Cooling Device With Segmented Spray Bars For Thermal Ridge Control
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Solution Overview
Problem
Existing cooling devices for flat rolled products are unable to effectively address temperature ridges, where one side of the product is hotter than the other, as they lack the capability to intensively cool one side more than the other.
Innovation Solution
A cooling device with individually controllable valve systems that allow for a central triangle and outer triangles flow rate profiles, enabling flexible adjustment of cooling medium distribution to counteract thermal ridges across the product's width, with options for binary valve operation, adjustable pump settings, and adjustable spray bar positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a symmetric trapezoidal flow rate profile is used with coordinated valve actuation, then uniform cooling across the product width is achieved, but the ability to selectively cool one side more intensively is lost
Solution Approach 1:
The spray bar is divided into multiple independently controllable sections (central section and at least two outer sections) with separate valve devices. This segmentation allows different flow rate profiles to be applied to different regions, enabling both uniform cooling (by coordinating all sections) and selective side cooling (by adjusting outer section valves independently), thus resolving the contradiction between temperature uniformity and adaptive cooling capability.
Solution Approach 2:
The valve devices are designed to be individually and dynamically controllable, allowing the flow rate profile to be changed in real-time based on the thermal state of the product. This dynamic control enables the system to switch between symmetric cooling modes (for uniformity) and asymmetric cooling modes (for ridge elimination), maintaining both precision and adaptability.
2Manufacturing precision
If the central flow rate profile maximum is positioned at the center, then uniform cooling is achieved, but the ability to address temperature ridges on one side is limited
Solution Approach 1:
The system applies different cooling intensities to different local regions of the product. The central section provides cooling to the center region, while the outer sections with independently controllable valves provide enhanced cooling to specific side regions where temperature ridges occur. This local quality approach allows the maximum of the central flow rate profile to remain at the center for uniformity, while simultaneously enabling asymmetric cooling distribution to eliminate thermal ridges through outer section adjustment.
3Adaptability or versatility
If dedicated individually controllable valve devices are installed for each section, then flexible cooling profiles are enabled, but device complexity increases
Solution Approach 1:
Instead of one complex valve system, the invention uses multiple simpler valve devices (one per section) that are independently controlled. Each valve device manages a specific section's cooling flow, simplifying the control logic for each individual valve while achieving complex overall cooling profiles through their coordinated operation. This segmented approach reduces the complexity of each valve component and its control system.
Solution Approach 2:
Each valve device, while controlling a specific section, serves multiple functions: it can operate independently for localized cooling, coordinate with other valves for uniform cooling, and be adjusted to create asymmetric profiles for ridge elimination. This multi-functionality of each valve device maximizes the cooling profile flexibility without proportionally increasing the overall system complexity.
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
Enables uniform or differential cooling of the product's edges and center, effectively eliminating thermal ridges and allowing for flexible cooling strategies to match temperature across the product's width.
Implementation Method 1
The flat rolled product passing through the cooling device is impinged upon with a flow rate profile of a liquid cooling medium
Implementation Method 2
a liquid cooling medium is injected into the sections via a respective dedicated, individually controllable valve device
Data Source
AI summary
A flat rolled article (2) passes through a cooling device (1) in a transportation direction (x) at the level of a passline (3). Spray bars (5, 6) extend transversely with respect to the transportation direction (x). The spray bars (5, 6) have, as viewed perpendicular to the transportation direction (x), in each case two outer regions (7, 8) and a central region (9) in between. A liquid cooling medium (13) can be fed into the regions (7, 8, 9) via respective dedicated, individually controllable valve devices (10, 11, 12). Flow rate profiles, pertaining to each region may be set, wherein each region (7, 8, 9) is triangular in shape. The central triangle and the two outer triangles combine to form a rectangle.