Coiling Mandrel Cooling Control for Uniform Temperature
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Solution Overview
Problem
Traditional coiling mandrels in hot rolling mills experience nonhomogeneous thermal expansions due to cooling and heating cycles, leading to thermal fatigue, cracks, and premature component failure, necessitating early replacement and increased costs.
Innovation Solution
A cooling control system equipped with temperature sensors and a control unit that adjusts cooling liquid flow based on measured temperature data to maintain even temperatures, reducing thermal variations and fatigue, featuring autonomous power supply and telecommunication for data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the mandrel is cooled by pouring water or internal cooling channels, then the high temperature areas are cooled, but nonhomogeneous thermal expansions occur leading to thermal fatigue and component failure
Solution Approach 1:
The patent implements a feedback control system where temperature sensors continuously monitor the mandrel temperature, and the cooling system adjusts water flow based on measured temperature values to maintain uniform temperature distribution and prevent thermal fatigue
Solution Approach 2:
The patent changes the cooling parameter from fixed flow rate to variable flow rate controlled by temperature feedback, allowing dynamic adjustment of cooling intensity to match actual thermal conditions and eliminate thermal gradients
2Productivity
If traditional cooling methods are used, then cooling is provided, but thermal variations cause fatigue cycles and cracks in the mandrel
Solution Approach 1:
The control unit receives temperature data from sensors and adjusts cooling water flow accordingly, creating a closed-loop system that maintains optimal temperature without excessive cooling that would cause thermal shock and extend mandrel service life
3Temperature
If cooling flow is increased to reduce temperature, then temperature control improves, but thermal shock increases causing more fatigue
Solution Approach 1:
The system dynamically changes cooling parameters based on real-time temperature measurements, adjusting water flow rate to achieve uniform temperature distribution while avoiding abrupt temperature changes that cause thermal shock and fatigue
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 system effectively limits thermal fatigue, extends the lifespan of mandrel components, and maintains tolerance within desired limits, reducing friction wear and operational costs by ensuring homogeneous temperature distribution.
Implementation Method 1
a group of temperature measuring sensors
Implementation Method 2
internal by means of suitable distribution channels with loss of the same
Implementation Method 3
The cooling of the high temperature areas due to the presence of the coil
Implementation Method 4
the region affected by such thermal variations expands when heated and contracts when cooled
Implementation Method 5
The recurrence of the above shows thermal shocks on the mandrel body
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention refers to a cooling control system of a coiling mandrel (102; 202; 302; 402; 502; 602) for metal products which comprises: an internal shaft (108; 308) with a plurality of sectors (109); an external drum which as a whole contains coaxially said internal shaft and which is circumferentially subdivided into a plurality of segments (104) arranged in a direct or indirect coupling connection with said sectors; and an internal and/or external cooling system of the mandrel. The segments are movable in a radial direction with respect to said internal shaft through an axial movement of the latter, causing the consequent radial expansion or collapse of the drum. The mandrel is further provided with a group of temperature detection sensors (130, 132, 134, 136; 234, 236; 332, 336; 43N; 53N; 63N; 3N). A method for monitoring and adjusting the temperature of a coiling mandrel is also described.