Patent Publication Number: US-11045969-B2

Title: Catcher tank assembly of waterjet cutting system

Description:
BACKGROUND 
     Technical Field 
     This disclosure relates to a catcher tank assembly of a waterjet cutting system, and in some embodiments, is directed to a catcher tank assembly having a particularly versatile form factor to enable the construction of catcher tank assemblies of divergent sizes and capabilities. 
     Description of the Related Art 
     High-pressure fluid jets, including high-pressure abrasive waterjets, are used to cut a wide variety of materials in many different industries. Systems for generating high-pressure waterjets and abrasive waterjets (collectively “waterjets”) are currently available, such as, for example, the Mach 4™ 5 axis waterjet system manufactured by Flow International Corporation, the assignee of the present invention. Other examples of waterjet cutting systems are shown and described in Flow&#39;s U.S. Pat. No. 5,643,058, which is incorporated herein by reference in its entirety. In such systems, high-pressure fluid, typically water, flows through an orifice in a cutting head to form a high-pressure jet, into which abrasive particles can be combined as the jet flows through a mixing tube. The high-pressure abrasive waterjet is discharged from the mixing tube and directed toward a workpiece to cut the workpiece along a designated path. 
     Workpieces are generally supported on a platform or held by a fixture for processing by the high-pressure jet. During processing of the workpiece, some energy of the high-pressure waterjet is absorbed by the workpiece itself while other energy is absorbed by a volume of water underlying, partially submerging or completely submerging the workpiece. A catcher tank is typically provided to hold water for this purpose. Conventional catcher tanks include unitary steel weldments having integral support structures for supporting a workpiece platform. Conventional catcher tanks are robust structures which can be particularly burdensome to fabricate and/or transport, and which are limited in their ability to adapt to changing conditions and new applications. 
     BRIEF SUMMARY 
     Embodiments described herein provide catcher tank assemblies and waterjet cutting systems having particularly versatile form factors to enable the construction of catcher tank assemblies and waterjet cutting systems of divergent sizes and capabilities. Components of the catcher tank assemblies may include modular units to facilitate shipment and enhance assembly of the catcher tank and related systems. 
     In one embodiment, a catcher tank assembly for a waterjet cutting machine may be summarized as including a catcher tank having a plurality of tank sections detachably coupleable together in a side-by-side manner to collectively define an internal tank cavity. The catcher tank assembly may further include a workpiece support system detachably coupleable to the catcher tank within the internal tank cavity. The workpiece support system may be formed of a plurality of workpiece support modules arrangeable in an array to support a workpiece platform when the catcher tank assembly is assembled. The workpiece platform may include, for example, a series of slats, mesh plates or other structures that form an upper work surface of the tank upon which a workpiece may be supported for processing. 
     The catcher tank may be configured such that a first row of the array of workpiece support modules is detachably coupleable to a first tank section and a second row of the array of workpiece support modules is detachably coupleable to a second tank section. The tank sections of the catcher tank may include two tank end units and an intermediate tank unit, wherein the end tank units are configured to detachably couple together to form a first tank configuration and detachably couple to opposing sides of the intermediate tank unit to form a second tank configuration. Each of the plurality of tank sections of the catcher tank may include a floor, opposing sidewalls and a flange extending across one of the opposing sidewalls, along the floor and across the other one of the opposing sidewalls to define a u-shaped mating interface for selectively assembling the tank sections in the side-by-side manner. 
     Each of the tank sections of the catcher tank may include an upstanding flange offset from an abutment edge, and the catcher tank may further include a cord configured to be compressibly disposed between the upstanding flanges of two adjacent tank sections when the two adjacent tank sections are coupled together. The abutment edges of the two adjacent tank sections may be configured to cooperatively control a degree of compression of the cord. The catcher tank may further include at least one spacer configured to be disposed between the upstanding flanges of the two adjacent tank sections to control a degree of compression of the cord. When two adjacent tank sections are coupled together, the abutment edges, the upstanding flanges and the at least one spacer may combine to define a box-like cavity to captively receive the cord. 
     The workpiece support system may further include a plurality of adjustment devices for selectively leveling the workpiece support modules when the workpiece support system is in an assembled configuration. The workpiece support system may further include a plurality of elongated support columns detachably coupleable to a floor of the catcher tank to support the workpiece support modules at a height above the floor. Adjacent sets of the elongated support columns may be configured to support opposing ends of a respective workpiece support module when the workpiece support system is in an assembled configuration. At least one set of the elongated support columns may support an end of each of two adjacent workpiece support modules when the workpiece support system is in an assembled configuration. When the workpiece support system is in an assembled configuration, a load capacity of the elongated support columns supporting a first one of the workpiece support modules may be at least twice the load capacity of the elongated support columns supporting a second one of the workpiece support modules. 
     The catcher tank assembly may further include a waste removal system, the waste removal system configured to span an interface between adjacent tank sections to transport a flushing fluid from a first one of the tank sections to at least a second one of the tank sections. The waste removal system may include a plurality of nozzles configured to generate flushing jets directed into areas of each of the plurality of tank sections. When the catcher tank assembly is in the assembled configuration, a first set of the nozzles in one region of the catcher tank may be selectively operable independent of a second set of the nozzles in another region of the catcher tank. The catcher tank assembly may further include a water level control system at least partially integrated into one of the tank sections, the water level control system configured to selectively control a height of the volume of water in the catcher tank during the cutting operation. The catcher tank may include a plurality of armor plates detachably coupled to interior sidewalls thereof. 
