# Patent

## Title
Rotatable plasma cutting torch assembly with short connections

## Abstract

A plasma torch assembly is provided with a torch body having a primary portion and a dielectric portion. The use of the dielectric portion allows for the length of the leads in the torch body to be shorter than known torches, especially in higher current applications. This provides for added stability and longevity of the torch and its components.

## Background
BACKGROUND OF THE INVENTION
Field of the Invention
Systems and methods of the present invention relate to plasma cutting, and more specifically to arc plasma cutting using a torch assembly that can be mounted in robotic arm systems.
Description of the Related Art
The use of plasma cutting systems in various industries has grown, including the use of plasma cutting systems with robotic systems. In such applications, the plasma cutting torch is secured to a robotic arm or motion mechanism which moves the torch in many different directions. In fact, in many robotic applications the robot has many different axis of movement. This complex movement often requires the torch to move relative to the robot arm which imparts a rotational movement. Because of the electrical and cooling liquid connections on the torch this rotational movement must be limited so as to not break these connections. Further, after a certain amount of movement the operation must be stopped so as to allow the robotic arm to unwind—which releases any torque from the torch connections. Therefore, the more complex the movement and control of the torch the more often the operation will have to be stopped to unwind the torch. This increases downtime of the cutting operation and can lead to premature failure of the torch connections through constant loading and unloading of torsional stresses. Therefore, torch construction is needed to mitigate these issues.
Further limitations and disadvantages of conventional, traditional, and proposed approaches will become apparent to one of skill in the art, through comparison of such approaches with embodiments of the present invention as set forth in the remainder of the present application with reference to the drawings.
BRIEF SUMMARY OF THE INVENTION
Embodiments of the present invention include equipment and methods for using a plasma cutting torch assembly which employs a torch body having a dielectric portion and a primary portion. The use of the dielectric portion allows the leads of the torch body to have a shorter length than known torch body configurations, particularly in higher current applications.



BRIEF DESCRIPTION OF THE DRAWINGS
The above and/or other aspects of the invention will be more apparent by describing in detail exemplary embodiments of the invention with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatical representation of an exemplary system using an exemplary torch of the present invention;
FIG. 2 is a diagrammatical representation of an exemplary torch of the present invention;
FIG. 3 is a diagrammatical representation of a cross-section of a portion of an exemplary torch of the present invention;
FIG. 4 is a diagrammatical representation of an exemplary torch that has been disassembled; and
FIG. 5 is a diagrammatical representation of a cross-section of an exemplary torch base of the present invention.



DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Exemplary embodiments of the invention will now be described below by reference to the attached Figures. The described exemplary embodiments are intended to assist the understanding of the invention, and are not intended to limit the scope of the invention in any way. Like reference numerals refer to like elements throughout.
FIG. 1 depicts an exemplary robotic system 10 using a torch 200 in accordance with an exemplary embodiment of the present invention. It is noted that for purposes of the following discussion, the system will be discussed as a plasma arc cutting system. However, exemplary embodiments are not limited to being used in arc cutting systems. Embodiments of the present invention can be used with many systems which require complex movement of a torch like assembly, in which rotational movement and forces are imparted. For example, embodiments of the present invention can be used with arc welding, electroslag welding, cladding, joining, hot wire and additive manufacturing systems without departing from the spirit or scope of the present invention. Arc welding systems can be of the GMAW, GTAW, SAW, FCAW type, as an example. Further, exemplary embodiments of the present invention can be used in automatic, robotic, semi-automatic and manual systems. As indicated above, the exemplary embodiments discussed herein will use an arc cutting system as exemplary but this is in no way intended to be limiting.
As shown in FIG. 1, the torch 200 is coupled to a robotic arm assembly 10. The robotic arm assembly 10 can be constructed and operated in accordance with known robotic cutting and welding systems and is not intended to be limiting in any way. As is generally understood, the movement and operation of the arm 10 can be controlled by a computer control system (not shown) and can also be coupled to a power supply (also not shown) which provides the current used to create the plasma arc in the torch 200 for the cutting operation. The general construction and operation of such systems is known and need not be described herein. The robotic arm typically has a tool connection end 20 to which the torch 200 is coupled for the cutting operation. The tool connection end 20 has a tool connection structure 21 which couples to the torch 200 and holds the torch 200 in the tool connection end. The connection structure 21 can be configured in a number of different ways. In many applications the tool connection structure 21 has an interior surface which couples to an outer surface of the torch 200 to hold the torch in place. Of the connection structure 21 can use any number of different connection methodologies to hold the torch 200 in place including fasteners, clamping structure, etc. Embodiments of the present invention are not limited in this regard.
FIG. 2 depicts an exemplary torch assembly 200 of the present invention. In many respects the torch assembly 200 is constructed and operated similar to known plasma torch constructions, except for the differences described in detail herein. Therefore, many known aspects of the torch construction and operation are not discussed in detail herein. As shown, exemplary embodiments of the present invention have a torch head portion 201. The torch head portion 201 represents the distal end of the torch 200 from which the plasma is propelled for the cutting operation. In FIG. 2 a shielding is not shown in the distal end, but often a shield is placed over the distal end of the torch head 201. The torch head 201 is coupled to a torch body 203. In the exemplary embodiment shown the threaded connection collar 202 couples the torch head 201 to the torch body 203. The torch body 203 typically has a number of electrical contacts and connections which couple the electrical current and cooling liquids and/or shielding gas from the upstream sources to the torch head. Coupled to the torch body 203 is the torch handle 205. The torch handle 205 is typically threaded onto the torch body 203 and is used to secure the torch 200 to the robotic system or the connection portion 21. Because of this if the torch needs to be service or replaced the torch head 201 and torch body 203 can be easily removed from the torch handle 205 without removing the torch handle 205 from its connection. As shown in FIGS. 2 and 3, the torch handle has an outer casing, which is typically metallic and protects the components internal to the torch handle 205.
As shown in the exemplary embodiment, the torch 200 also includes a rotating collar 210 which is free to rotate 360 degrees relative to the surface of the torch handle 205. When mounted to the robot or other motion control device, the outer surface of the rotating collar 210 is coupled to the connection structure 21. For example, in the embodiment shown the connection structure can be a clamping mechanism that clamps onto the outer surface of the collar 210 so as to secure the torch 200 to the robot (or gantry, etc.). The collar is a cylindrical structure with an inner diameter that is slightly larger than the outer diameter of the torch handle 205 such that the collar 210 is free to fully rotate relative to the handle 205. Thus, as the robot, gantry or whatever motion control structure is moved and rotated the torch 200 remains relatively stationary (from a rotational standpoint). Because of this, the robot does not have to be moved to “unwind” the torch and little or no torque forces are applied to the torch connections (not shown in FIG. 2). Further, as explained more fully below, the collar 210 is secured to the torch handle 205 in a longitudinal direction such that the torch 200 does not slide in and out of the collar 210—which would affect the cutting accuracy of the torch 200. This is explained more fully below.
