Amorphous Ribbon Cooling Roll Online Polishing
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Solution Overview
Problem
Existing methods for producing amorphous ribbons fail to maintain the cooling roll's surface in prime condition when damage varies laterally, affecting the ribbon's magnetic properties and productivity.
Innovation Solution
A method and apparatus for online polishing of the cooling roll's circumferential surface during production, using polishing members with different characteristics to address uneven damage, ensuring continuous prime condition by differentiating polishing modes and contact lengths across the lateral direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform polishing is applied across the cooling roll surface, then the polishing process is simple, but the cooling roll surface cannot be maintained in prime condition when damage varies in the lateral direction
Solution Approach 1:
The patent applies different polishing modes to different lateral regions of the cooling roll surface. Specifically, the polishing member is differentiated in polishing mode across the lateral direction, with different regions receiving different polishing intensities or methods based on their specific damage conditions. This resolves the contradiction by making the polishing process adaptive to local surface conditions rather than applying uniform treatment everywhere.
Solution Approach 2:
The cooling roll surface is divided into multiple lateral regions, each subjected to appropriate polishing treatment. The polishing member itself is segmented or differentiated to provide different polishing characteristics across the width of the roll, allowing precise control over surface quality in different zones while maintaining overall process feasibility.
2Manufacturing precision
If the cooling roll surface is polished frequently to maintain prime condition, then surface quality is maintained, but production time is reduced and productivity decreases
Solution Approach 1:
The patent implements online polishing of the cooling roll surface during the amorphous ribbon production process. The polishing member operates continuously or intermittently without interrupting the ribbon production, maintaining the cooling roll surface in prime condition throughout production rather than requiring periodic shutdowns for maintenance. This resolves the contradiction by making the polishing action continuous and integrated into the production flow.
Solution Approach 2:
The polishing action is performed in advance or concurrently with production needs, preventing surface degradation before it impacts ribbon quality. By maintaining the surface proactively during production rather than reactively after damage occurs, the system avoids production interruptions while ensuring surface quality.
3Manufacturing precision
If online polishing is implemented during production, then the cooling roll surface is maintained in prime condition, but the polishing mode must be differentiated across the lateral direction increasing system complexity
Solution Approach 1:
The polishing member is designed with differentiated polishing modes across its lateral extent, allowing different regions of the cooling roll to receive appropriately tailored polishing treatment. This localized differentiation achieves high surface quality without requiring an overly complex system, as each zone receives only the specific treatment it needs.
4Productivity
If the cooling roll surface is not polished, then production proceeds without interruption, but the surface roughness increases and magnetic properties of the ribbon deteriorate
Solution Approach 1:
The polishing operation is integrated into the continuous production process, occurring online without interrupting ribbon manufacturing. The polishing member operates simultaneously with production, ensuring the cooling roll surface is maintained in prime condition throughout production runs, thereby preserving both productivity and product quality.
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 maintains the cooling roll's surface in prime condition, ensuring consistent magnetic properties and prolonged productivity by effectively addressing uneven damage, thereby enabling stable mass production of high-quality amorphous ribbons.
Implementation Method 1
a cooling roll made of copper alloy or other metal material of large thermal conductivity is therefore ordinarily used as a cooling roll that can rapidly remove heat from the molten alloy
Implementation Method 2
using a polishing member to polish a circumferential surface of the cooling roll
Data Source
AI summary
A method and apparatus are provided for producing an amorphous ribbon by ejecting and rapidly solidifying molten alloy on a circumferential surface of a rapidly rotating cooling roll, wherein the cooling roll is polished online during amorphous ribbon production. When the circumferential surface of the cooling roll after peeling off the ribbon is polished using a polishing member, the circumferential surface of the cooling roll is polished continuously or intermittently across its lateral direction while differentiating the polishing mode in accordance with the surface properties.