     According to another embodiment, a waterjet cutting system may be summarized as including a catcher tank and a cutting head movably coupled to a multi-axis machine and operable to process a workpiece via a cutting operation. The catcher tank is configured to hold a volume of water for absorbing the energy of a jet generated by the cutting head of the waterjet cutting machine during the cutting operation, and includes a plurality of tank sections detachably coupled together in a side-by-side manner to collectively define an internal tank cavity. The waterjet cutting system may further include a workpiece support system detachably coupled to the catcher tank, the workpiece support system including a plurality of workpiece support modules arranged in an array to support a workpiece platform on which to support the workpiece during the cutting operation. The tank sections of the catcher tank may include two tank end units coupled together in an abutting relationship or at least one intermediate tank unit sandwiched between tank end units. 
     According to another embodiment, a method of constructing a catcher tank may be summarized as including: detachably coupling a plurality of tank sections together in a side-by-side manner to form a catcher tank which collectively defines an internal tank cavity to hold a volume of water for absorbing energy of a jet generated by the waterjet cutting machine during a cutting operation; and detachably coupling a workpiece support structure to the catcher tank such that a plurality of workpiece support modules are arranged in an array to support a workpiece platform on which to support a workpiece to be processed during the cutting operation. 
     The method may include detachably coupling two tank end units together in an abutting relationship or sandwiching at least one intermediate tank unit between tank end units. The method may further include compressing a cord between adjacent tank sections. Detachably coupling a workpiece support structure to the catcher tank may include coupling a first row of the array of workpiece support modules to a first tank section and coupling a second row of the array of workpiece support modules to a second tank section. The method may further include attaching a plurality of elongated support columns to a floor of the catcher tank to support the workpiece support modules at a height above the floor with adjacent sets of the elongated support columns positioned to support opposing ends of a respective workpiece support module. The method may further include leveling the workpiece support modules such that the workpiece platform is substantially level. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is an isometric front view of a waterjet cutting system having a catcher tank assembly, according to one embodiment. 
         FIG. 2  is a side elevational view of the waterjet cutting system of  FIG. 1 . 
         FIG. 3  is a cross-sectional view of the catcher tank assembly of the waterjet cutting system of  FIG. 1  taken along line  3 - 3  of  FIG. 2 . 
         FIG. 4  is a partial detail view of the cross-section of the catcher tank assembly of  FIG. 3  showing a mating interface of adjacent tank sections of the catcher tank assembly. 
         FIG. 5  is an isometric partially exploded view of the catcher tank assembly of the waterjet cutting system of  FIG. 1  with a workpiece platform entirely removed to reveal workpiece support modules of a workpiece support system of the catcher tank assembly. 
         FIG. 6  is an isometric view of the catcher tank assembly of  FIG. 5  in an assembled configuration with the workpiece platform added but partially removed to reveal the workpiece support modules. 
         FIG. 7  is an isometric view of a catcher tank assembly, according to another embodiment, including an intermediate tank section received between opposing end tank units. 
         FIG. 8  is an isometric view of workpiece support modules of the catcher tank assembly of the waterjet cutting system of  FIG. 1 . 
         FIG. 9  is an isometric partial detail view of the portion of the workpiece support modules of  FIG. 8 . 
         FIG. 10  is an isometric enlarged detail view of the portion of the workpiece support modules of  FIG. 8 . 
         FIG. 11  is a side elevational view of a series of workpiece support modules, according to one embodiment, illustrating leveling capabilities thereof. 
         FIG. 12  is a front elevational view of the workpiece support modules of  FIG. 11  illustrating additional leveling capabilities thereof. 
         FIG. 13  is an isometric view of workpiece support modules, according to another embodiment. 
         FIG. 14  is a partial isometric view of workpiece support modules, according to yet another embodiment. 
         FIG. 15  is an isometric view of the catcher tank assembly of the waterjet cutting system of  FIG. 1  with the workpiece platform and workpiece support system removed to reveal a waste removal system of the catcher tank assembly, according to one embodiment. 
         FIG. 16  is a top plan view of the catcher tank assembly shown in  FIG. 15 . 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one of ordinary skill in the relevant art will recognize that embodiments may be practiced without one or more of these specific details. In other instances, well-known structures associated with waterjet systems and catcher tank assemblies may not be shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments. For instance, it will be appreciated by those of ordinary skill in the relevant art that a high-pressure fluid source and an abrasive source may be provided to feed high-pressure fluid and abrasives, respectively, to a cutting head of the waterjet system to facilitate high-pressure abrasive waterjet cutting of workpieces supported by the catcher tank assemblies described herein. As another example, well known control systems and drive components may be integrated into the waterjet cutting system to facilitate movement of the cutting head relative to the workpiece to be processed. As still yet another example, it will be appreciated by those of ordinary skill in the relevant art that conventional welding techniques and conventional fastening devices (e.g., threaded bolts of appropriate grade and size) may be employed to construct the various embodiments of the catcher tank catcher tank assemblies described herein. In addition, it will be appreciated by those of ordinary skill in the relevant art that a variety of materials may be used for the various components described herein, such as, for example, metals, plastics and composites of different strengths, grades and other material properties, based on numerous design factors including, for example, operating and loading conditions. 
     Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to.” 
     Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. 
     As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. 
     Embodiments described herein provide catcher tank assemblies and waterjet cutting systems having particularly versatile form factors to enable the construction of catcher tank assemblies and waterjet cutting systems of divergent sizes and capabilities. Components of the catcher tank assemblies may include modular units to facilitate transport and enhance assembly of the catcher tank and related systems. 