FIG. 3 depicts a close up view of the collar 210 and the torch handle 205 where the collar 210 is shown in cross-section. As described above the collar 210 is sized such that it's inside diameter is slightly larger than the outside diameter of the outer casing of the torch handle 205. However, the gap between the collar 210 and the torch handle 205 should not be too large such that the torch 200 is not supported in a stable manner. In exemplary embodiments of the present invention, the gap between the inner surface of the collar 210 and the outer surface of the torch handle 205 is in the range of 0.0005 and 0.002 inches. The gap may be larger in some applications, however, the gap should not be so large such that the accuracy of the cutting operation is compromised. The outer surface of the outer casing of the torch handle has two grooves 301 in its outer surface, where the grooves 301 are positioned at each of the respective distal ends of the collar 210. In the embodiment shown, the grooves 301 go around the entire diameter of the torch handle 205, but in other exemplary embodiments, the grooves 301 need no go around the entire diameter. In each of the grooves 301 a lock ring 310 is placed where the inner diameter of the lock rings 310 sit inside the respective grooves 301 while an outer diameter of each of the lock rings 310 protrudes beyond the outer surface of the torch handle 205. Thus, once positioned in each of their respective grooves 301 the lock rings 310 hold the collar 210 in position longitudinally along the length of the torch handle 205. With this construction there is no structure or component positioned between the inner surface of the collar 210 and the outer surface of the handle 205. That is there is no structure or component between the entirety of the inner surface of the collar 210 and the outer surface of the handle 205. This provides a significant advantage over more complex rotational connections which have numerous rotational elements or do not easily connect with known robotic connections. These elements can wear or otherwise be compromised—particularly in environments normally associated with cutting and metal fabrication. Thus, embodiments of the present invention provide a highly reliable rotational connection which greatly improves the usage and life of a torch 200.
The lock rings 310 can be constructed similar to split washers where the rings are nearly circular but have a gap between two ends of the ring, such that the gap allows the rings 310 to be placed into the grooves 301. The grooves 301 should be of a depth and shape so as to allow for the sufficient seating of the rings so that the rings 310 can hold the collar 210, and thus the torch 200 in a longitudinally fixed position relative to each other. Each of the collar 210 and the rings 310 can be made of materials such as brass, stainless steel, etc., so long as they have sufficient strength to support the torch 200 during operation.
It is noted that in the embodiment shown in FIG. 3 a single pair of grooves are shown in the outer casing of the torch handle 205. However, in other exemplary embodiments the torch handle 205 can a plurality of pairs of grooves 301 in the outer casing of the torch handle 205. Each respective pair of grooves 301 would be separated by the needed distance to accommodate the collar 210 as shown in FIG. 3. However, each pair can be displaced from each other by a predetermined increment (for example, 0.5 inch, 1 inch, etc.). Such an embodiment would provide a user with flexibility when mounting the torch assembly 200 to a specific robot or for a specific operation. That is, the user could then adjust the amount the torch assembly protrudes from a robot mount, or the like, by adjusting which pair of grooves 301 in the torch handle is used. This is accomplished by changing the position of the collar 210 along the length of the torch handle 205 casing, using of the pairs of grooves 301 as desired. The user could remove the rings 310 and slide the collar 210 to the desired pair of grooves and then install the rings 310 at the corresponding grooves 301. This will provide additional flexibility to the use of the torch 200. Such a configuration can also allow for the use of collars of different lengths depending on a desired application.
Additionally, in further exemplary embodiments at least one protrusion from the surface of the torch handle 205 casing could be used to restrain the collar 210. For example, at the upstream end of the collar 210 a protrusion could extend radially out from the surface of the torch handle 205 to engage with the upstream end of the collar 210 and a groove and ring restraining configuration can be used at the downstream end of the collar 210, to allow for the removal and replacement of the collar 210.
FIG. 4 depicts components of an exemplary torch 200 as described herein. As explained previously, the torch 200 is made up of a number of main components. As shown in FIG. 4, the torch head 201 has a threaded collar 202 which secures the torch head to a threaded portion 204 of the torch body 203. The torch body 203 also has a plurality of torch connections 401 which align with corresponding connections within the torch head 201. These connections 401 allow for the transfer of cutting/shielding gas, torch coolant and electrical current from the torch body 203 to the torch head 201. Also, some of these connections 401 can be used to align the head 201 and the body 203 such that their connection has the proper alignment. Further, the torch body 203 also has a plurality of upstream connections 403 which serve a similar purpose to the torch connections 401 discussed above. However, these connections couple the torch body to connections within the torch handle 205. Because of the high currents experienced during cutting and plasma arc initiation, in known torch constructions these connections are quite long. That is, these connections 403 are long to prevent sparks or arcing between internal components of the torch during high voltage pulses. However, because these connections are long they are prone to damage from torsional movement of the torch 200 during operation. As further explained below, embodiments of the present invention obviate these concerns and are capable of using much shorter connection lengths which are less prone to wear and damage. This is explained further, with respect to FIG. 5.
