PLASMA TORCH

Abstract: A plasma torch appropriate for the use in cutting or welding metallic material, which prevents breakage of an insulating cylindrical body and consequent melting of the contact part between an electrode table and electrode, and permits easy removal of a swirler from a nozzle when disassembling the plasma torch. For this purpose, the contact surface (61) between the nozzle (6) and the swirler (5), that (4b) between the swirler (5) and the insulating cylindrical body (4), that (3a) between the insulating cylindrical body (4) and the electrode (3), and that (3a) between the electrode (3) and the electrode table (2) are arranged on a line running from the nozzle (6) to the torch proper (1). Regarding the insulating cylindrical body (4), the inner diameter (d1) on the surface in contact with the flange (31) of the electrode (3) is smaller than that (d2) on the surface in contact with the swirler (5). The inside of the cylindrical part (62) of the nozzle (6) is stepped or tapered for enlarging the diameter of the upper part thereof above the swirler except the whole or a part of the seat for the swirler (5).

Description: Technical Field The present invention relates to a plasma torch for use in cutting or welding metallic material. Background Art A conventional plasma torch comprises a torch body, an electrode table, an electrode, an insulating cylindrical body, a swirler and a nozzle as the main component elements thereof, the plasma torch being constituted by simply fastening the outer surface of the electrode table to the nozzle in the above-described sequential order and by inserting the thus-fastened elements into the torch body. Another example has been known which is constituted in such a manner that a cap is fitted to the outer surface of the leading portion of the plasma torch and thereby the same is protected and another example has been known which is constituted in such a manner that the insulating cylindrical body and the swirler are integrally molded (for example, see Japanese Patent Utility Model Laid-Open No. 63-19978). Since the conventional plasma torches have been respectively constituted in the above-described simple manner, they can easily be manufactured. However, there arises the following problems when they are used: (1) The insulating cylindrical body can be broken. (2) The contact part between the electrode table and the electrode can be melted. The reason why the above-described problems take place will be specifically described with reference to a plasma torch shown in Fig. 5. When the plasma torch is used, its electrode 3, which is one of the consumables, must be exchanged on occasion. In a case where the electrode 3 is mounted, a cap 7 is screwed so as to cause the electrode 3 to be fitted to the outer surface of an electrode table 2 via an insulating cylindrical body 4 and a nozzle 6. At this time, the force applied to the cap 7 acts on an outer peripheral portion 42 of the insulating cylindrical body 4. However, an inner peripheral portion 41 of the insulating cylindrical body 4 gives the electrode 3 the insertion force. That is, shearing force is generated in the insulating cylindrical body 4. Since the insulating cylindrical body 4 is usually made of ceramic, it has a disadvantageous point in that it is too weak against an impact or an excessively large stress though it has satisfactory heat resistance. Therefore, the insulating cylindrical body 4 will be gradually broken, causing the force with which the electrode 3 is brought into contact with the electrode 3 to be reduced. As a result, there arises a problem in that a defective electric connection (that is, defective contact) takes place and thereby the contact part 3b can be melted. Plasma torches in different constructions are known from JP-A-01 150 480, JP-A-63 250 097 and JP-A-63 011 187. Generally these constructions include the electrode table, the electrode the swirlier and the nozzle with their contact surfaces arranged on the same longitudinal axis. To provide an electrical contact between the elements the position of the electrode with respect to the torch body is important. JP-A-63 250 097 illustrates a method in such a manner that an electrical connection is established by screwing the electrode into the electrode table and locating of the electrode is performed by bringing the flange of the electrode and the table into contact. Additional tools and methods are necessary to perform said method. One the other hand the use of ceramics as in the case of the other documents is extremly difficult. Accordingly, an object of the present invention is to provide a plasma torch the insulating cylindrical body of which cannot be easily broken and as well as its contact part between the electrode table and the electrode cannot easily be melted. Furthermore, the present invention is to provide a plasma torch which uses the above-described plasma torch but the structure of which is further improved. Disclosure of the Invention In order to achieve the object, a plasma torch according