       FIGS. 1 and 2  show an example embodiment of a waterjet cutting system  10 . The waterjet cutting system  10  includes a catcher tank assembly  12  which is configured to support a workpiece  14  to be processed by the system  10 . The waterjet cutting system  10  further includes a bridge assembly  18  which is movable along a pair of base rails  20  and straddles the catcher tank assembly  12 . In operation, the bridge assembly  18  moves back and forth along the base rails  20  with respect to a translational axis X to position a cutting head  22  of the system  10  for processing the workpiece  14 . A tool carriage  24  is movably coupled to the bridge assembly  18  to translate back and forth along another translational axis Y, which is aligned perpendicularly to the translational axis X. The tool carriage  24  is further configured to raise and lower the cutting head  22  along yet another translational axis Z to move the cutting head  22  toward and away from the workpiece  14 . An articulated wrist  26  is provided to adjust an orientation of the cutting head  22  relative to the workpiece  14  to enable processing of the workpiece  14  along particularly complex tool paths and tool orientations. During operation, movement of the cutting head  22  with respect to each of the translational axes X, Y, Z and axes of the articulated wrist  26  may be accomplished by various conventional drive components and an appropriate control system  28 . 
     A waste removal system  30  may be coupled to the catcher tank assembly  12  to receive and process waste collected from the interior of the catcher tank assembly  12  during operation. Other well known systems associated with waterjet cutting machines may also be provided such as, for example, a pump for supplying high-pressure fluid to the cutting head  22  and/or an abrasive hopper for feeding abrasives to the cutting head  22  to enable abrasive waterjet cutting. These other well known systems, however, are not shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments. 
     Further details of the catcher tank assembly  12  of the example embodiment are shown in  FIG. 3 . As shown in  FIG. 3 , the catcher tank assembly  12  includes a catcher tank  40  formed of tank sections  42 ,  44  detachably coupleable together in a side-by-side manner to collectively define an internal tank cavity  46 . In some embodiments, the tank sections  42 ,  44  each include opposing sidewalls  47 , a floor  48  extending therebetween and an end wall  49  to collectively define each end tank section or unit  42 ,  44 . In embodiments having only two tank sections  42 ,  44 , such as the example embodiment illustrated in  FIG. 3 , the tank end sections  42 ,  44  combine in an abutting relationship to collectively define the internal tank cavity  46 . In other embodiments, the catcher tank  40  may include one, two or more intermediate tank sections  43  ( FIG. 7 ) between the catcher tank end sections or units  42 ,  44 . 
     The catcher tank assembly  12  further includes a workpiece support system  50  detachably coupleable to the catcher tank  40  within the internal tank cavity  46 . The workpiece support system  50  may be formed in some embodiments to include a plurality of workpiece support modules  52  arrangeable in an array to support a workpiece platform  54  when the catcher tank assembly  12  is fully assembled. The workpiece platform  54  can include a series of slats  56 , mesh plates, grates or other structures that form an upper work surface  58  of the workpiece platform  54  of the catcher tank  40  upon which the workpiece  14  may be supported for processing. The workpiece support modules  52  may be supported at a height above the floor  48  of the catcher tank  40  by one or more underlying support structures  64 . In the illustrated embodiment of  FIG. 3 , for example, the workpiece support modules  52  are supported on each of opposing ends by elongated support columns  60  joined together by a cross member  62  to form a general H-shaped support structure  64 . The H-shaped support structures  64  are removably coupled at one end to upstanding flanges  66  protruding from the floor  48  of the catcher tank  40  and are removably coupled at the other end to the workpiece support modules  52 . Collectively, the support structures  64  and the workpiece support modules  52  form a comprehensive support system for the workpiece platform  54 . 
     The catcher tank assembly  12  may include at least one tank section  44  having a dedicated region or volume  68  for optional accessories of the waterjet cutting system  10 . For example, in one embodiment, the tank section  44  may include a region  68  adjacent the end wall  49  sized to contain therein a water level control system  69  to control a height of the volume of water within the internal cavity  46  of the catcher tank  40  during operation. In some embodiments, the region  46  may be sized to hold a bladder of the water level control system  69  having a capacity of at least  250  gallons, for example, to selectively raise and lower the water level at least four inches. In this manner, the water level in the catcher tank  40  may be quickly adjusted to maintain the water level just below the workpiece to be processed or at a level to partially submerge or completely submerge the workpiece during a cutting operation. This can advantageously reduce operating noise and enable cleaner cuts. The region  68  may also contain, in some embodiments, components of the waste removal system  30  when the catcher tank assembly  12  is provided with such a system, including, for example, waste pickups  132  and portions of a conduit routing system  122 . 
     As shown in  FIG. 3 , the tank sections  42 ,  44  combine along a mating interface  70  to form the catcher tank  40 . Further details of the mating interface are shown in  FIGS. 4 and 5 . For instance, with reference to  FIG. 4 , the tank sections  42 ,  44  of the example embodiment each include an abutment edge  72  for abutting an adjacent tank section  42 ,  44  during assembly. Each of the tank sections  42 ,  44  further includes an upstanding flange  74  offset from the respective abutment edge  72  to form a channel  75  between the abutting tank sections  42 ,  44 . A cord  76  or other sealing device may be positioned between the adjacent flanges  74  of the tank sections  42 ,  44  within this channel  75  to create a water tight seal as the tank sections  42 ,  44  are urged together. The tank sections  42 ,  44  may be urged together, for example, via a plurality of threaded fastener assemblies  78  or other fastening devices. The cord  76  may be selected to deform by a predetermined amount as the tank sections  42 ,  44  are drawn together during assembly. A degree of compression of the cord  76  may be controlled, for example, by the abutment edges  72  coming into contact with each other. In addition, a spacer  80  may be positioned between the flanges  74  to control the degree of compression. 
