WATERJET CUTTING MACHINE SYSTEM

Embodiments of the present disclosure may include a waterjet cutting machine, including a frame, a cap including a liquid inlet port and an abrasive supply port, a pivoting assembly disposed at the second end of the frame and further including a nozzle that may be pivotable about a horizontal axis between +/−130 degrees relative to the horizontal axis. The nozzle may be configured to discharge a high-pressure liquid and an abrasive to perform a shape nozzle and taperless cutting operation. The waterjet cutting machine may also include a shaft assembly disposed within the frame that may rotate about a vertical axis as well as a rotary bowl with a liner selectively removably coupled to the shaft with standoff fasteners and a plurality of set screws. The rotary bowl and liner may protect the inside surface of the waterjet cutting machine from the effects of the abrasive for optimal performance.

FIELD

The present technology relates to a waterjet cutting machine system.

INTRODUCTION

Waterjet cutting machines are used to cut a variety of materials, including metals, plastics, and composites. These machines typically use a high-pressure stream of water to cut through the material, and may also use an abrasive material to enhance the cutting process. Certain approaches to the design of waterjet cutting machines have included fixed nozzle designs, where the nozzle is stationary and the material to be cut is moved beneath it, and gantry-style designs, where the nozzle is mounted on a movable gantry that moves over the material to be cut. Other approaches have included designs that use multiple nozzles to increase cutting speed, or that use robotic arms to move the nozzle over the material. However, none of these approaches provide a comprehensive and integrated solution that combines the features described in this disclosure.

Abrasive erosion is also a concern when it comes to waterjet cutting machines. Exposure to abrasive particles, such as garnet, aluminum oxide, and/or sand as used in the cutting process, can gradually wear away internal components of the machine due to the texture of the abrasive contacting internal surfaces of the waterjet cutting machine. This erosion can lead to reduced cutting accuracy, decreased machine efficiency, and increased maintenance requirements. In particular, abrasive eroding away aluminum material of the waterjet cutting machine can lead to costly repairs and replacement of the waterjet cutting machine. To mitigate these problems, regular inspections, regular replacements, and proper maintenance is required to ensure optimal performance of the waterjet cutting machine. However, these solutions can create different issues which affect the overall efficiency, operating time, and costs of the waterjet cutting machine.

Accordingly, there is a need for a waterjet system with flexibility in material cutting approaches and which can optimize dispensing and minimize wear associated with use of abrasive materials. The present technology meets these needs in providing a nozzle capable of rotating +/−130 degrees about a horizontal axis along with providing a replaceable rotary bowl with a liner capable of receiving an abrasive and providing minimal corrosion against the rotary bowl to reduce erosion of the interior surface of the waterjet cutting machine.

SUMMARY

In concordance with the instant disclosure, a waterjet system with a nozzle capable of rotating +/−130 degrees about a horizontal axis along with providing a replaceable rotary bowl with a liner capable of receiving an abrasive and providing minimal corrosion against the rotary bowl to reduce erosion of the interior surface of the waterjet cutting machine, has surprisingly been discovered.

Embodiments of the present disclosure may include a waterjet cutting machine, including a frame, a cap including a liquid inlet port and an abrasive supply port, a pivoting assembly including a nozzle that may be pivotable about a horizontal axis between +/−130 degrees relative to the horizontal axis, a shaft assembly disposed within the frame and including a shaft, and a rotary bowl with a liner removably disposed atop the shaft. The pivoting assembly may be configured to rotate about a first vertical axis powered by a motor and further coupled to the nozzle. The nozzle may be configured to discharge a high-pressure liquid and an abrasive to perform a shape nozzle and taperless cutting operation while also capable of rotating +/−130 degrees relative to a horizontal axis. Advantageously, the rotation of the nozzle at +/−130 degrees provides a capability of performing the shape nozzle and taperless cutting operation in difficult to reach areas, which other waterjet cutting machines cannot provide.

The rotary bowl may be selectively removably coupled to the shaft with standoff fasteners by set screws disposed in the set screw apertures. The rotary bowl may include a liner to protect the inside surface of the waterjet cutting machine from the abrasive. The liner may receive the abrasive through the abrasive supply port such that the liner may be capable of absorbing the natural effects of the abrasive rather than eroding away the inside of the waterjet cutting machine. The liner may be manufactured with stainless steel as well and may be placed inside a bottom portion of the interior surface of the rotary bowl.

