Cooling Path Pump Pressure Control for Hot Rolled Metal
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Solution Overview
Problem
Existing cooling paths for hot rolled metal face challenges in precisely managing coolant delivery, especially when a water tank cannot be placed close to the coolant outlets, leading to delayed coolant provision and high energy consumption due to unnecessary coolant pumping.
Innovation Solution
A method where the control device of the cooling path dynamically adjusts pump pressure based on total coolant flow, line resistance, and predicted coolant flows to ensure precise and efficient coolant delivery without the need for storage between the pump and outlets, using both usable and bypass coolant outlets to optimize coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a water tank is placed far from the coolant outlets, then the system occupies less space and has simpler structure, but the coolant delivery is delayed and less precise
Solution Approach 1:
The control system performs preliminary calculations of the required coolant flow rates and pump pressure in advance based on predicted future coolant demands. This allows the pump to be pre-positioned and activated at optimal moments, compensating for the time delay inherent in long line systems without requiring a water tank near the outlets.
2Reliability
If coolant is pumped continuously at high pressure, then the coolant outlets are always supplied with sufficient coolant, but energy consumption increases significantly
Solution Approach 1:
The system dynamically adjusts the pump pressure and coolant flow rates in real-time based on actual cooling requirements, line resistance conditions, and predicted future demands. This dynamic control ensures reliable coolant supply only when and where needed, avoiding continuous high-pressure pumping and significantly reducing energy consumption.
Solution Approach 2:
The control system uses feedback from flow sensors, pressure sensors, and predictions of future coolant requirements to continuously optimize pump operation. This feedback mechanism allows the system to maintain reliable coolant supply while minimizing energy consumption by adjusting pump pressure to match actual system needs.
3Productivity
If the pump pressure is increased to overcome line resistance, then coolant flow to outlets is improved, but pump wear increases and service life decreases
Solution Approach 1:
The control system calculates the minimum necessary pump pressure in advance based on predicted coolant flow requirements and line resistance conditions. By pre-positioning the pump at optimal pressure levels, the system achieves required coolant flow rates while avoiding excessive pressure that would accelerate pump wear and reduce service life.
Solution Approach 2:
The system optimizes pump operating parameters (pressure, flow rate) by changing them dynamically to match actual system requirements. This prevents operation at excessively high pressures that would cause premature pump failure, thereby extending pump service life while maintaining adequate coolant flow productivity.
4Manufacturing precision
If rapid adjustments in coolant flow are made, then cooling precision is maintained, but pump activation becomes more complex and frequent
Solution Approach 1:
The control system performs preliminary calculations of required coolant flow rates and pump pressure in advance based on predicted future cooling requirements. This advance planning allows for smoother, more predictable pump activation patterns while maintaining precise cooling control, reducing the complexity of real-time pump control decisions.
Solution Approach 2:
The system uses dynamic control to adjust coolant flow rates and pump pressure in response to changing cooling requirements. This dynamic adjustment maintains precise cooling control while optimizing pump operation patterns to reduce overall control complexity compared to frequent abrupt activations.
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
This approach allows for precise and efficient coolant delivery, reducing energy consumption by up to 50% and enabling rapid adjustments in coolant flow without compromising cooling accuracy, thus extending pump service life and simplifying its activation.
Implementation Method 1
a pump (7), which extracts coolant (2) from a coolant reservoir (8) and feeds it via a line system (9) to a number of coolant outlets (4)
Implementation Method 2
coolant outlets (4), which are controlled via valves (10) positioned upstream of the coolant outlets (4)
Implementation Method 3
a cooling path for cooling hot rolled material composed of metal
Data Source
AI summary
In a cooling path, hot rolled material composed of metal is cooled. The cooling path has a pump which extracts coolant from a coolant reservoir and feeds said coolant via a line system to a number of coolant outlets which are controlled by means of valves positioned upstream of the coolant outlets. A control device of the cooling path determines activation states (Ci) for the valves for a respective point in time taking into consideration coolant flows (Wi) which are intended to be discharged via the coolant outlets at the respective point in time, in conjunction with a working pressure (pA) of the coolant prevailing at the inlet side of the valve. By adding the coolant flows (Wi), said control device determines a total coolant flow (WG).