Aluminum Extrusion Cooling Layout With Air-Upper and Water-Lower Units
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Solution Overview
Problem
Existing equipment for cooling extruded aluminum section bars has limited control over cooling curves and requires costly corrosion-resistant materials and heavy actuators due to the presence of water nozzles, increasing operational costs and complexity.
Innovation Solution
A heat treatment equipment with a lightweight, non-corrosion resistant upper unit equipped only with air jet outlets, allowing the use of less expensive pneumatic actuators and reducing the need for corrosion-resistant materials by eliminating coolant delivery systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water nozzles are installed on the upper unit for cooling section bars, then cooling effectiveness is improved, but the weight of the upper unit increases requiring expensive electric or hydraulic actuators
Solution Approach 1:
The cooling function is segmented between two separate units: the upper unit uses only air outlets (lightweight) and the lower unit uses water nozzles (heavy). This segmentation allows the upper unit to be moved by inexpensive pneumatic actuators while the lower unit with water delivery remains stationary or is moved by more powerful actuators, resolving the weight-actuator cost contradiction.
Solution Approach 2:
Air acts as an intermediary medium between the upper unit and the section bar, providing initial cooling without requiring heavy water delivery infrastructure on the upper unit. The air cooling from the upper unit works in conjunction with water cooling from the lower unit to achieve effective cooling while maintaining lightweight construction on the movable upper unit.
2Temperature
If water nozzles are installed on the upper unit, then cooling capability is improved, but corrosion-resistant materials are required increasing manufacturing costs
Solution Approach 1:
The water delivery system is segmented and assigned only to the lower unit, which can be constructed with corrosion-resistant materials at a lower cost since it remains stationary. The upper unit, which moves and would require expensive corrosion-resistant materials like stainless steel, is equipped only with air outlets, significantly reducing material costs while maintaining cooling capability through the combined air-water cooling system.
Solution Approach 2:
The upper unit uses air outlets instead of water nozzles, allowing construction with cheaper, non-corrosion resistant materials. Air cooling is sufficient for the upper unit's function, and the combination with lower unit water cooling achieves the required overall cooling effect without the high material costs of making the entire upper unit corrosion-resistant.
3Ease of manufacture
If the upper unit is made lightweight without water nozzles, then actuator cost is reduced, but cooling control precision may be affected
Solution Approach 1:
The air cooling system from the upper unit and the water cooling system from the lower unit are merged into a coordinated dual-mode cooling system. This combination allows precise control over the cooling process by independently controlling air and water delivery, achieving the required cooling precision while keeping the upper unit lightweight with inexpensive pneumatic actuators.
Solution Approach 2:
The system dynamically switches between air cooling (upper unit), water cooling (lower unit), or combined cooling modes depending on the section bar's temperature and cooling requirements. This dynamic operation allows precise temperature control while maintaining the lightweight, low-cost construction of the upper unit with pneumatic actuators.
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
The solution enables cost-effective and efficient cooling of aluminum section bars with improved control over cooling cycles, reducing operational costs and maintaining structural integrity without the need for heavy or expensive components.
Implementation Method 1
the outlets (601) being served by ventilation means (501) and thus adapted to the emission of air jets
Implementation Method 2
the nozzles (602) being served by means for generating a pressurized cooling fluid, generally water, and thus adapted to the emission of pressurized water or liquid jets
Data Source
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AI summary
Equipment (100) for the heat treatment of manufactured items at high temperatures, in particular for the controlled cooling of extruded section bars made of aluminum, said equipment (100) being adapted to be arranged downstream of an extrusion press defining an extrusion direction (103) of the extruded section bars downstream of the extrusion press (200), said equipment (100) comprising a supporting device (105) adapted to restingly support at least one such extruded section bar in a substantially horizontal position; an upper cooling unit (500) arranged above said supporting device (105) and adapted to be switched by translation in a substantially vertical direction relative to said supporting device (105) between a first upper position and a second lower position; a lower cooling unit (600) arranged at said supporting device (105); wherein said equipment (100) comprises ventilation means (501) adapted to generate a ventilated air flow and means adapted to generate a refrigerant liquid flow; wherein said lower unit (600) comprises a first plurality of outlets (601) and nozzles (602) in fluid communication respectively with said refrigerant fluid flow generating means, said outlets (601) and nozzles (602) being each adapted to convey a refrigerant fluid jet towards said at least one extruded section bar (104).