Furnace Cooling Element Bead Welding Design
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Solution Overview
Problem
Existing cooling elements for melting furnaces face issues with high heat transfer resistance and susceptibility to cracking due to thermal stress, leading to water leakage and impaired heat transfer, particularly in cast copper elements with coarse grain structures and explosive joining methods.
Innovation Solution
A cooling element design featuring cooling tubes with beads for welding cover plates, which retains the microstructure and avoids material weakening, using fusion welding and a configuration that increases the heat transfer surface area by incorporating beads and multiple cooling tubes, allowing for efficient heat dissipation and easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cast copper cooling elements are used, then manufacturing is simplified, but the elements are susceptible to cracking due to coarse grain structure and thermal stress
Solution Approach 1:
The patent changes the manufacturing method from sand casting to a process that produces fine-grained copper structure through controlled solidification and hot working. This parameter change in the manufacturing process transforms the grain structure from coarse to fine, thereby improving reliability while maintaining ease of manufacture.
2Ease of manufacture
If explosive welding is used to join cover plates, then assembly is simplified, but heat transfer resistance increases and material structure is weakened
Solution Approach 1:
The patent replaces the explosive welding process with a mechanical pressing and heating process. This substitution eliminates the harmful effects of explosive welding while achieving adequate bonding of cover plates, thereby reducing heat transfer resistance and avoiding material structure weakening.
3Ease of repair
If cooling elements are designed to be removable from outside, then maintenance is easier, but the furnace requires opening and refractory mass filling becomes complex
Solution Approach 1:
The patent segments the cooling element into a modular design where the copper cooling element and cover plates can be separately installed and removed. This segmentation allows the cooling element to be inserted through the furnace opening and secured with cover plates, enabling easy maintenance while simplifying the installation process compared to traditional integrated designs.
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 reduces heat transfer resistance, enhances the cooling capacity, and prevents material weakening, ensuring reliable operation and easy maintenance by maintaining the microstructure and increasing the heat transfer surface area through the use of beads and multiple cooling tubes.
Implementation Method 1
at least one cooling tube with a coolant channel for conducting a coolant
Implementation Method 2
coolant channel for conducting a coolant
Implementation Method 3
the at least one cooling pipe has at least one bead running in the longitudinal direction of the at least one cooling pipe
Implementation Method 4
at least one cover plate which is welded to the at least one cooling pipe
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
The invention relates to a cooling element for a melting furnace, having at least one cooling pipe for passing through a coolant, and having a support element (21) to which the at least one cooling pipe (2, 20) is fastened, wherein at least one cover plate (22, 23) is welded to the at least one cooling pipe (2, 20), wherein the at least one cooling pipe (2, 20) has at least one bead (14, 15) which extends in the longitudinal direction of the at least one cooling pipe (2, 20) and to which the at least one cover plate (22, 23) is welded.