     In some embodiments, when the two adjacent tank sections  42 ,  44  are coupled together, the abutment edges  72 , the upstanding flanges  74  and the spacer  80  combine to define a box-like cavity to captively receive the cord  76 . In this manner, the degree of the compression and effectiveness of the seal between the tank sections  42 ,  44  can be controlled by the structure of the tank sections  42 ,  44  interoperating with each other and the spacer  80 . In addition, the cord  76  or other seal device may be protected by the spacer  80  from an overhead environment that could otherwise deteriorate the seal during operation. The box-like structure of the example embodiment thus provides a sealing mechanism that is particularly robust and reliable. Of course, it is appreciated that other sealing arrangements may be used in connection with the tank sections  42 ,  44 , such as, for example, a generally planar gasket or gaskets between directly abutting faces of the tank sections  42 ,  44 . The illustrated seal arrangement characterized by the enclosed box-like structure, however, performs exceptionally well in a relatively compact form factor. This is particularly the case when providing threaded fastener assemblies  78  in regular intervals (e.g., six inch intervals) along the entire length of the mating interface  70 , as shown best in  FIG. 5 . 
       FIG. 5  further illustrates the mating interface  70  of the catcher tank assembly  12  in a partially assembled configuration. As can be appreciated from  FIG. 5 , the mating interface  70  may traverse the entire height of one sidewall  47  of the catcher tank  40 , the entire length of the floor  48  and the entire height of the opposing sidewall  47  to form a generally u-shape mating interface  70 . The cord  76  or other seal device and the spacer  80  are received between the tank sections  42 ,  44  at this mating interface  70  and compressed therebetween to form the fluid tight seal. In some embodiments, apart from conduit couplings  82  and optional armor plates  84  which may span the mating interface  70  when the catcher tank assembly  12  is fully assembled, the catcher tank assembly  12  may otherwise be free of components spanning over the mating interface  70 . In this manner, the catcher tank assembly  12  may include substantially completed subassemblies that may be transported in a substantially complete form and assembled in a particularly efficient manner. 
     Devices to facilitate transfer of the tank sections  42 ,  44  or substantially completed subassemblies including the tank sections  42 ,  44  may be provided. For example, pockets  86  ( FIGS. 3, 15 and 16 ) spaced to receive the tines of a forklift may be integrated into the floor  48  of each of the tank section  42 ,  44 . The tank sections  42 ,  44  may also include eyelets, lugs or other features (not shown) for interfacing with lifting devices such as an overhead crane to transport or manipulate the tank sections  42 ,  44  during assembly. 
     As shown in  FIG. 5 , the workpiece support system  50  may include a first set of workpiece support modules  52  arranged in a row within one of the tank sections  42  and a second set of workpiece support modules  52  arranged in a row within the other tank section  44 . Accordingly, each tank section  42 ,  44  may be transported with a respective row of workpiece support modules  52  coupled thereto for subsequent assembly, or alternatively, may be transported without the workpiece support modules  52  and assembled together prior to receiving the workpiece support modules  52 . In addition, as discussed in further detail elsewhere, one or more of the workpiece support modules  52  may be replaced with workpiece support modules having different load capacities, such as the relatively higher capacity workpiece support modules  52 ′ described further below with reference to  FIG. 13 . In addition, the workpiece support modules  52  may be replaced with specialized workpiece fixtures  88 , such as, for example, the specialized workpiece fixture  88  illustrated in  FIG. 7  which includes actuators and stationary supports to support a workpiece for subsequent processing. Further details of work support features that may be included in a specialized workpiece fixture  88  can be found in Flow&#39;s U.S. Patent Application Publication No. 2009/0140482, which is incorporated herein by reference in its entirety. In still other embodiments, the workpiece support modules  52  may be omitted altogether. In this manner, the catcher tank assembly  12  provides a particularly versatile system which can be selectively configured to accommodate a wide range of processing activities, including, for example, the cutting of relatively thick, heavy substrates (e.g., steel plates having a thickness of 6 inches or more) supported on relatively higher capacity workpiece modules  52 ″ ( FIG. 13 ) or the cutting of complex or irregular workpieces (e.g., an aircraft fuselage) supported by specialized fixtures  88  ( FIG. 7 ). 
     As further shown in  FIG. 5 , the workpiece support modules  52  may be supported at opposing ends thereof by the support structures  64 . In addition, one support structure  64  may be arranged to support an end of each of two adjacent workpiece support modules  52 . In this manner, the number of support structures  64  for each row of workpiece support modules  52  may be one more than the number of modules  52 . This advantageously provides a particularly efficient workpiece support system  50  which is scalable. In addition, because the support structures  64  provide a common attachment or support area for adjacent workpiece support modules  52 , the support structures  64  can assist in maintaining a particularly level, planar workpiece platform  54  ( FIG. 6 ) by providing a common attachment area for otherwise independent components. 
