Cooling Section Valve Calibration for Rolling Stock
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Solution Overview
Problem
In hot rolling technology, the valve-specific characteristics in cooling sections change due to wear and tear, dirt, etc., leading to suboptimal coolant application and undesired material properties in rolling stock, as existing methods do not account for these changes.
Innovation Solution
An operating method where an automation device determines and accounts for valve-specific characteristics such as switch-on and switch-off delays, and average coolant flow rates by measuring coolant flow in the main line, and adjusts valve opening and closing times accordingly, using a programmable automation device and data carrier with a machine-readable operating program.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If valve-specific characteristics are determined and taken into account, then manufacturing precision of coolant application is improved, but device complexity increases due to additional measurement and control requirements
Solution Approach 1:
The system performs self-calibration by automatically determining valve-specific characteristics through measurement campaigns and storing them in memory. The automation device autonomously executes the calibration process without external intervention, reducing operational complexity while improving precision
Solution Approach 2:
Valve-specific characteristics are determined in advance during a calibration operation before normal production. The measured characteristics are stored and subsequently used to pre-adjust valve opening and closing times, ensuring precise coolant application from the start of production without continuous complex measurements
2Reliability
If valve-specific characteristics are determined through measurement campaigns, then reliability of coolant application is improved, but loss of time occurs during calibration operations
Solution Approach 1:
The calibration operation with measurement campaigns is performed once during setup or maintenance periods before normal production. The obtained valve-specific characteristics are stored and reused for extended periods, ensuring reliable coolant application without recurring time losses during production runs
Solution Approach 2:
The system creates a digital model (copy) of the valve characteristics through measurement and stores it in memory. This digital representation is then used repeatedly to control valve timing without needing to physically re-measure, saving time during ongoing production while maintaining reliability
3Device complexity
If centralized detection in the main line is used, then device complexity is reduced, but measurement precision of individual valve characteristics deteriorates
Solution Approach 1:
The calibration process is segmented into individual valve measurements. During calibration, each valve is opened and closed separately while the centralized measuring arrangement records the corresponding coolant quantity time profile. This allows precise determination of individual valve characteristics even with centralized detection
Solution Approach 2:
The measuring arrangement provides feedback on the coolant quantity time profile to the automation device. This feedback enables the system to calculate and store accurate valve-specific characteristics (opening delay, closing delay, average flow rate) from the centralized measurements, maintaining precision without increasing device complexity
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
Ensures accurate and reproducible coolant application, aligning with the setpoint coolant quantity profile, thereby achieving the desired material properties in rolling stock by dynamically adapting to the current operating state of the cooling section.
Implementation Method 1
detecting the time profile of the coolant quantity flow caused thereby by means of a measuring arrangement arranged in the main line
Data Source
Figure 1
Figure 2~4
Figure 3
AI summary
The invention relates to a cooling section having a plurality of coolant outlets (2), by means of which a coolant (4) can be applied to a rolling stock (3) passing through the cooling section (1) during the normal operation of the cooling section (1). The coolant outlets (2) are supplied with the coolant (4) via transmission lines (5) and a mutual main line (6), which the transmission lines (5) have in common. Individually opening and closing valves (7) are disposed in the transmission lines (5) such that the supply of coolant (4) to the coolant outlets (2) can be produced and interrupted by transmission line. An automation device (8) of the cooling section (1) opens and closes the valves (7) at valve-specific opening times and at valve-specific closing times during the normal operation of the cooling section (1) in order to apply coolant (4) to the rolling stock (3) in accordance with a quantitative target coolant course. During the determination of the valve-specific opening times, said automation device takes into consideration a respective valve-specific characteristic. In calibration operation of the cooling section (1), the respective valve-specific characteristic is initially determined at least for some of the valves (7) by opening and closing the respective valve (7), and detecting the chronological course of the quantitative coolant flow (Q) effected thereby by means of a measuring arrangement (12) disposed in the main line (6).