Cooling Section Control for Uniform Steel Rolling Stock
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Solution Overview
Problem
The cooling process for flat rolled metal stock, particularly steels, faces challenges in achieving uniform cooling due to non-linear heat transfer at low temperatures, leading to uneven cooling and potential plastic deformations, which affects the quality of the rolling stock.
Innovation Solution
An operating method for a cooling section that divides cooling devices into released and non-released categories, with actual cooling capacities determined for each rolling stock point, allowing for real-time control and adaptation of the cooling function based on the state of the rolling stock, using a model that accounts for energy variables and phase transformations to ensure precise coolant application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cooling section applies coolant continuously to achieve high cooling rate, then the productivity is improved, but at low temperatures the non-linear heat transfer causes uneven cooling and plastic deformations worsening the manufacturing precision
Solution Approach 1:
The patent applies dynamic control of cooling devices by dividing them into released and non-released categories, allowing the cooling system to adapt its behavior based on real-time temperature conditions. The control device dynamically adjusts which cooling devices are active and modifies their cooling capacities according to the current state of the rolling stock, enabling high cooling rates when appropriate while preventing uneven cooling and deformations at critical temperature ranges.
Solution Approach 2:
The patent changes the operational parameters of cooling devices by assigning different cooling capacities (released vs. non-released) based on temperature conditions. The control device calculates optimal cooling capacities for each rolling stock point and adjusts the cooling section's operation accordingly, modifying heat transfer parameters to maintain uniformity while achieving required cooling rates.
2Manufacturing precision
If the cooling section uses a large number of individually controllable cooling devices to achieve precise temperature control, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The patent segments the cooling devices into released and non-released groups, allowing selective activation based on process requirements. This segmentation enables precise temperature control in critical areas while reducing the operational complexity of the entire cooling section by deactivating unnecessary devices during specific phases of the cooling process.
Solution Approach 2:
The control device performs preliminary calculations to determine the optimal set of released and non-released cooling devices before initiating the cooling process. By pre-calculating which devices should be active and their respective cooling capacities, the system achieves precise temperature control without requiring all cooling devices to operate simultaneously, thereby reducing operational complexity.
3Productivity
If the cooling section applies high cooling rate to achieve favorable material properties, then the productivity is improved, but the non-linear heat transfer at low temperatures causes uneven cooling worsening the manufacturing precision
Solution Approach 1:
The patent implements a feedback mechanism where the control device continuously monitors the temperature state of the rolling stock and adjusts the cooling capacities of released and non-released devices accordingly. This feedback loop ensures that high cooling rates are applied when beneficial for material properties while automatically reducing or redistributing cooling capacity when non-linear heat transfer begins to cause uneven cooling, maintaining uniformity of material properties throughout the process.
Solution Approach 2:
The system dynamically adjusts the distribution of cooling capacities between released and non-released devices based on real-time temperature conditions. As the rolling stock cools and approaches critical temperature ranges where non-linear heat transfer occurs, the control device dynamically modifies which devices remain released and adjusts their capacities, maintaining both high cooling efficiency and uniform material properties.
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 method ensures uniform cooling across the rolling stock, reducing the risk of deformations and improving material quality by optimizing coolant application and heat transfer, even at low temperatures, and allows for flexible cooling rates and multiple applications within the cooling section.
Implementation Method 1
the sections of the rolling stock passing through the active areas of the cooling devices one after the other... each section of the rolling stock located in the effective area of the respective cooling device is acted upon with a respective amount of coolant
Data Source
Figure 1
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AI summary
A flat rolled material (1) is transported through a cooling zone (2) such that sections (15) of the rolled material (1) sequentially pass through operating areas (8, 9) of cooling devices (6, 7). Virtual rolled material points (P) are assigned to the sections (15). Tracking of the sections (15) is carried out using a working cycle (δt') during the transport of the segments (15) through the cooling zone (2). The cooling devices (6, 7) are controlled according to actual cooling efficiency (mi) assigned to the corresponding rolled material points (P) for the cooling devices (6, 7). By this means, the section (15) respectively located in the operating area (8, 9) of the respective cooling device (6, 7) is supplied with a respective amount of coolant. The cooling devices (6, 7) are divided into released and not released cooling devices. A rolled material point (P) is respectively iteratively selected. Beginning at a starting point (xA), a status (E) is determined which the corresponding rolled material point (P) has at the starting point (xA) before the corresponding section (15) reaches the operating area (8, 9) of the next released cooling device (6, 7).