     Each of adjacent sets of the support structures  64  may be removably coupled together by one or more cross members  65 . The cross members  65  may be, for example, stock angle iron, bars, plates or other structural members having a variety of shapes. As discussed earlier, the support structures  64  may be removably coupled to the floor  48  of the catcher tank  40 , such as, for example, by bolting the support structures  64  to upstanding flanges  66 . The upstanding flanges  66  may be, for example, stock angle iron welded or otherwise secured to the floor  48 . The support structures  64  are also removably coupled to the workpiece support modules  52 . In this manner, the workpiece support modules  52 , support structures  64  and cross members  65  can be broken down and setup quickly and efficiently to reconfigure the workpiece support system  50  within the interior of the catcher tank  40  and thereby adjust or adapt to changing conditions. For instance, the waterjet cutting system  10  may be used to process a first type or class of workpieces (e.g., lightweight, planar materials) in one application and then be reconfigured with different support structures  64 ′ or specialized fixtures to process a second type or class of workpieces (e.g., heavy slab materials or substrates having complex curved surfaces) in another application. For example, a relatively higher capacity support structure  64 ′ having, for example, thicker or more rigid support columns  60 ′ may be provided as discussed in more detail further below with reference to  FIG. 13 . As another example, in some embodiments, the support structure  64  may include more support columns  60  (e.g., six or more support columns  60 ). 
       FIG. 6  shows the catcher tank assembly  12  in an assembled configuration with the platform  54  received in and supported by the array of workpiece support modules  52  of the workpiece support system  50 . A workpiece  14  is shown on the platform  54  ready for processing. As can be appreciated from  FIG. 6 , in a final assembled configuration, the catcher tank assembly  12  may include the optional armor plates  84  secured around the perimeter of the internal tank cavity  46  which is defined by the joined tank sections  42 ,  44 . The armor plates  84  may be removably secured to the tank sections  42 ,  44  by fasteners or by hanging the armor plates  84  from protrusions formed in the tank sections  42 ,  44 , for example. In other embodiments, armor plates  84  may be integrally formed in the tank sections  42 ,  44 ; however, removably securing the armor plates  84  enables more versatility and allows the armor plates  84  to be selectively replaced or serviced. Additional armor plates or structures (not shown) may also be provided within the tank cavity  46  to protect the floor  48  of the tank sections  42 ,  44  or other internal structures during operation. 
       FIG. 7  further illustrates the versatility of the catcher tank assemblies  12 ,  12 ′ and subcomponents described herein. The catcher tank assembly  12 ′ shown in  FIG. 7 , for example, includes an intermediate tank section or unit  43  disposed between the tank sections or tank end units  42 ,  44  of the previously described catcher tank  40  to form a catcher tank  40 ′ characterized by a much larger tank capacity. Although only one intermediate tank section or unit  43  is shown, two, three, four or more intermediate tank sections or units  43  may be provided to selectively construct catcher tanks  40 ′ of increasing capacity. Each mating interface  70  between the tank sections  42 ,  43 ,  44  is provided with a seal arrangement to provide a water-tight catcher tank  40 ′. 
     The intermediate tank sections or units  43  may be configured to accept additional rows of workpiece support modules  52 , such that, when the catcher tank assembly  12 ′ is fully assembled, the workpiece support modules  52  are arranged in a two-dimensional array having a plurality of rows and a plurality of columns to collectively support the workpiece platform  54 ′ within the confines of the catcher tank  40 ′. For example, the catcher tank assembly  12 ′ may include a 4×3 array of workpiece support modules  52  as illustrated in  FIG. 7 . In other embodiments, the array of workpiece support modules  52  may be arranged, for example, in a 2×2, 2×3, 2×4, 2×5, 2×6, 3×2, 3×3, 3×4, 3×5, 3×6, 4×2, 4×4, 4×5, 4×6, 5×2, 5×3, 5×4, 5×5, 5×6 array or in arrays with more or fewer rows and columns. Still further, tank sections or units  42 ,  43 ,  44  may be provided in different widths to provide flexibility in tank width as well as depth. In this manner, catcher tank assemblies  12 ,  12 ′ having an extremely wide variance of capacities may be constructed from a particularly limited set of modular tank sections  42 ,  43 ,  44  and modular components of the workpiece support system  50 . 
     In some embodiments, each of the tank sections or units  42 ,  43 ,  44  may be sized to fit within the confines of a standard  40  ft shipping container such that the tank sections or units  42 ,  43 ,  44  may be conveniently shipped to remote locations in shipping containers and assembled on site to construct a catcher tank assembly  12 ,  12 ′ having a footprint far in excess of the footprint of the shipping container itself (e.g. two to three times larger). 
     Further details of the workpiece support system  50  are described with reference to  FIGS. 8 through 10 . As shown in  FIG. 8 , a series of workpiece support modules  52  may be arranged in a linear pattern to form an interconnected row. Each of the workpiece support modules  52  can be supported at opposing ends thereof by the upstanding support structure  64 , such as, for example, the H-shape support structure described earlier which includes a set of upstanding support columns  60  and cross member  62 . Adjacent sets of the support structures  64  may likewise be connected by one or more cross members  65 . 
     The entirety of the workpiece support system  50  can be removably coupled to the interior of the catcher tank assemblies  12 ,  12 ′ described herein, and more particularly, without any connection to sidewalls  47  or end walls  49  of the same. In this manner, the workpiece support system  50  can be a freestanding, self-supporting comprehensive workpiece platform support structure separate from the catcher tanks  40 ,  40 ′ altogether. The workpiece support system  50  may be bolted or otherwise removably secured to the floor  48  of the catcher tanks  40 ,  40 ′, and more particularly, a row or more of the workpiece support system  50  may be bolted or otherwise removably secured to the floor  48  within a respective tank section or unit  42 ,  43 ,  44 . Of course, in some embodiments, the workpiece support system  50  could be fixedly secured to the floor  48  of the catcher tanks  40 ,  40 ′, for example, by welding the support structures  64  thereto; however, fixedly joining components of the workpiece support system  50  reduces the versatility of the system  50  to adapt to changing conditions and diminishes the ability of the catcher tank assemblies  12 ,  12 ′ to accommodate a wide variety of processing activities. 