to the present invention is constituted in such a manner that: the electrode table has a flange on the outer surface thereof; the electrode has, on the outer surface of the end portion thereof which confronts the electrode table, a flange which is positioned in contact with the surface of the flange adjacent to the nozzle; the end surface of the insulating cylindrical body adjacent to the electrode table is positioned in contact with the surface of the flange adjacent to the nozzle and the insulating cylindrical body has a stepped portion in its portion adjacent to the nozzle; the end surface of the swirler adjacent to the electrode table is positioned in contact with the surface of the stepped portion of the insulating cylindrical body adjacent to the nozzle; and the end surface of the swirler is positioned in contact with a nozzle directional inner side surface of the nozzle. An inner diameter of the insulating cylindrical body of a surface which is positioned in contact with the flange of the electrode is smaller than an outer diameter which is positioned in contact with the swirler. Further a cap an end portion of which is circumscribed with the nozzle and another end portion of which is secured to the outer surface of the torch body and a cap an end portion of which is circumscribed with the cap and another end portion of which is secured to the outer surface of the torch body are provided, an assist gas passage is formed between the caps and an assist gas jetting hole is formed in an end portion of the cap. The insulating cylindrical body and the swirler are integrally molded. As a result of the thus-arranged structure, the contact surfaces of the above-described elements are arranged in line running from the nozzle 6 to the torch body 1. Therefore, the insertion force applied in a direction from the nozzle 6 to the electrode table 2 becomes substantially the compressive stress in the above-described elements. As a result, although the insulating cylindrical body 4 can be broken, it cannot easily be broken in comparison to the conventional structure. As a result, melting of the contact surface 3a due to the defective contact between the electrode 3 and the electrode table 2 can be prevented. On the other hand, the contact force between the electrode 3 and the electrode table 2 is, as can be understood from the above-made description, substantially the same as the insertion force applied via the nozzle 6. As a result, further reliable contact can be realized at the contact surface 3 so that the prevention of melting can be further completely performed. The contact force applied via the nozzle 6 sometimes generates internal stress except for the compressive stress depending upon the shape or the state of fitting of the elements. Even if the internal stress is generated, insertion force F can be made to be substantially pure compressive stress - σ in each element by determining the inner diameter of the insulating cylindrical body 4. As a result, the above-described operation and effect can further be improved. The above-described structure of the plasma torch can be applied to a plasma torch provided with the caps 7 and 8 and having an assist gas jetting function and as well applied to a plasma torch arranged in such a manner that the insulating cylindrical body 4 and the swirler 5 are integrally molded. Furthermore, the stepped portion or a tapered portion is formed in the cylindrical portion 62 of the nozzle 6 and the diameter of the upper portion above the swirler 5 is enlarged except for the whole or a part of the swirler seat. The mounting/removing of the swirler can significantly easily be performed in comparison to the conventional structure. In particular, the removal of the swirler 5 from the nozzle 6 at the time of disassembling the plasma torch can be smoothly performed even if the cylindrical portion is deformed to some degree or small dust adheres to the inner surface of the cylindrical portion. Fig. 1 is a partial enlarged cross sectional view which illustrates a plasma torch; Fig. 2 illustrates a detail of the plasma torch; Fig. 3 is a partial enlarged cross sectional view which illustrates a conventional plasma torch. Referring to Fig. 1, an electrode 3 is fastened to the outer surface of the leading portion of an electrode table 2 included in a torch body 1 and having a flange 21 for enlarging the contact area, the electrode 3 having a flat portion 3a, which confronts the flange 21, and a stepped portion 3b on the outer surface thereof. Furthermore, an insulating cylindrical body 4 is fastened to the outer surface of the above-described flat 3a of the electrode 3 in such a manner that it is brought into contact with the flat 3a. In addition, by utilizing the stepped portion 4b formed on the outer surface of the insulating cylindrical body 4, a swirler 5 for generating a swirling gas is fastened to the above-described outer surface. Furthermore, a conical and cylindrical nozzle 6 is fastened to the outer surface of the swirler 5. The above-described elements are