By providing a rotary bowl and liner that are easily replaceable, the waterjet cutting machine is configured to mitigate erosion of the inside surface of a waterjet cutting machine resulting from the abrasive and provides an efficient means to reduce replacement of the entire waterjet cutting machine. This effectively provides a waterjet cutting machine system that is less costly and requires less maintenance than other waterjet cutting machines that do not utilize the rotary bowl with the liner. Additionally, the shaft assembly may be further configured to rotate the rotary bowl about a second vertical axis to which the shaft assembly also rotates about the second vertical axis at an infinite rotation. The shaft assembly may further house a motor with double the torque of other waterjet cutting machines to provide optimal performance and improved rotational speed and accuracy.

DETAILED DESCRIPTION

The present technology relates to a waterjet cutting machine100with a pivoting assembly114capable of rotating a nozzle116+/−130 degrees relative to a horizontal axis (A) and a rotary bowl142with a liner148that is replaceable and also capable of receiving an abrasive to provide minimal corrosion to the waterjet cutting machine100, as shown generally inFIGS.1-18. Advantageously, the rotation of the nozzle at +/−130 degrees provides a capability of performing the shape nozzle and taperless cutting operation in difficult to reach areas. Additionally, the waterjet cutting machine is configured to mitigate erosion of the inside surface of a waterjet cutting machine resulting from the abrasive and provides an efficient means to reduce replacement of the entire waterjet cutting machine.

The industry has restrained itself previously to only utilizing, producing, and selling nozzles with a circular or round cross-section in the interior for the high-pressure liquid and abrasive material to pass through. There may be an inside diameter (ID) and an outside diameter (OD) to which the dimensions for both may be different based on manufacturer and application. However, they are always round in cross-section regarding the control of focusing the stream.

As used and described herein relating to the waterjet cutting machine system100of the present disclosure, the term “shape nozzle” is used to define the stream control by using Electric Discharge Machining (hereinafter “EDM”) to machine a shape through the inside length of the nozzle116. Without limiting to any particular shape in cross-section, other shapes contemplated include a square, half moon, triangle, oval and more shapes. One of ordinary skill in the art may select suitable shapes of the shape nozzle within the scope of the present disclosure.

The use of the shape nozzle in accordance with the present disclosure has several advantages including, but not limited to, improved cutting speeds/feed rates, better abrasive utilization, finer cut details such as tight inside corners. This permits for cutting of materials that are thicker in size or harder in machinability. As a non-limiting example, the thickness in size may start at 1-inch or 25-millimeters in materials such as carbon steel, stainless steel, titanium, and many other materials.

As further used and described herein relating to the waterjet cutting machine system100of the present disclosure, the term “taperless” and any terms relating to “taper control” are related to the tilting of the nozzle116dynamically to offset the flared path that the jet stream takes when cutting through different materials. The thicker, denser, or harder the machinability of the material, the more apparent this description becomes. The tilt control is designed to give the finished dimensions of a cut part the same tolerance and measurement at the top of the material as in the bottom of the finished part. Advantageously, with the tilt being controlled properly, any dimensional error ends up in the scrap side of the cut where there is no concern to the quality of the finished project.

FIGS.1-18illustrate a waterjet cutting machine100, according to an embodiment of the present disclosure. The waterjet cutting machine100may include a frame102, a cap108, a pivoting assembly114, a shaft assembly130, and a rotary bowl142. The frame102may include a first end104and a second end106, where the cap108may be disposed on the first end104of the frame102and the pivoting assembly114may be disposed at the second end106of the frame102. The shaft assembly130may further be disposed within the frame102and the rotary bowl142may be removably disposed atop the shaft134and beneath the cap108. Advantageously, the frame102may be sized to accommodate the shaft assembly130within the frame102. The cap108may include a liquid inlet port110and an abrasive supply port112. Desirably, the cap108may include a diameter to cover a bearing of the rotary bowl142.

The shaft assembly130may include a motor132and a shaft134which is cylindrical in shape, as shown inFIGS.7B and8. As a non-limiting example, the motor132may be a direct drive motor with a torque of 18 Newton-meters. Other waterjet cutting machines provide a motor with a torque of 9 Newton-meters. Advantageously, the motor132with a torque of 18 Newton-meters provides improved rotational speed and accuracy of the waterjet cutting machine100. One of ordinary skill in the art may select a suitable motor132.

