiments, the signaling devices 202 in the communication network 200 employ different data transmission means. For example, while one signaling device 202 transmits the data as RE signals, another signaling device 202 transmits the data as optical signals. In some embodiments, network 200 includes multiple receivers 204. Each receiver 204 is configured (e.g., tuned) to read signals from one or more of the signaling devices 202 and transmit the extracted data to processor 206. In some embodiments, a single receiver 204 is used to read the signals from all signaling devices 202 in communications network 200. Processor 206 can thus process data associated with several consumables simultaneously.
    [0039] Figure 4 is an exemplary thermal processing system 300 that uses the communications network of Figure 2 to control the operation of a thermal processing torch, such as the plasma arc torch 100 of Figure 1. plasma arc 100 may include one or more consumables, including nozzle 110, electrode 105, shield 125, inner retaining cap 115 and an outer retaining cap 302. At least one signaling device 202 is assigned to at least minus one of the consumables for transmitting the corresponding consumable information to the processor 206 through the receiver 204. The system 300 also includes a power supply 304 to supply the electrical current necessary to generate a plasma arc in the torch 100. signaling devices 202 on respective consumables may be used by processor 206 to control and optimize the operation of at least one of the power supply of 304 plasma, 306 motors and drives, 308 gas console, 310 height controller, and 312 cutting plane software.
    [0040] Processor 206 may be located inside or outside of plasma arc torch 100. In some embodiments, processor 206 is housed in power supply 304. In some embodiments, each plasma power supply 304, motor, and drivers 306, gas console 308, height controller 310, and cutting plan software 312 houses at least one processor for processing data from signaling devices 202 to control the functions of respective modules 304, 306, 308 or 310.
    [0041] Based on the information collected from the signaling devices 202, the processor 206 can regulate many functions of the plasma system simultaneously or almost simultaneously and in real time or near real time. These system functions include, but are not limited to initial sequencing, CNC interface unctions, gas, interrupts. In some embodiments, processor 206 uses consumable information to automatically adjust various parameters of system 300. In some embodiments, processor 206 uses consumable information to verify that certain predefined parameters of system 300 are compatible with consumables within the torch 100. As an example, based on data collected about the various consumables of the torch 100, the processor 206 can control and verify one or more of the following components: (i) power supply 304 settings to regulate the power of the torch 100, (ii) configure the 312 cut plane software for processing a workpiece, (iii) configure the 308 gas console to control the shield and/or plasma gases supplied to the 100 torch, (iv) configure the height controller 310 to adjust the height between the torch 100 and the workpiece, and (v) configure the various motors and drives 306.
    [0042] In some embodiments, based on data collected from one or more signaling devices 202, processor 206 interacts with cutting plane software 312 to automatically select a cutting program that defines the parameters for processing a part such as cutting speed, direction, paths, cutting plane sequences, etc. The cutting program can also define gas types, gas pressure and/or adjust the flow and height control for the torch depending on the data collected from the consumables. Traditionally, when a set of consumables is mounted on a torch, an operator must manually configure the 312 cutting plan software to create the cutting program for the torch by providing information to the software, including the type and thickness of the torch. material of the workpiece being processed, the type of gas to be used, and the rated current of the consumable assembly. In particular, the operator must manually input to the processor 206 the rated current of the consumable set. In the present invention, because the rated current information for each consumable is stored in at least one signaling device 202, the processor 206 can electronically collect the information from one or more signaling devices 202 and automatically determine the configuration of the proper current without user intervention.
    [0043] In some embodiments, based on the consumable data collected, the processor 206 selects an appropriate cutting program from the cutting plan software 312, taking into account the consumable data from the signaling devices 202 and the operating parameters informed by the user, including the characteristics of the workpiece being cut and the desired shape of the cut. For example, an operator can first send a generic program file to the 312 cut plan software. The generic program file specifies for each workpiece thickness, variable cutting speeds, gas flows, notch compensations, height of the blowtorch, etc., which change with the different consumable parts. Thus, after identifying the consumables using the signaling devices 202, the processor 206 interacts with the generic program file to configure a cutting program for the torch. In some embodiments, after a cutting program is created, the processor 206 uses the consumption data collected from the signaling devices 202 to verify that the correct consumables are installed in the torch that are appropriate for the program. In addition, the processor 206 can instruct the cutting plan software 312 to automatically adjust or set the correct program parameters to improve compatibility with the consumables loaded on the torch. For example, a consumable that requires 400A of current has larger inputs and notches compared to a consumable that requires 130A of current. Thus, the 312 cut plan software can select few parts to fit into a cut plan program if the 400A consumable is loaded into a torch.