     With reference to  FIG. 9 , the workpiece support modules  52  of the workpiece support system  50  may be formed as a generally rectangular module having opposing longitudinal platform support members  90  separated from each other by transverse cross members  92 . The workpiece support modules  52  may resemble a lattice or ladder structure. A tab portion  94  of the transverse cross members  92  may extend through the longitudinal platform support members  90  and be secured thereto by driving wedge-shaped fasteners  96  through an aperture in the tab portion  94 , as shown best in  FIG. 10 . In this manner, the lattice or ladder-like structure of the workpiece support modules  52  may be assembled and disassembled in a particularly efficient manner. Of course, it is appreciated that in other embodiments conventional fastening devices, such as, for example, threaded bolts, may be used to join components of the workpiece support modules  52 . Still further, in other embodiments, the workpiece support modules  52  may be unitary structures, such as, for example, a unitary structure having components joined together by welding or a unitary casting. 
     As best shown in  FIG. 10 , the longitudinal platform support members of the workpiece support modules  52  may include a series of upstanding fingers  97  and corresponding slots  98  to selectively receive slats  56  ( FIG. 3 ) to collectively define the platform  54  ( FIG. 3 ). In other embodiments, the workpiece support modules  52  may include other mounting arrangements to selectively receive mesh plates, grates or other structures to form the workpiece platform  54  ( FIG. 3 ). The workpiece support modules  52  may further include feet  99  for mounting the workpiece support modules  52  to the upstanding support structures  64 . The feet  99  may be secured to the workpiece support modules  52  in a removable manner similar to that discussed above with respect to the cross members  92 . For example, a tab portion  100  of each foot may extend through another component of the module  52  and receive a wedge-shaped fastener  96  through an aperture in the tab portion  100 . Again, it is appreciated that in other embodiments conventional fastening devices, such as, for example, threaded bolts, may be used to join components of the workpiece support modules  52 . In addition, in some embodiments, the feet  99  may be formed integrally in the longitudinal platform support members  90  or cross members  92 . 
     Each foot  99  is positioned to align with an upper end of a respective support column  60  of the workpiece support structure  64  when the workpiece support system  50  is assembled. Each support column  60  of the support structures  64  may include a mount plate  102 , flange or other structure with mounting apertures  104  therein for receiving fasteners to attach a respective foot  99  thereto. While the workpiece support modules  52  may be bolted or otherwise joined flush to an upper end of the support structures  64 , in some embodiments, height adjustment devices  106  may be provided intermediate the workpiece support modules  52  and the support structures  64  to enable leveling adjustments of the workpiece support modules  52 . For instance, a threaded adjustment bolt  108  or other adjustable stop may be provided on each foot  99  to selectively set a height of a gap between the foot  99  and the respective support structure  64  to which it is joined during assembly. Adjustments may be made to the gap by turning the adjustment bolt  108  prior to securing the foot  99  to the support structure  64  by tightening other threaded fasteners received in the mounting apertures  104  in the mount plate  102 , for example. By selectively adjusting each gap, the upper work surface  58  ( FIG. 3 ) of the workpiece platform  54  ( FIG. 3 ) may be leveled to a relatively high degree of precision. 
     The overall adjustability of the workpiece support system  50 , according to one embodiment, is illustrated in  FIGS. 11 and 12 . More particularly,  FIG. 11  illustrates the leveling capabilities over a depth of a catcher tank assembly which includes five rows of workpiece support modules  52 . In some embodiments, the degree of adjustability  110  may be ±1, 2 or 3 degrees from a horizontal reference plane  112  or more or less.  FIG. 12  illustrates the leveling capabilities over a width of a catcher tank assembly which includes three workpiece support modules  52  arranged in a row. In some embodiments, the degree of adjustability  114  may be ±1, 2 or 3 degrees from the horizontal reference plane  112  or more or less. 
       FIGS. 13 and 14  still further illustrate the versatility of embodiments of the catcher tank assemblies  12 ,  12 ′ described herein. For instance,  FIG. 13  shows another embodiment of a workpiece support system  50 ′ which is configured to support relatively more weight than the system  50  illustrated in  FIG. 8 . The overall system  50 ′ shares similar features and qualities to the previously described system  50 ; however, certain components may be of different shapes, sizes, and strengths. For instance, the workpiece support system  50 ′ is similar in that it includes a plurality of workpiece support modules  52 ′ formed as a generally rectangular module having opposing longitudinal platform support members  90 ′ separated by transverse cross members  92 ′. A tab portion  94 ′ of the transverse cross members  92 ′ also extends through the longitudinal platform support members  90 ′ and can be secured thereto by driving wedge-shaped fasteners  96 ′ through an aperture in the tab portion  94 ′. In this manner, the lattice or ladder-like structure of the workpiece support modules  52 ′ may be assembled and disassembled in a particularly efficient manner. Again, it is appreciated that in other embodiments conventional fastening devices, such as, for example, threaded bolts, may be used to join components of the workpiece support modules  52 ′. Still further, in other embodiments, the workpiece support modules  52 ′ may be unitary structures, such as, for example, a unitary structure having components joined together by welding or a unitary casting. 
