Concave Cooling Head for Rolling Rolls
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Solution Overview
Problem
Existing roll cooling technologies face challenges in achieving uniform cooling over the width and circumference of rolling rolls, leading to thermomechanical fatigue and degradation, while requiring high water pressure and flow velocities, and are not adaptable to variable roll diameters.
Innovation Solution
A cooling system utilizing a concave cooling head with multiple nozzles positioned in a two-dimensional pattern, creating a highly turbulent water cushion between the head and the roll surface, with adjustable side plates and lower transverse plates to control coolant flow, operating at lower pressures and flow rates, and designed to accommodate rolls of varying diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional spray nozzles are used for roll cooling, then cooling efficiency is improved, but water pressure and flow velocity requirements increase significantly
Solution Approach 1:
The cooling head features a concave front face with a cylindrical shape that matches the roll curvature. This curved geometry allows the water cushion to conform to the roll surface, improving heat transfer efficiency while operating at lower pressures compared to flat nozzle systems.
Solution Approach 2:
The invention utilizes a hydraulic cushion of water between the cooling head and the roll surface. This water cushion, maintained at controlled pressure, provides intensive cooling through highly turbulent flow while reducing the need for high-velocity spray systems, thereby lowering energy consumption.
2Temperature
If cooling nozzles are positioned close to the roll surface, then cooling efficiency increases, but stress gradient and cracking risk increase
Solution Approach 1:
A water cushion acts as an intermediary layer between the cooling head and the roll surface. This cushion maintains optimal cooling contact while distributing thermal stresses more uniformly, preventing the high stress concentrations and surface cracking associated with direct nozzle-to-surface cooling.
Solution Approach 2:
The system controls water pressure within a specific range (1-6 bar) to maintain the water cushion at optimal thickness. This parameter control allows the cooling system to operate close to the roll surface for efficient cooling while the cushion itself prevents excessive stress gradients.
3Ease of manufacture
If fixed cooling head design is used, then manufacturing simplicity is maintained, but adaptability to variable roll diameters is reduced
Solution Approach 1:
The cooling head incorporates adjustable side plates and lower transverse plates that can be repositioned to accommodate different roll diameters. This dynamic adjustment capability allows a single cooling head design to adapt to variable roll sizes while maintaining the concave cylindrical geometry needed for effective cooling.
Solution Approach 2:
The cooling head is divided into adjustable components (side plates, lower transverse plates) that can be independently positioned. This segmentation allows the cooling head to be configured for different roll diameters without requiring complete redesign, balancing manufacturing simplicity with adaptability.
4Reliability
If uniform cooling over roll width and circumference is achieved, then roll degradation is reduced, but cooling system complexity increases
Solution Approach 1:
Multiple nozzles are distributed in a two-dimensional pattern on the concave front face of the cooling head. This arrangement provides locally optimized cooling at different positions on the roll surface, achieving uniform overall cooling while maintaining a relatively simple cooling head structure compared to systems with individually regulated nozzles.
Solution Approach 2:
The concave cylindrical front face design serves multiple functions: it provides the geometric shape needed for water cushion formation, supports the nozzle array for uniform water distribution, and adapts to different roll diameters. This multi-functionality reduces the need for additional complex components.
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 achieves homogeneous cooling, reduces thermomechanical fatigue, lowers energy consumption, and extends roll lifespan by maintaining consistent temperature distribution with reduced water pressure, allowing for substantial cost savings and improved roll surface integrity.
Implementation Method 1
creating a highly turbulent water cushion between the head and the roll surface
Implementation Method 2
The heating of the hot rolling rolls is due to the transmission of heat to the rolls by conduction from the product
Implementation Method 3
the cooling of rolling rolls has been intensively studied because of the very strong influence of this on the degradation of said rolls
Data Source
AI summary
The present invention relates to a device for cooling a working roll (1, 2) belonging to a rolling stand used for rolling a long or flat product (3), characterized in that it comprises a cooling head in the form of a box section (6A, 6B) that is sealed except along a front face (42) lying a short distance from said roll (1, 2), and in which face a plurality of nozzles (41) has been machined or positioned in a determined pattern, said box section (6A, 6B) being concave and cylindrical at its front face (42). The box section (6A, 6B) is also fitted with transverse (5, 7) and lateral (8) plates which collaborate with the front face (42) of the box section so as to control the flow of cooling liquid and confine said liquid in the form of a highly turbulent flow. This then yields optimal cooling of the roll both in terms of the uniformity of the cooling across the surface thereof and in terms of the reduction in temperature as a result of the turbulent effect created.