    [0044] In some embodiments, based on data collected from one or more signaling devices 202, the processor 206 can manipulate a 308 gas console to control the flow of plasma and shield gases to the torch 100, checking and adjusting the gas console settings. The 308 gas console houses solenoid valves, flow meters, pressure gauges and buttons used to control the flow of plasma and shield gases. For example, flow meters are used to set preflow rates and cut-off flow rates for plasma and shield gases. The 308 gas console may also have a multi-inlet gas supply area where the plasma and shield gases are turned on. A switch can be used to select the desired gases. Plasma and shield gases are monitored by gas pressure gauges. In one example, a signaling device 202 associated with the shield 125 of the plasma arc torch 100 may store information on the type and composition of one or more suitable shielding gases for use with the shield 125, along with the adjustment of the optimal flow rate of shielding gases. Based on this data, the 206 processor can interface with the 308 gas console to supply the plasma arc torch 100 with the appropriate shielding gas for the optimal flow rate.
    [0045] In some embodiments, based on data collected from one or more signaling devices 202, the processor 206 manipulates the torch height controller 310, which regulates the height of the torch 100 relative to the workpiece. Torch height controller 310 may include a control module for controlling an arc voltage during cutting by adjusting the standoff (i.e., the distance between the torch 100 and the workpiece) to maintain a voltage value. of predetermined arc. Torch height controller 310 may also include an external control module for controlling the standoff. Torch height controller 310 may further include a tie rod, which is controlled by the control module via a motor or drive 306, to slide torch 100 in a vertical direction relative to the workpiece to maintain the desired tension during the cut. In one example, based on data collected from a torch consumables, torch height controller 310 can automatically determine the height to position the torch relative to the top of a workpiece. Therefore, the 310 torch height controller does not need to perform height idealization to set an appropriate cut height and pierce height before starting arc voltage control.
    [0046] In some embodiments, the processor 206 is configured to prevent the thermal processing system 300 from starting an operation on the workpiece, if it determines that the consumables installed in the torch 100 are incompatible with each other, it is not compatible with the 300 thermal processing system, or inconsistent with other operating parameters pre-selected by an operator. If that determination is made, processor 206 may trigger an audible or visual alert that indicates to the operator that one or more of the connected consumables are not supported and that the consumables must be replaced or the parameters reported by the operator must be revised. In addition, processor 206 can prevent an operation from starting if an alert is triggered. For example, processor 206 may interrupt torch operation if the current configuration of shield 125, which is transmitted to processor 206 by a signaling device 202 assigned to shield 125, is different from the current configuration of nozzle 110, which is transmitted to the processor 206 through a signaling device 202 corresponding to the nozzle 110.
    [0047] In some embodiments, processor 206 is configured to prevent thermal processing system 300 from operating if it determines that at least one of the consumables installed in torch 100 is not manufactured, or otherwise supported by a recommended manufacturer. . For example, processor 206 may interrupt torch operation if it does not recognize the manufacturer's identification, serial number and/or part number transmitted by a consumable signaling device. Thus, thermal processing system 300 can be used to detect and prevent the use of inferior or counterfeit consumables.
    [0048] In some modalities, the processor 206 recommends one or more corrective actions for the operator to face alarm situations. For example, processor 206 may suggest installing one or more consumables in torch 100 to avoid potential incompatibility with other components of thermal processing system 300. Processor 206 may suggest suitable part types for processing based on the configured rating of installed consumable . Processor 206 can recommend a cutting sequence that reconciles the settings of installed consumables with settings provided by the operator.
    [0049] In general, the signaling devices 204 can store information about other torch components in addition to the consumables. For example, the signaling devices 204 can store information about the torch body 102 or about one or more connections. Therefore, as a person skilled in the art will fully appreciate, the exemplary communication network 200 of Figure 2 and the configuration of Figure 3 can be easily adapted to store information about any component of the torch.
