Adjustable Nozzle Deck for Uniform Rolling Mill Cooling
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Solution Overview
Problem
Conventional cooling conveyors in rolling mills produce non-uniform cooling paths due to varying air distribution, leading to different metallurgical properties along the length of the steel rod, as a result of 'hard' transitions in air velocity and flow between edge and central regions, causing inconsistent cooling rates and properties.
Innovation Solution
A conveyor system with a flexible nozzle deck featuring adjustable nozzle structures that control air flow by varying the size of air passage regions, combined with a control system to regulate fan speeds and nozzle positions, ensuring uniform cooling across both edge and central regions through a fixed outer jet and adjustable center jet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If greater nozzle area is used at edge regions to compensate for higher ring density, then cooling effectiveness at edge regions is improved, but air velocity uniformity across the conveyor width deteriorates due to hard transitions between edge and central regions
Solution Approach 1:
The nozzle deck is designed with locally varied nozzle characteristics - edge nozzles have larger effective areas to compensate for higher ring density at edges, while central nozzles have smaller areas. This local differentiation ensures uniform air velocity distribution across the entire conveyor width despite varying thermal demands at different locations.
Solution Approach 2:
The system employs adjustable nozzles that can dynamically modify their effective area through movement along the conveyor width. This dynamic adjustment capability allows the nozzles to adapt to varying ring density patterns and maintain optimal air velocity uniformity under different operating conditions.
2Temperature
If different numbers of nozzles are located at edge and central conveyor regions, then cooling demand at edge regions is met, but cooling path uniformity deteriorates due to non-uniform intervals between successive coolant applications
Solution Approach 1:
The conveyor width is divided into multiple zones with nozzles strategically positioned in each zone. The segmentation allows for tailored cooling approaches in edge regions (with more nozzles) versus central regions (with fewer nozzles), while maintaining overall cooling path uniformity through careful spacing design.
Solution Approach 2:
The system varies nozzle parameters (number, position, effective area) along the conveyor width to match the spatial distribution of cooling demands. Edge regions receive more nozzles with larger effective areas, while central regions have fewer nozzles with smaller areas, creating a parameter gradient that ensures uniform cooling paths despite varying local demands.
3Temperature
If vanes or dampers are used in plenum chambers to direct more air to edge regions, then air flow distribution is improved, but device complexity increases due to additional mechanical components
Solution Approach 1:
The invention replaces complex mechanical flow control systems (vanes, dampers) with a simplified nozzle-based solution. The nozzle deck directly shapes and directs air flow to match the required distribution pattern through its geometric design, eliminating the need for additional mechanical flow control components in the plenum chambers.
Solution Approach 2:
The flow distribution function is extracted from the plenum chamber system and transferred to the nozzle deck. By taking out the flow control functionality from the upstream plenum chamber and implementing it at the nozzle level, the system eliminates the need for complex internal plenum chamber structures with vanes and dampers.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution achieves uniform cooling paths and metallurgical properties along the steel rod by maintaining consistent air flow intervals and velocities, enhancing cooling efficiency and uniformity, as illustrated by improved cooling rates and reduced temperature deviations.
Implementation Method 1
A cooling structure that uses a first jet of air for cooling the central portion of the rolling mill material. A nozzle deck that is positioned on the edge regions of the conveyor system and produces a second jet of air for cooling the edge portions of the rolling mill
Data Source
AI summary
A system for cooling rolling mill material is provided that includes a conveyor system that receives rolling mill material and passes the rolling mill material through one or more cooling regions. A cooling structure that operates uniformly across the central and edge regions of the conveyor system. The cooling structure uses a first jet of air for cooling the central portion of the rolling mill material. A nozzle deck is positioned on the edge regions of the conveyor system produces a second of jet of air for cooling the edge portions of the rolling mill. The nozzle deck includes one or more adjustable nozzle structures for controlling the air flow produced by the second jet of air by varying the size of their air passage regions.