inserted into the torch body 1. As a result of the thus-arranged structure, a contact surface (61) between the nozzle 6 and the swirler 5, a contact surface (4b) between the swirler 5 and the insulating cylindrical body 4, a contact surface 3a between the insulating cylindrical body 4 and the electrode 3 and a contact surface (3a) between the electrode 3 and the electrode table 2 are arranged on a line running from the nozzle 6 to the torch body 1. As a result, insertion force acting from the nozzle 6 to the electrode 2 becomes only substantially the compressive stress in the above-described elements. In order to cause only compressive stress - σ is mainly applied, the insulating cylindrical body 4 is arranged in such a manner that the stepped portion 4b formed on its outer surface for fastening the swirler 5 is formed outer (inner diameter d2) than the inner diameter dl of the flat portion 3a which confronts the flange 21 (omitted from illustration) of the electrode 2. That is, the structure is arranged such that a relation of d2 > d1 is held. By determining the inner diameter as described above, insertion force F becomes pure compressive force - σ in each element. A conical and cylindrical cap 7 is fastened to the outer surface of each of the nozzle 6 and the torch body 1. Furthermore, another cap 8 is fastened to the outer surfaces of the above-described cap 7 and the torch body 1. A passage 82 for passing an assist gas is formed between the cap 7 and the cap 8. Furthermore, the leading portion of the cap 8 has a jet hole 81 formed therein for the purpose of jetting out the assist gas against a portion to be machined. The assist gas is used for the purpose of shielding the plasma flow and the portion to be machined from the outside air at the time of performing the plasma machining work. Furthermore, referring to the drawing, "O" rings, magnets and the like are disposed in order to prevent an undesirable introduction of cooling water and to support the established inward or outward fastening of elements. The swirler 5 and the insulating cylindrical body 4 are integrally molded. Therefore, one contact surfaces can be decreased from the structure and as well as the rigidity can be improved. Therefore, an effect can be obtained to prevent the breakage and to improve the efficiency in transmitting insertion force F. According to the above-described embodiments, the breakage of the insulating cylindrical body 4 can satisfactorily be prevented and melting can also be prevented due to the defective electrical connection between the electrode table 2 and the electrode 3.

Claims: A plasma torch in which the outer surfaces of an electrode table (2), an electrode (3), an insulating cylindrical body (4), a swirler (5) and a nozzle (6) are sequentially fastened from said electrode table (2) toward said nozzle (6) and said elements are inserted into a torch body (1), whereby said electrode table (2) has a flange (21) on the outer surface thereof; said electrode (3) has, on the outer surface of the end portion thereof which confronts said electrode table (2), a flange (31) which is positioned in contact with the surface of said flange (21) adjacent to said nozzle (6); the end surface of said insulating cylindrical body (4) adjacent to said electrode table (2) is positioned in contact with the surface of said flange (31) adjacent to said nozzle (6) and said insulating cylindrical body (4) has a stepped portion (4b) in its portion adjacent to said nozzle (6); the end surface of said swirler (5) adjacent to said electrode table (2) is positioned in contact with the surface of said stepped portion (4b) of said insulating cylindrical body (4) adjacent to said nozzle (6); and the end surface of said swirler (5) is positioned in contact with a nozzle directional inner side surface (61) of said nozzle (6) and wherein an inner diameter (d1) of said insulating cylindrical body (4) of a surface which is positioned in contact with said flange (31) of said electrode (3) is smaller than an outer diameter (d2) which is positioned in contact with said swirler (5). A plasma torch according to claim 1, wherein a cap (7) an end portion of which is circumscribed with said nozzle (6) and another end portion of which is secured to the outer surface of said torch body (1) and a cap (8) an end portion of which is circumscribed with said cap (7) and another end portion of which is secured to the outer surface of said torch body (1) are provided, an assist gas passage (82) is formed between said caps (7) and (8) and an assist gas jetting hole (81) is formed in an end portion of said cap (8). A plasma torch according to claim 1 or 2, wherein said insulating cylindrical body (4) and said swirler (5) are integrally molded.

Inventors: HORIAI KUNIO, TAKABAYASHI YUICHI, HORIAI, KUNIO, TAKABAYASHI, YUICHI, HORIAI, KUNIO KOMATSU RESEARCH INSTITUTE, TAKABAYASHI, YUICHI KOMATSU RESEARCH INSTITUTE
Applicants: KOMATSU MFG CO LTD, KABUSHIKI KAISHA KOMATSU SEISAKUSHO
Application year: 1990
Main classification: H05H1
IPC codes: H05H1