    [0050] Furthermore, one skilled in the art will fully appreciate that the invention described herein is not only applicable to plasma cutting devices, but also to welding type systems and other thermal processing systems. In some embodiments, the invention described herein is configured to operate with a variety of cutting technologies, including, but not limited to, plasma arc, laser, oxy fuel, and/or waterjet technologies. For example, signaling devices configured to operate with one or more cutting technologies. Processor 206, based on information transmitted by signaling devices 202, can determine whether consumables installed in a torch are compatible with the specific cutting technology. In some embodiments, based on the selected cutting technology and consumables information, the processor 206 can set or adjust operating parameters, such as the height of the cutter head above the workpiece, which may vary depending on the technology. of cutting and consumables.
    [0051] As an example, it is known to use waterjet systems that produce high pressure, high speed waterjets to cut various materials. These systems typically work by pressurizing water or other suitable fluid at a high pressure (eg, up to 90,000 psi (6,327.63 Kgf/cm2) or more) and forcing the fluid through a small nozzle orifice at high velocity to focus a lot of energy on a small area. An abrasive jet is a type of water jet, which can include abrasive materials in the fluid jet to cut harder materials. In some embodiments, the signaling devices 202 are connected to the consumables of a waterjet system, such as a waterjet nozzle, an abrasive jet nozzle, a mixing tube used to mix fluid with abrasive particles, and /or one or more filters and valves. A signaling device 202 associated with an abrasive jet nozzle can identify, for example, the types of abrasives suitable for use with the nozzle, the amount of pressurized fluid pressure that can be fed to the nozzle, and can also indicate other consumables that are suitable for use with a particular nozzle. Identification of certain combinations of consumable sets for a given waterjet system can also be performed to verify compatibility with a given system or to limit operating conditions and parameters such as maximum pressure or flow settings , or types or amounts of abrasives.
    [0052] It is also to be understood that the various aspects and embodiments of the invention may be combined in various ways. Based on the teachings of this specification, a person skilled in the art can readily determine how to combine these various modalities. Furthermore, modifications may occur for those skilled in the art after reading the specification. The present patent application includes such modifications and is limited only by the scope of the claims.
    权利要求:
    Claims (14)
    [0001]
    1. Consumable component of a thermal processing torch (100) which includes a receiver (204) disposed within the thermal processing torch, CHARACTERIZED in that it comprises: a body of the consumable component; and a signaling device (202) including a radio frequency identification (RFID) tag located on or within the body of the consumable component for transmitting a signal related to the consumable component, the signal which is independent of a detectable physical characteristic of the consumable component, the signaling device being configured to store information to be transmitted by the signal that identifies two or more among the name, brand, manufacturer, serial number, usage history, at least one operating parameter and type , and the signaling device being located within the thermal processing torch when the consumable component is installed in the thermal processing torch and the signaling device being configured to allow the signal to be readable by the receiver disposed within the thermal processing torch .
    [0002]
    2. Consumable component according to claim 1, CHARACTERIZED by the fact that the signal transmitted by the signaling device identifies at least one unique characteristic for the type of consumable component, where optionally the type of consumable component comprises a nozzle (110 ), a shield (125), an electrode (105), an inner retaining cap (115), an outer retaining cap (302), a gas diffuser (120) or a soldering tip.
    [0003]
    3. Consumable component according to claim 1, CHARACTERIZED by the fact that any of the following applies: a) the signal transmitted by the signaling device identifies at least one unique characteristic for the consumable component that is capable of distinguish the consumable component from another consumable component of the same type; b) the signaling device is adapted to transmit the signal before, during and or after ignition of the plasma arc, or a combination thereof; or c) the torch comprises a plasma arc torch.
    [0004]
    4. Consumable component according to claim 1, CHARACTERIZED by the fact that the signaling device is located on a surface of the body, to minimize exposure to heat during the operation of the torch; where optionally, a) the surface is adjacent to a torch cooling mechanism, and away from the torch plasma arc, or in a torch seal ring channel, or a combination thereof, and/or b) the torch device signaling is protected by another torch component to minimize exposure of the signaling device to at least one thermal energy, radiation, noxious gases, or high frequency energy.