FIG. 5 is a cross-sectional view of an exemplary torch body 203 of the present invention. Unlike known torches, the torch body 203 is made up of two torch components, a primary torch body portion 510 and a dielectric torch body portion 520. The primary torch portion 510 is metallic using known materials used for torch body construction, while the dielectric torch body portion 520 is made from a non-conductive dielectric material, such as a plastic resin, or the like. Ideally, the dielectric portion 520 is made from a non-conductive material that is resistant to high levels of heat, due to the cutting environment. The dielectric portion 520 is inserted into a cavity portion 511 of the primary torch body portion 510. The dielectric portion can be either press fit or threaded into the cavity 511. Of course other methods can be used so long as the dielectric portion 520 is sufficiently secured into the cavity 511. Further the primary portion 510 also has a separator portion 513 which separates the cavity 511 from the downstream cavity 512. The separator portion 513 has a plurality of opening in it to allow the electrical, coolant and shielding connections and tubes to pass through the separator 513 as shown. In exemplary embodiments, a distal end 521 of the dielectric portion 520 abuts against the separator 513 when the portion 520 is inserted into the cavity 511. The dielectric portion 520 has an upstream end portion 523 which has a threaded portion 524, where the threaded portion 524 threads into the downstream end of the torch handle 205.
As shown in FIG. 5, in exemplary embodiments the dielectric portion 520 has an upstream end 523 which extends beyond the most upstream end of the primary portion 510, which provides additional insulative benefits. Further, as shown, the dielectric portion 420 has a length which contacts the separator 513 such that the dielectric portion 520 covers the entirety of the inner surface of the walls of the cavity 511.
In some exemplary embodiments of the present invention, the dielectric portion 520 has a cavity 525 which extends through the length of the portion 520 and this cavity is filled with a dielectric material, such as a potting material. This provides added insulation and stability for the torch body and the conduits 530. Further, the dielectric portion 520 has an overall length which is in the range of 35 to 75% of the overall length of the torch body 203, as measured from the distal end of the primary portion 510 to the upstream end of the dielectric portion 520.
The torch body 203 also has a plurality of conduits 530 which are used to pass electric current, coolant and/or shielding gas through the torch body 203 to the torch head 201 to facilitate a cutting operation. A primary conduit 531 extends the furthest from the upstream end 523 and can be used to deliver electrical current and coolant through the torch body 203.
In known torch constructions, which are used for high amperage applications, the high voltage pulse lead 531 is quite long. For example, in known torches the high voltage pulse lead 531 has a length L (measured from the upstream end 523) of at least 1.5 inches. This length is needed in known torches to provide a sufficient distance between the connection portion 532 of the high voltage pulse lead 531 and the end 523 on the torch body housing. As explained previously, known torch body housings are metallic. Because of this, if the length L was too short, during high voltage electrical pulses (for example during arc initiation) an arc can jump from the connector 532 to the end of the torch body housing. This arc jump can cause significant damage to the torch components. Thus, known torches must have a longer length L to prevent arc jumping events. However, as explained above these longer lengths are prone to bending and torsional damage.
Unlike known torches, because embodiments of the present invention employ the construction described above the length L can be considerably shorter, meaning that the conduits are less susceptible to torsional and bending damage. For example, in embodiments of the present invention, the length L of the high voltage pulse lead 531 is in the range of 0.25 to 0.75 inches in length. This significantly improves the durability of the lead 531. This is particularly true in torches whose operational/cutting current levels are 100 amps and higher. Embodiments of the present invention are particularly advantageous in torches and torch systems which are operating at 100 amps or higher as arc initiation is through the use of high voltage pulses. As explained this typically requires longer leads, and as such advantages from embodiments of the present invention can be achieved.
Further, much like the high voltage pulse lead 531, the coolant conduit 533 can also be significantly reduced in length, as compared to known torches. In exemplary embodiments of the present invention, the coolant conduit 533 can have a length L in the range of 2 to 6.5 inches, as measured from the end 523 to the tip of the connector 534—which connects the conduit 533 to the coolant supply connection within the torch handle 205. In other exemplary embodiments, the length L is in the range of 2 to 4 inches.
Additionally, because of the advantages of the discussed embodiments, the torch handle 205 can also be significantly reduced in length, greatly reducing the overall length of the torch assembly 200.
While the invention has been particularly shown and described with reference to exemplary embodiments thereof, the invention is not limited to these embodiments. It will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the following claims.