     The longitudinal platform support members  90 ′ of the workpiece support modules  52 ′ may include a series of upstanding fingers  97 ′ and corresponding slots  98 ′ to selectively receive slats  56  ( FIG. 3 ) to collectively define the platform  54  ( FIG. 3 ). The slots  98 ′, however, may be relatively thicker and/or longer to receive slats  56  that are able to support a more substantial static load. Again, in other embodiments, the workpiece support modules  52 ′ may include other mounting arrangements to selectively receive mesh plates, grates or other structures to form the workpiece platform  54 . 
     Like the previously described workpiece support modules  52 , the workpiece support modules  52 ′ of the relatively higher capacity workpiece support system  50 ′ may further include feet  99 ′ for mounting the workpiece support modules  52 ′ to upstanding support structures  64 ′. The feet  99 ′ may be secured to the workpiece support modules  52 ′ in a removable manner similar to that discussed above. For example, a tab portion  100 ′ of each foot may extend through another component of the workpiece support modules  52 ′ and receive the wedge-shaped fastener  96 ′ through an aperture in the tab portion  100 ′. Again, it is appreciated that in other embodiments conventional fastening devices, such as, for example, threaded bolts, may be used to join components of the workpiece support modules  52 ′. In addition, in some embodiments, the feet  99 ′ may be formed integrally in the longitudinal platform support members  90 ′ or cross members  92 ′. 
     Each foot  99 ′ is positioned to align with an upper end of a respective support column  60 ′ of the workpiece support structure  64 ′ when the workpiece support system  50 ′ is assembled. Each support column  60 ′ of the support structures  64 ′ may include a mount plate  102 ′, flange or other structure with mounting apertures  104 ′ therein for receiving fasteners to attach a respective foot  99 ′ thereto. While the workpiece support modules  52 ′ may be bolted or otherwise joined flush to an upper end of the support structures  64 ′, in some embodiments, height adjustment devices  106 ′ may be provided intermediate the workpiece support modules  52 ′ and the support structures  64 ′ to enable leveling adjustments of the workpiece support modules  52 ′. For instance, a threaded adjustment bolt  108 ′ or other adjustable stop may be provided on each foot  99 ′ to selectively set a height of a gap between the foot  99 ′ and the respective support structure  64 ′ to which it is joined during assembly. 
     Some differences between the workpiece support modules  52 ′ of the relatively higher capacity workpiece support system  50 ′ include relatively taller longitudinal platform support members  90 ′. In addition, the thickness and/or grade of the components may be such that the workpiece support modules may support a considerably larger static load (e.g., two or more times the load) without experiencing permanent deformation. For example, in one embodiment, the relatively lower capacity workpiece support system  50  may be configured to support a static load of about 1500 kg/m 2  without permanent deformation and within a generally accepted safety margin. In contrast, in one embodiment, the relatively higher capacity workpiece support system  50 ′ is configured to support a static load of about 3000 kg/m 2  without permanent deformation and within a generally accepted safety margin. In some embodiments, the workpiece support system  50 ′ may be configured to support a static load of about 4000 kg/m 2  without permanent deformation and within a generally accepted safety margin. The support columns  60 ′ of the relatively higher capacity workpiece support system  50 ′ may also be relatively shorter and less susceptible to buckling under extreme loading conditions. Still further, the cross members  92 ′ of the relatively higher capacity workpiece support system  50 ′ may be significantly more rigid than cross members  92  of the relatively lower capacity workpiece support system  50 . For example, the cross members  92 ′ of the relatively higher capacity workpiece support system  50 ′ may be stock channel structures as opposed to flat plate structures. 
     Despite the aforementioned differences and other differences, the relatively higher capacity workpiece support system  50 ′ is nevertheless configured to interface with the catcher tank assemblies  12 ,  12 ′ within the same footprint area as the relatively lower capacity workpiece support system  50 . In some embodiments, the relatively higher capacity workpiece support system  50 ′ may attach to the catcher tank assemblies  12 ,  12 ′ in the same manner as the relatively lower capacity workpiece support system  50 . Accordingly, the catcher tank assemblies  12 ,  12 ′ may be selectively fitted with a relatively higher capacity workpiece support system  50 ′ or a relatively lower capacity workpiece support system  50  or combinations of the same. For example, some catcher tank assemblies  12 ,  12 ′ may be provided with one or more rows of the relatively higher capacity workpiece support system  50 ′ and one or more rows of the relatively lower capacity workpiece support system  50 . Still further, as illustrated in  FIG. 14 , components from each of the different workpiece support systems  50 ,  50 ′ may be combined to form hybrid rows in which different capacity workpiece support modules  52 ,  52 ′ are provided within the same row. In such embodiments, a spacer or extension  116  may be provided to adapt the relatively lower capacity workpiece support module  52  to interface with the underlying support structure  64 ′ of the relatively higher capacity workpiece support system  50 ′. Accordingly, a workpiece platform  54  ( FIG. 3 ) may ultimately be supported in an assembled configuration by an array of workpiece support modules  52 ,  52 ′ of varying capacities. In addition, in some embodiments, the specialized workpiece fixtures  88  may replace one or more of the workpiece support modules  52 ,  52 ′, as illustrated in  FIG. 7 . Additionally, in some embodiments, areas within the catcher tank  40 ,  40 ′ may be provided without any support structures. 