    [0005]
    A method for transmitting information about a consumable component (105, 110, 115, 120, 125, 302) of a thermal processing torch (100) including a signal receiver (204) as defined in claim 1, method being CHARACTERIZED by comprising: installing on the torch the signal receiver and the consumable component, wherein the consumable component has a signal component connected to it, the signal component comprises a radio frequency identification (RFID) tag and is adapted to generate a signal that conveys information about the consumable component; locate the signal component within the thermal processing torch when the consumable component is installed in the thermal processing torch; communicating the signal from the signal component to the signal receiver, the signal being readable by the signal receiver within the thermal processing torch; and updating the information encoded in the signal component after a torch operation.
    [0006]
    6. Method according to claim 5, CHARACTERIZED by the fact that any of the following applies: a) the consumable component comprises an electrode (105), a nozzle (110), a shield (125), a diffuser gas (120), a retaining cap (115, 302) or a replaceable torch body (102); b) the RFID tag is configured to store the information assigned to the consumable component; c) the signal comprises a radio signal; or d) updating the information encoded in the signal component comprises writing the signal component data relating to the date, time or location of use of the consumable component after torch operation, where optionally the method further comprises detecting a failure or a situation of the consumable component's life based on the current information.
    [0007]
    7. System for transmitting information about a thermal processing torch (100), the system being CHARACTERIZED by comprising: a signal detector (204) disposed in the thermal processing torch; at least one consumable selected from a group comprising: an electrode (105), a nozzle (110), a shield (125), a retaining cap (115), a soldering tip, and a gas diffuser (120) ; at least one signaling device, comprising a radio frequency identification (RFID) tag, connected to the at least one consumable for transmitting information about the at least one consumable to the signal detector, the at least one signaling device being configured to storing information identifying at least one operating parameter of the torch and a value for at least one operating parameter, where the signaling device is located within the thermal processing torch when the consumable is installed in the thermal processing torch and the device The signaling device is configured to allow the information readable by the signal detector within the thermal processing torch; and a controller coupled to the signal detector for i) receiving information from the at least one signaling device, and ii) transmitting at least a portion of the information to at least one processor (206), a gas console (308) , a cutting plan software (312), a height controller (310), and a drive motor (306), at least one of the processor, gas console, cutting plan software, height controller , and the drive motor adjusts torch operation based on the value of at least one operating parameter.
    [0008]
    The method of claim 5, wherein the method is for identifying the consumables, in a thermal processing system including a torch, the method being CHARACTERIZED by comprising: providing a first consumable (105, 110, 115, 120, 125, 302) having a first feature and a second consumable (105, 110, 115, 120, 125, 302) having a second feature, wherein the second feature is different from the first feature and at least one of the the first or second feature is independent of a measured physical property of the corresponding consumable, the first consumable includes a signaling device comprising a radio frequency identification tag (RFID) connected thereto for transmitting information about the first features of the first consumable; installing the first and second consumables on the torch such that the signaling device is located within the thermal processing torch and is readable within the torch; and communicating information about at least one of the first characteristics of the first consumable or the second characteristic of the second consumable to a controller by a first methodology.
    [0009]
    9. Method according to claim 8, CHARACTERIZED by the fact that: a) the first methodology comprises communicating, by the signaling device, the information as a signal, the signal being a radio signal; and/or b) the method further comprises communicating information about the first characteristic of the first consumable and the second characteristic of the second consumable to the controller by the first methodology.
    [0010]
    10. Method according to claim 8, CHARACTERIZED in that it additionally comprises: communicating information about the first characteristic of the first consumable to the controller by the first methodology; and communicating information about the second characteristic of the second consumable to the controller by a second methodology, wherein the second methodology is different from the first methodology; where optionally the first methodology comprises using the signaling device coupled to the first consumable to transmit the first feature as a first signal, the second methodology comprises using a second signaling device coupled to the second consumable to transmit the second feature as a second signal, the second signal comprises a pneumatic signal, a radio signal, a light signal, a magnetic signal or a hydraulic signal.