As shown inFIG.7A, the shaft assembly130may be configured to rotate the pivoting assembly114about a first vertical axis (B) while the shaft assembly130may be configured to rotate about the second vertical axis (C). Advantageously, the shaft assembly130may be configured to rotate the second vertical axis (C) at an infinite rotation without tangling the system's cables and wires. The shaft134may include a plurality of standoff fasteners138disposed on a top portion of the shaft134and an elongate bore136formed through a length of the shaft134, as shown inFIG.7B. The elongate bore136of the shaft134may be in fluid communication with both the liquid inlet port110of the cap108and the nozzle116of the pivoting assembly114to direct water through the system. The shaft134may also include an elongate groove140formed along the length of the shaft134. It should be appreciated that the flexible tube127may be disposed inside of and along an entire length of the elongate groove140, which directs the abrasive through the shaft134, as further explained below. In general, the elongate bore136and the elongate groove140are illustrated inFIG.7B. It should be appreciated that the elongate bore136may extend the entire length and through the center of the shaft134. The elongate bore136may also be spaced apart from the elongate groove140. It should also be appreciated that the elongate groove140may be formed in an outer surface of the shaft134and may extend the entire length of the shaft134as well. The shaft assembly130may be protected by a cover131that may be coupled to the shaft assembly130by the first end104of the frame102and the second end106of the frame102, as shown inFIG.7B.

The pivoting assembly114may further include a swing arm118, an abrasive wire guard120, a mixing body122, a motor166, and a nozzle116that may be pivotable about a horizontal axis (A) between +/−130 degrees relative to the horizontal axis (A), with reference toFIGS.1,4-8, and18. Advantageously, the nozzle116may be configured to discharge a high-pressure liquid and an abrasive to perform a shape nozzle and taperless cutting operation at +/−130 degrees about the horizontal axis (A). In particular, as shown inFIG.1, the nozzle116rests at 0-degrees relative to the horizontal axis (A) when pointing straight down. With reference toFIG.6, the nozzle116is capable of rotating up to + or −130 degrees relative to the horizontal axis (A), as shown in phantom inFIG.6. When the nozzle116points straight down, as shown inFIG.1, it rests back at 0-degrees but is capable of rotating 130 degrees in the other direction. Other waterjet cutting machines can only rotate the nozzle about a horizontal axis +/−60 degrees to 90-degrees, at most. Desirably, this capability of rotating to +/−130 degrees is beneficial for hard-to-reach areas when utilizing the waterjet cutting machine100.

With further reference to the pivoting assembly114, shown generally inFIGS.1,4,5,7A-7B,8, and18, the swing arm118may be configured to rotate about the first vertical axis (B) and the abrasive wire guard120may be configured to protect an electrical wiring configuration of the swing arm118. The mixing body122may include a first end124and a second end126and a side mix port128. The first end124of the mixing body122may be in fluid communication with the elongate bore136of the shaft134for receiving water from the liquid inlet port110through the elongate bore136of the shaft134. The side mix port128of the mixing body122may be configured to receive the abrasive for mixing the abrasive with the high-pressure liquid within the mixing body122and for delivery to the nozzle116. The second end126of the mixing body122may be in fluid communication with the nozzle116which ultimately releases the high-pressure liquid with the abrasive for a shape nozzle and taperless cutting operation.

As shown inFIG.18, a flexible tube127may be coupled to and in communication with the side mix port128of the mixing body122in order to gravity feed the side mix port128of the mixing body122with the abrasive. It should be appreciated that there is also a venturi-generated vacuum from the flow of the high-pressure liquid that also facilitates the delivery of the abrasive to the side mix port128. The flexible tube127may further extend from the side mix port128through the elongate groove140of the shaft134and may be in communication with the abrasive aperture158of the rotary bowl142to receive the abrasive. The flexible tube127may be attached to the abrasive aperture158at a fitting (not shown) on an underside of the abrasive aperture158from the bottom surface of the rotary bowl142, for example. The abrasive supply port112supplies the abrasive to the rotary bowl142and the abrasive may travel through abrasive aperture158and into the flexible tube127disposed inside the elongate groove140of the shaft134. The abrasive travels the length of the flexible tube127and is then received by the side mix port128of the mixing body122.

As further described below, the shaft assembly130may be configured to rotate the rotary bowl142infinitely or continuously about the second vertical axis (C). The connection of the flexible tube127to the rotary bowl142rotating infinitely or continuously about the second vertical axis (C) maintains the integrity of the flexible tube127while the rotation occurs. In other words, if the rotary bowl142were not also rotating infinitely or continuously about the second vertical axis (C), the flexible tube127coupled to the rotary bowl142would otherwise twist and snap, thereby rendering the flexible tube127unusable.