       FIGS. 15 and 16  show the catcher tank assembly  12  without the workpiece support system  50  coupled thereto to reveal a portion  120  of the waste removal system  30  ( FIG. 1 ) which may be positioned within a lower region of the catcher tank  40 . The portion  120  of the waste removal system  30  within the catcher tank  40  may include the conduit system  122  coupled to a plurality of nozzles  124  which are configured to produce flushing jet streams  126  within each tank section or unit  42 ,  44  of the catcher tank  40 . The flushing jet streams  126  are arranged to effectively cover at least a majority of the footprint of an operative working area  130  of the catcher tank assembly  12 . The flushing jet streams  126  interoperate to flush waste or debris, such as, for example, spent abrasives, within the catcher tank  40  toward a plurality of waste pickups  132 . The pickups  132  may be located beneath covers  134  in an end region of the catcher tank  40  outside of the foot print of the operative working area  130 . In this manner, the pickups  132  are substantially protected from deteriorative influences of the cutting jet during operation. Likewise, as best shown in  FIG. 16 , a substantial portion of the conduit system  122  may be located under covers in peripheral regions of the catcher tank  40  outside of the operative working area  130 . This portion of the conduit system  122  is likewise substantially protected from deteriorative influences of the cutting jet during operation. 
     The conduit system  122  may include valves and controls to selectively route a flushing fluid to selected areas of the catcher tank  40  independently of each other. For example, nozzles  124  located on one stretch of the conduit system  122  may be activated independently of nozzles  124  located on another stretch of the conduit system  122 . This is particularly beneficial in larger catcher tank assemblies having three or more tank sections or units  42 ,  43 ,  44  wherein it may be quite inefficient to operate nozzles  124  remote from a processing location. For example, the cutting head  22  ( FIGS. 1 and 2 ) may be processing a workpiece within one area overlying one particular tank section  42 ,  43 ,  44  for an extended period of time such that spent abrasives or other debris generated during the cutting process is not generated within other tank sections  42 ,  43 ,  44 . During such periods, portions of the conduit system  122  corresponding to the inactive areas may be temporarily restrained from passing fluid through the nozzles  124  to, among other things, conserve energy. The activation of regions of the waste removal system  30  may be controlled automatically in tandem with movements of the cutting head  22  via the control system  28  ( FIGS. 1 and 2 ). Waste and wastewater collected via the pickups  132  can be routed external to the catcher tank assembly  12  via a discharge conduit  140  for subsequent processing and optional reintroduction of recycled fluid back into the catcher tank  40  and/or reintroduction of recycled abrasives back into the waterjet cutting system  10 . 
     The various features and aspects described herein provide for catcher tank assemblies  12 ,  12 ′ having particularly versatile form factors to address a wide variety of demands and changing conditions. For instance the interconnectivity of the modular tank sections  42 ,  43 ,  44  can enable a user to construct catcher tanks  40 ,  40 ′ of varying sizes and capabilities to meet the specific demands of specialized work cells in a production line. 
     As an example, a relatively small catcher tank  40  may be constructed of two end units  42 ,  44  in an abutting relationship and located in a production line dedicated to certain activities requiring no more work area than that provided by the relatively smaller catcher tank  40 . Further, the catcher tank  40  in this cell may be dedicated to cutting relatively softer materials that do not require cutting with abrasives, but rather which may be processed with a pure water jet. In this scenario, the user may opt not to install a waste removal system  30 . Further, it may not be advantageous based on the expected processing demands within this cell to install a water level control system  69  ( FIG. 3 ). 
     In contrast, a relatively larger catcher tank  40 ′ having three, four, five or more tank sections  42 ,  43 ,  44  may be located in the same production line wherein a larger work area is required to process workpieces. This relatively larger catcher tank  40 ′ may be dedicated, for example, to processing larger, heavy slab materials. These types of materials may require the use of abrasive waterjets for efficient processing and benefit from the use of water level control systems  69 . Thus, the catcher tank  40 ′ may be provided with a waste removal system  30  installed therein and a water level control system  69  integrated into one of the tank sections  44  within a dedicated region  68  ( FIG. 3 ) for optional accessories. In addition, workpiece support systems  50 ′ having a relatively higher load capacity may be required to safely process the heavier workpieces. Despite the different processing requirements, the catcher tank assemblies  12 ,  12 ′ can be constructed with many of the same components and can be readily reconfigured from one catcher tank configuration to another. 
     Furthermore, the catcher tank assemblies  12 ,  12 ′ described herein can be readily dissembled for transport or relocation within an assembly line, for example. Smaller catcher tank assemblies  12  may be easily converted into larger catcher tank assemblies  12 ′, and vice versa. Smaller capacity workpiece support systems  50  may be easily converted into larger capacity workpiece support systems  50 ′, and vice versa. Catcher tank assemblies  12 ,  12 ′ can be easily upgraded with new or different capabilities (e.g., water leveling, waste removal). These and other benefits are realized as a result of the various aspects of the catcher tank assemblies  12 ,  12 ′ disclosed herein. 
     Although the shapes and features of the tank sections  42 ,  43 ,  44  and workpiece support systems  50 ,  50 ′ are illustrated in particularly versatile and compact form factors, it is appreciated that the shapes and sizes of various features of the components can vary significantly while still providing the functionality described herein. For instance, although the tank sections  42 ,  43 ,  44  are shown as including vertical opposing sidewalls  47  and end walls  49 , the sidewalls  47  and end walls  49  may, for example, flare outwardly to form a tank cross-section having a flat bottomed V-shape. In addition, although many of the components of the workpiece support systems  50 ,  50 ′ are illustrated as conventional stock materials (e.g., angle iron, u-channels and plates), it is appreciated that these components may take a variety of forms including, for example, castings with complex curved surfaces. Still further, although it is contemplated that many of the structural components of the catcher tank sections  42 ,  43 ,  44  and workpiece support systems  50 ,  50 ′ can be formed of mild or high strength steel, other materials of appropriate strength and durability may be used. Accordingly, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of the specific details shown and described herein. 
     These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.