    [0011]
    11. Method according to claim 5, in which the signal receiver is an RFID reader, the method being CHARACTERIZED in that it comprises: storing, in the RFID tag, the data corresponding to two or more between the name, brand, manufacturer , serial number, type, usage history, and at least one operating parameter of the consumable component, wherein at least a portion of the data identifies a unique characteristic of the consumable component; install, on the torch, the RFID tag, RFID reader and the consumable component, where the consumable component has the RFID tag attached to it, the RFID tag is adapted to generate a signal that transmits the data; locate the RFID reader and RFID tag inside the torch or on a torch surface; communicate the RFID tag signal to the RFID reader; and updating the data stored on the RFID tag after a torch operation to include information related to the use of the consumable component.
    [0012]
    12. Method according to claim 11, CHARACTERIZED by the fact that any of the following applies: a) the data identify at least one unique characteristic of the type of consumable component; b) the type of consumable component comprises a nozzle (110), a shield (125), an electrode (105), an internal retaining cap (115), an external retaining cap (302), a gas diffuser (120 ) or a soldering tip; c) at least a single characteristic of the consumable component is capable of distinguishing the consumable component from another consumable component of the same type; d) at least one of the RFID tag or RFID reader is protected by another torch component to minimize exposure of the RFID tag or RFID reader to at least one thermal energy, radiation, harmful gases, or high frequency energy ; or e) the method further comprises predicting a failure or an end-of-life situation of the consumable component based on information relating to the use of the consumable component.
    [0013]
    13. Method according to claim 11, CHARACTERIZED by the fact that at least one of the RFID tag or the RFID reader is located on a surface of the body to minimize exposure to heat during the operation of the torch; where optionally the surface is adjacent to a torch cooling mechanism, away from the torch plasma arc, or in a torch seal ring channel, or a combination of these.
    [0014]
    14. Method according to claim 11, CHARACTERIZED by the fact that a first part of the data is fixed and a second part of the data is modifiable during a lifetime of the consumable component; where optionally the first portion of the data comprises the serial number of the consumable component and the second portion of the data relates to use of the modifiable consumable component after use of the consumable component.
    类似技术:
    公开号 | 公开日 | 专利标题
    BR112014024906B1|2021-05-18|optimization and control of the processing material using a thermal processing torch
    JP6397102B2|2018-09-26|Replaceable consumable parts for heating torches, torches and related methods
    US10346647B2|2019-07-09|Configuring signal devices in thermal processing systems
    US9737954B2|2017-08-22|Automatically sensing consumable components in thermal processing systems
    US20130263420A1|2013-10-10|Optimization and Control of Material Processing Using a Thermal Processing Torch
    US9672460B2|2017-06-06|Configuring signal devices in thermal processing systems
    US9395715B2|2016-07-19|Identifying components in a material processing system
    CN105900533A|2016-08-24|Automated cartridge detection for a plasma arc cutting system
    WO2016138524A1|2016-09-01|Automatically sensing consumable components in thermal processing systems
    CN107073625B|2020-09-01|Configuring a signaling device in a thermal processing system
    同族专利:
    公开号 | 公开日
    KR102036216B1|2019-10-24|
    RU2634709C2|2017-11-03|
    US10455682B2|2019-10-22|
    AU2013243978A1|2014-10-23|
    EP2835040A2|2015-02-11|
    RU2014144287A|2016-05-27|
    US20130264320A1|2013-10-10|
    EP2835040B1|2019-05-08|
    BR112014024906A2|2017-09-19|
    TR201908419T4|2019-07-22|
    AU2013243978B2|2016-09-15|
    WO2013151602A2|2013-10-10|
    CN104322152A|2015-01-28|
    JP2015520676A|2015-07-23|
    KR20150001790A|2015-01-06|
    WO2013151602A3|2014-03-20|
    JP6251722B2|2017-12-20|
    WO2013151602A4|2014-05-22|
    CN104322152B|2018-04-13|
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    法律状态:
    2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-12-31| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-07-14| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|
    2021-04-13| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-05-18| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 14/01/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/439,259|2012-04-04|
    US13/439,259|US10455682B2|2012-04-04|2012-04-04|Optimization and control of material processing using a thermal processing torch|
    PCT/US2013/021364|WO2013151602A2|2012-04-04|2013-01-14|Optimization and control of material processing using a thermal processing torch|
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