Cooling Section Application Devices for Fast Flow Switching
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Solution Overview
Problem
Current cooling systems in rolling mills face challenges with slow switching times and pressure shocks when adjusting coolant flow, leading to inefficiencies and inaccuracies in temperature management for hot rolled metal products.
Innovation Solution
A method and control device that dynamically adjust coolant flow by using an active device to provide an additional flow of medium, either air or water, to a buffer region, allowing for precise control of the cooling flow to match a setpoint flow, even with less dynamic control valves, thereby reducing energy consumption and improving switching times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If control valves are used to adjust coolant flow, then flow control is achieved, but switching times are slow and pressure shocks occur
Solution Approach 1:
The buffer region is pre-filled with coolant before cooling operations begin. This preliminary action ensures that when control valves adjust flow rates, the coolant is already available in the buffer, enabling rapid response without waiting for flow establishment and eliminating pressure shocks associated with valve opening/closing transients
Solution Approach 2:
The buffer region acts as an intermediary between the coolant supply system and the application devices. It decouples the supply system from the demand side, allowing control valves to operate without directly causing pressure shocks in the application devices, while still enabling precise flow control
2Manufacturing precision
If control valves are used to precisely control coolant flow, then flow accuracy is improved, but system complexity increases
Solution Approach 1:
By pre-filling the buffer region with coolant, the system eliminates the need for complex dynamic control mechanisms during operation. The preliminary preparation of the buffer simplifies the overall control system while maintaining precise flow control capabilities through the control valves
3Manufacturing precision
If rapid switching of coolant flow is achieved, then temperature management accuracy is improved, but energy consumption increases
Solution Approach 1:
The buffer region is pre-filled with coolant to enable rapid switching without requiring high-energy pump operations during transient states. This preliminary preparation allows the system to achieve fast response times for temperature control while minimizing energy consumption during flow transitions
Data Source
AI summary
A cooling section (2) is situated in a rolling line or upstream or downstream of the rolling line. A hot metal rolled material (1) is cooled in the cooling section. A control device (13) of the cooling section (2) dynamically determines setpoint actuation states (S1*) for control valves (10) situated in supply lines (8) and actuates the control valves (10) accordingly. Main flows (F1) of a liquid, water-based coolant (7) are supplied to application devices (6) of the cooling section (2) via the supply lines (8) in accordance with the actuation. The supply lines (8) conduct the main flows (F1) to buffer regions (12) of the application devices (6). Proceeding from there, cooling flows (F) of the coolant (7) are applied to the hot rolled material (1). The control device (13) also dynamically determines setpoint actuation states (S2*) for active devices (16) and actuates the active devices (16) accordingly. The active devices (16) conduct additional flows (F2) of a further medium (18) to the buffer regions (12) via further supply lines (17) in accordance with the actuation. The cooling flows (F) depend on both the main flows (F1) and the additional flows (F2). The additional flows (F2) are positive or negative depending on the actuation state (S2*) of the active devices (16). The control device (13) adjusts the additional flows (F2) by correspondingly actuating the active devices (16) such that the cooling flows (F) are as identical as possible to setpoint flows (F*) of the coolant (7) at all times.