Coolant Spray Module Layout for Uniform Metal Quenching
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Solution Overview
Problem
Conventional coolant spray systems for heat-treated metal products suffer from uneven cooling due to varying coolant spray pressures caused by gravity, leading to non-uniform quenching and difficulty in controlling injection angles and amounts.
Innovation Solution
A coolant spray module system with a combined coolant distribution pipe, divided into upper and lower sections, maintains uniform coolant pressure across nozzles by applying higher pressure to upper sections, and adjustable nozzle angles and spray modules to prevent unwanted coolant direction and ensure uniform cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant is sprayed from nozzles at different locations in a conventional quenching system, then the metal product is cooled, but the coolant spray pressure varies due to gravity causing uneven cooling
Solution Approach 1:
The patent applies different coolant pressures to nozzles at different locations (upper vs lower sections) to compensate for gravitational effects. Each nozzle receives locally optimized pressure to ensure uniform spray output across all positions, directly resolving the pressure variation issue caused by gravity.
Solution Approach 2:
The system dynamically adjusts the pressure parameter of coolant supplied to different nozzle sections. By changing the pressure parameter locally for upper and lower nozzles, the system maintains consistent spray characteristics despite gravitational influences, achieving uniform cooling across the metal product surface.
2Ease of operation
If nozzles are integrated with the quenching ring to form a single body, then the structure is simplified, but the spraying angle of the coolant cannot be adjusted
Solution Approach 1:
The nozzle system is segmented into separate adjustable components rather than being integrated as a single fixed body. This segmentation allows independent adjustment of spray angles while maintaining structural organization, resolving the contradiction between adjustability and complexity.
Solution Approach 2:
The nozzle assembly incorporates dynamic adjustment capabilities, allowing the spray angle to be changed during operation. This dynamic feature enables flexible control of coolant direction without requiring complete structural redesign, balancing operability with manageable complexity.
3Quantity of substance
If the interval between outer ring and inner ring is adjusted using fastener, then the nozzle shape and size can change, but it is difficult to precisely control the injection amount of coolant
Solution Approach 1:
The system incorporates feedback mechanisms to monitor and control coolant injection amounts. By measuring actual spray output and adjusting parameters accordingly, the system achieves precise control over coolant quantity, overcoming the limitations of simple mechanical adjustment methods.
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 uniform cooling of metal products by maintaining consistent coolant pressure and allowing for precise control of spray angles and amounts, preventing uneven cooling and improving product quality.
Implementation Method 1
the pressures of the coolant sprayed out are different from each other depending on the location of the nozzles due to the influence of gravity
Implementation Method 2
Quenching is referred to a process of quickly cooling down a metal product, which is heated to a high temperature by heat treatment
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
A coolant spray module system for a heat treatment metal product includes a first coolant spray module (1) comprising a first module housing (10), a first module cover (20), and a first nozzle (30), wherein the first module housing (10) comprises: a first passing hole (11) provided in the first module housing (10), wherein the heat treatment metal product passes through the first passing hole (11); a first coolant distribution pipe (12) provided on the first module housing (10) along an inner circumference of the first module housing (10) and carrying a coolant; and a coolant supply port (14) provided on an outer circumferential surface of the first module housing (10) and connected to the first coolant distribution pipe (12) via a coolant supply pipe (15).