The swing arm118may be rotatably coupled to the shaft assembly130, as shown inFIGS.7A and18. Particularly, the swing arm118may rotate about the first vertical axis (B) while the nozzle116may pivot about the horizontal axis (A)+/−130 degrees. The swing arm118may further include a first planar end160and a second planar end162. The first planar end160may be orthogonal to the second planar end162and the first planar end160of the swing arm118may be coupled to the second end106of the frame102, as shown inFIGS.4,5,7A, and7B.

With reference toFIGS.5and7B, the swing arm118may also include a motor166, a tilt mount plate168, a tilt adjustment plate170, and a cutting head mount172. The first planar end160of the swing arm118may be coupled to the second end106of the frame102. The motor166may be mounted to the second planar end162of the swing arm118. In particular, the nozzle116of the pivoting assembly114may be coupled to the motor166such that the motor166may be configured to pivot the nozzle116+/−130 degrees about the horizontal axis (A). As a non-limiting example, the motor166may be a Yaksawa electric motor (Yaksawa Electric Corporation, Japan). One of ordinary skill in the art may select suitable motors166as part of the pivoting assembly114.

With continued reference toFIG.7B, the swing arm118may be configured to receive a rotation limit bar164. In particular, the rotation limit bar164may be coupled to the second planar end162of the swing arm118. It should be appreciated that coupling the rotation limit bar164to the swing arm118may limit the nozzle116from pivoting more than +/−72.5 degrees relative to the horizontal axis (A). When the rotation limit bar164is not coupled to the swing arm118, the nozzle116may be capable of pivoting about the horizontal axis (A)+/−130 degrees, as described hereinabove.

Desirably, the rotation limit bar164is capable of minimizing the full degree of rotation of the nozzle116relative to the horizontal axis (A) based on specific projects utilizing different water tank types. Standard water tanks cannot handle the nozzle116pivoting the full +/−130 degrees relative to the horizontal axis (A). So, the rotation limit bar164may be an additional component selectively added by the user or installer to the waterjet cutting machine system100in order to limit the degree of rotation to +/−72.5 degrees relative to the horizontal axis (A). Advantageously, the user or installer may include and couple the rotation limit bar164to the swing arm118or alternatively remove the rotation limit bar164to allow for the full +/−130 degree of rotation capability.

Additionally, the tilt mount plate168may be coupled to the motor166and the tilt adjustment plate170may be coupled to the cutting head mount172in series. The cutting head mount172may further be coupled to the nozzle116. The tilt mount plate168, the tilt adjustment plate170, and cutting head mount172may all be secured and fastened by a plurality of set screws155. An alignment compensation pivot174may be provided between the coupling of the tilt mount plate168and the motor166. The alignment compensation pivot174may be manually adjusted.

The rotary bowl142may include an upper lip144, an inlet tube146, an interior surface150, a liner148, and a wear cup149as shown inFIGS.7B-9and11-17. Particularly, the rotary bowl142may be manufactured from aluminum. The interior surface150may include a top portion152and a bottom portion154. The top portion152may include a larger diameter than the diameter of the bottom portion154of the rotary bowl142. As a non-limiting example, the top portion152may include a 0.13×45-degree chamfer. As another non-limiting example, the bottom portion154may include a 0.05×45-degree chamfer. Generally, the rotary bowl142may have a larger diameter than the diameter of the liner148in order for the rotary bowl to hold the liner148inside the interior surface150as well as couple the wear cup149to the top portion152of the rotary bowl142. Since the rotary bowl142may have a larger diameter to accommodate the addition of the liner148and coupling of the wear cup149, the bearing size may also be sized to accommodate the diameter of the rotary bowl142for optimal performance of the waterjet cutting machine100.

The inlet tube146may be in fluid communication with the liquid inlet port110of the cap108and may be configured to receive the high-pressure liquid from the liquid inlet port110. As a non-limiting example, the inlet tube146may have a 0.01×45-degree chamfer. The interior surface150of the rotary bowl142may be configured to receive the abrasive from the abrasive supply port112. The shaft assembly130may be further configured to rotate the rotary bowl142about the second vertical axis (C) at an infinite rotation.

With further reference toFIGS.12and13, the rotary bowl142may also include an O-ring groove145, as shown inFIG.12, capable of receiving an O-ring143, and a snap ring groove147, as shown inFIG.13, respectively. Advantageously, the O-ring groove145provides placement for the O-ring143to create a seal against the cap108for maintaining the vacuum. This vacuum specifically helps pull the abrasive received by the abrasive supply port112down the abrasive aperture158of the rotary bowl142through the flexible tube127disposed inside the elongate groove140of the shaft134, as further described below. Desirably, the snap ring groove147helps keep the wear cup149(as shown inFIG.7B) in place.