## Claims

1. A cutting torch body, comprising:
a metallic primary body portion comprising a first cavity in an upstream end of said primary body portion and a second cavity in a downstream end of said primary body portion, and said first and second cavities are separated by a separator portion;
a dielectric torch body portion which is inserted into said first cavity, where an upstream end of said dielectric portion extends beyond said upstream end of said primary body portion;
at least one high voltage pulse electrical conduit which passes through said first cavity, said separator portion and said second cavity, and where said at least one high voltage pulse electrical conduit includes an electrical connector having an upstream end which extends beyond said upstream end of said dielectric portion by a distance in a range of 0.25 to 0.75 inches; and
at least one cooling fluid conduit which passes through said first cavity, said separator portion and said second cavity, and where said at least one cooling fluid conduit has an upstream end which extends beyond said upstream end of said dielectric portion by a distance in a range of 2 to 6.5 inches.

2. The cutting torch body of claim 1, wherein said dielectric portion has a length which is within a range of 35 to 75% of the length of the torch body as measured from a distal end of the primary body portion to the upstream end of the dielectric portion.

3. The cutting torch body of claim 1, wherein said dielectric portion has an inner cavity through which said at least one cooling conduit and said at least one high voltage pulse electrical conduit pass, and said inner cavity of said dielectric portion is filled with a dielectric material.

4. The cutting torch body of claim 1, wherein a distal end of said dielectric portion contacts said separator portion and where said dielectric portion extends along an entire length of said first cavity.

5. The cutting torch body of claim 1, wherein said upstream end of said dielectric portion has threads on an outer surface for coupling said cutting torch body to a torch handle.

6. The cutting torch body of claim 1, wherein said length of said at least one cooling conduit above said upstream end of said dielectric portion is in a range of 2 to 4 inches.

7. The cutting torch body of claim 1, wherein said cutting torch body is for use in cutting applications using a cutting current or 100 amps or higher.

8. A cutting torch assembly, comprising:
a cutting torch head having a distal end and an upstream end, and
a cutting torch body coupled to said upstream end of said torch head, said torch body comprising:
a metallic primary body portion comprising a first cavity in an upstream end of said primary body portion and a second cavity in a downstream end of said primary body portion, and said first and second cavities are separated by a separator portion;
a dielectric torch body portion which is inserted into said first cavity, where an upstream end of said dielectric portion extends beyond said upstream end of said primary body portion;
at least one high voltage pulse electrical conduit which passes through said first cavity, said separator portion and said second cavity, and where said at least one high voltage pulse electrical conduit includes an electrical connector having an upstream end which extends beyond said upstream end of said dielectric portion by a distance in a range of 0.25 to 0.75 inches; and
at least one cooling fluid conduit which passes through said first cavity, said separator portion and said second cavity, and where said at least one cooling fluid conduit has an upstream end which extends beyond said upstream end of said dielectric portion by a distance in a range of 2 to 6.5 inches.

9. The cutting torch assembly of claim 8, wherein said dielectric portion has a length which is within a range of 35 to 75% of the length of the torch body as measured from a distal end of the primary body portion to the upstream end of the dielectric portion.

10. The cutting torch assembly of claim 8, wherein said dielectric portion has an inner cavity through which said at least one cooling conduit and said at least one high voltage pulse electrical conduit pass, and said inner cavity of said dielectric portion is filled with a dielectric material.

11. The cutting torch assembly of claim 8, wherein a distal end of said dielectric portion contacts said separator portion and where said dielectric portion extends along an entire length of said first cavity.

12. The cutting torch assembly of claim 8, wherein said upstream end of said dielectric portion has threads on an outer surface for coupling said cutting torch body to a torch handle.

13. The cutting torch assembly of claim 8, wherein said length of said at least one cooling conduit above said upstream end of said dielectric portion is in a range of 2 to 4 inches.

14. The cutting torch assembly of claim 8, wherein said cutting torch body is for use in cutting applications using a cutting current or 100 amps or higher.

15. The cutting torch body of claim 1, wherein the primary body portion includes both of a wall and the separator portion, and wherein the separator portion extends to the wall to form the first cavity.

16. The cutting torch body of claim 15, wherein the wall is integral with the separator portion.

17. The cutting torch body of claim 8, wherein the primary body portion includes both of a wall and the separator portion, and wherein the separator portion extends to the wall to form the first cavity.

18. The cutting torch body of claim 17, wherein the wall is integral with the separator portion.