Rolling Mill Cooling Section Layout for Pressure Shock Mitigation
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Solution Overview
Problem
Existing cooling systems in rolling mills experience pressure shocks or pulses when valves are closed quickly, which can cause excessive stress and are not effectively mitigated by existing pneumatic or pressure vessel solutions.
Innovation Solution
The cooling devices are grouped with dedicated pressure vessels connected upstream of their valves, allowing for rapid closure without pressure shocks by diverting water flow into the vessels, which are partially filled with water and air to manage pressure fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If valves are closed quickly to improve control precision and response time, then productivity and control accuracy are improved, but pressure shocks occur causing excessive stress and potential damage
Solution Approach 1:
The patent introduces a bypass conduit that is pre-configured to provide an alternative flow path before pressure shocks can occur. When the main valve closes rapidly, water flow is automatically redirected through the bypass conduit, cushioning the pressure shock before it reaches the cooling devices and piping system. This allows the main valve to close quickly without causing harmful pressure surges.
Solution Approach 2:
The bypass conduit acts as an intermediary element between the water supply and the cooling devices. It provides a mediator path for water flow that absorbs and mitigates pressure shocks, allowing the main control valve to operate quickly while the bypass conduit handles the pressure management function.
2Object-affected harmful factors
If a single bypass conduit is used to reduce pressure shocks, then pressure shock mitigation is improved, but device complexity increases due to additional active control components
Solution Approach 1:
The bypass conduit is designed to operate automatically based on pressure differential without requiring external control signals. When the main valve closes and pressure builds up, the bypass conduit automatically opens to relieve pressure, and closes when pressure normalizes. This self-regulating mechanism eliminates the need for additional sensors, actuators, and control logic that would be required for an actively controlled bypass system.
Solution Approach 2:
The patent extracts the pressure shock mitigation function from the main control system and implements it through a passive mechanical bypass conduit. This separates the fast response control function (main valve) from the pressure management function (bypass conduit), allowing each to operate independently without adding complexity to the overall control system.
3Object-affected harmful factors
If valve switching time is limited to 1 second to avoid pressure shocks, then pressure shock mitigation is improved, but productivity and control precision deteriorate
Solution Approach 1:
The bypass conduit is pre-configured to activate automatically when pressure shocks occur or are imminent. This allows the main valve to close rapidly (in 0.6 seconds or less) without needing to limit the switching time to 1 second, because the bypass conduit cushions the pressure shock before it becomes harmful.
Solution Approach 2:
The patent converts what would normally be a harmful pressure shock into a beneficial automatic activation signal for the bypass conduit. The pressure surge that would normally indicate a problem instead triggers the bypass mechanism to open, which then benefits the system by protecting it from damage while allowing fast valve operation.
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 configuration allows for rapid and precise control of water flow, minimizing pressure shocks and oscillations, enhancing operational efficiency and reducing wear on control systems.
Implementation Method 1
The pressure vessel is filled partly with water and partly with air. In this configuration, pressure shocks, which could otherwise occur in the event of a rapid interruption of the volume flow through the spur conduits, can be avoided or at least reduced in intensity as a result of the buffer action of the pressure vessel.
Data Source
AI summary
A device for cooling a metal rolling stock (1) rolled in a rolling train, having multiple cooling devices (4), to which water (5) is supplied via a respective branch line (7) and by means of which the water (5) is applied to the rolling stock (1). The branch lines (7) are equipped with a respective valve (8), by means of which the water flow flowing through the respective branch line (7) is adjusted. Each of the valves (8) is paired with a drive (9), via which the respective valve (8) is actuated. The cooling devices (4) form multiple groups, each of which is paired with a dedicated pressure vessel (10) in a proprietary manner. Each pressure vessel (10) is connected to a respective feed line (12) at a respective connection point (11), and the water (5) is supplied to the branch lines (7) of the cooling devices (4) of the corresponding group via said feed line. When viewed in the flow direction of the water (5), each connection point (11) is arranged upstream of the valves (8) of the respective group of cooling devices (4).