The rotary bowl142may further include an abrasive aperture158, one or more standoff apertures156, and one or more set screw apertures157. The abrasive aperture158may be in the bottom portion154of the interior surface150of the rotary bowl142. The abrasive aperture158may be aligned with the flexible tube127inside the elongate groove140of the shaft134for permitting abrasive from the abrasive supply port112to gravity feed from the rotary bowl142through the abrasive aperture158and into the flexible tube127disposed inside the elongate groove140of the shaft134to ultimately send the abrasive to the side mix port128of the mixing body122. The one or more standoff apertures156may be disposed on a bottom surface of the rotary bowl142and the one or more set screw apertures157may be disposed on a side surface of the rotary bowl142. The one or more standoff apertures156may be in communication with the one or more set screw apertures157and a respective standoff aperture156may selectively receive a respective standoff fastener138of the shaft134, as shown inFIG.9.

The rotary bowl142may be selectively removably coupled to the shaft134with the standoff fastener138by a set screw155disposed in the set screw aperture157, as further shown inFIG.9. Advantageously, the rotary bowl142may be easily replaced by un-fastening the set screw155from the set screw apertures157of the rotary bowl142. By providing a rotary bowl142that is easily replaceable, it mitigates erosion of the inside surface of the waterjet cutting machine100due to the abrasive and provides an efficient way to reduce replacement of the entire waterjet cutting machine100. This effectively provides a system that is less costly and requires less maintenance than other waterjet cutting machines that do not utilize the rotary bowl142with the liner148.

The liner148may be manufactured from stainless steel and particularly may be disposed in the bottom portion154of the interior surface150of the rotary bowl142, as shown inFIGS.9,11, and14. It should also be appreciated that the liner148may also be made from carbide or other suitable abrasive-resistant materials, as desired. The liner148may circumscribe the inlet tube146of the rotary bowl142while the inlet tube146may extend through an entirety of the rotary bowl142including outwardly and past the upper lip144of the rotary bowl142. The inlet tube146may be fluid communication with the liquid inlet port110of the cap108to receive water.

The abrasive supply port112of the cap108may be oriented on an abrasive supply port axis (D), and the liquid inlet port110of the cap108may be oriented on a liquid supply port axis (E), as shown inFIGS.4and9. The abrasive supply port axis (D) may be offset a first distance (D1) from the liquid supply port axis (E), as shown inFIG.9. The abrasive aperture158of the rotary bowl142may also be offset a second distance (D2) from the inlet tube146of the rotary bowl142, as shown inFIG.16. An abrasive exit axis (F) on which the abrasive aperture158is disposed, may be offset a second distance (D2) from the liquid supply port axis (E), as shown inFIG.16. Generally, the first distance (D1) may be equal to, less than, or greater than the second distance (D2). One of ordinary skill in the art may select suitable distances (D1and D2). In particular, the abrasive supply port axis (D) may be closer to the liquid supply port axis (E) so that the abrasive falls on the liner148and not on the wall of the rotary bowl142. Advantageously, having the abrasive to fall in the liner148allows the liner148to absorb most of the erosion caused by the abrasive over time. In turn, the liner148and the rotary bowl142may be replaced to provide optimal performance of the waterjet cutting machine100.

Advantageously, the waterjet cutting machine100overcomes limitations of other waterjet cutting machines. The pivoting assembly114allows the nozzle116to pivot about the horizontal axis (A)+/−130 degrees, unlike other waterjet cutting machines. The rotary bowl142provides an effective way to prolong the shelf life of the waterjet cutting machine100by including a liner148that takes the effects of the erosion caused by the abrasive. Ultimately, the rotary bowl142and the liner148may easily be replaced due to the placement of one or more set screw apertures157on the side of the rotary bowl142. Rather than replacing the entire waterjet cutting machine100, the rotary bowl142and the liner148may simply be replaced once the rotary bowl142and the liner148have surpassed their shelf life, thereby reducing the need for costly repairs and consistent maintenance of the waterjet cutting machine100. Desirably, the shaft assembly130includes an efficient motor132with an increased torque that provides improved rotational speed and accuracy of the shaft assembly130within the waterjet cutting machine100. Ultimately, the waterjet cutting machine100with the pivoting assembly114capable of pivoting the nozzle +/−130 degrees about the horizontal axis (A) and the replaceable rotary bowl142with the addition of the liner148overcome limitations of other waterjet cutting machines for optimal performance of shape nozzle and taperless cutting operation.