Die Thermoregulation via Integrated Cooling and Pre-heating
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Solution Overview
Problem
Existing thermoregulation systems for high-temperature dies in industrial processes face challenges in efficiently pre-heating and cooling dies, with pressurized systems posing safety and structural issues, and existing solutions only being suited for cooling, not pre-heating, which can lead to inefficient energy consumption and vapor formation.
Innovation Solution
A combined thermoregulation system integrating a primary hydraulic circuit for cooling and an auxiliary pre-heating circuit using hot water from an open storage tank at atmospheric pressure, allowing for both cooling and pre-heating with a single fluid, avoiding vapor formation and enabling operation at relatively low pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a pressurized tank and high-pressurized closed circuit are used for cooling fluid circulation, then cooling effectiveness is improved, but structural problems about sealing and safety worsen
Solution Approach 1:
The system divides the fluid circulation into separate zones: an open atmospheric tank zone for storage and an enclosed circuit zone for active cooling. This segmentation allows the cooling circuit to operate at high pressure while the storage tank remains at atmospheric pressure, resolving the contradiction between cooling effectiveness and sealing safety.
Solution Approach 2:
A pressure-reducing valve acts as an intermediary device between the high-pressure cooling circuit and the atmospheric tank. It mediates the pressure difference, allowing hot fluid to return to the tank safely while maintaining high pressure in the cooling circuit for effective heat transfer.
2Device complexity
If liquid fluid at atmospheric pressure is used for die pre-heating, then system simplicity is improved, but vapor formation and thermal loss worsen
Solution Approach 1:
The system merges the cooling and pre-heating circuits into a single integrated thermal management system. The pre-heating circuit uses the same fluid from the atmospheric tank, eliminating the need for separate heating systems while maintaining operational efficiency through pressure control.
Solution Approach 2:
A pressurization pump is introduced to the pre-heating circuit to pressurize the liquid fluid before it enters the die. This hydraulic pressurization prevents vapor formation by maintaining the fluid above its vapor pressure, while the system remains relatively simple by using the existing atmospheric tank as the fluid source.
3Device complexity
If existing cooling-only systems are used, then system simplicity is improved, but versatility for both pre-heating and cooling worsens
Solution Approach 1:
The system achieves multi-functionality by using a single integrated circuit that can operate in multiple modes: cooling mode using the atmospheric tank with high-pressure circulation, and pre-heating mode using the same tank with pressurized fluid delivery. This universal design allows one system to perform both thermal management functions.
Solution Approach 2:
The system dynamically switches between cooling and pre-heating operations by controlling the pressurization pump and flow distribution. The same physical infrastructure adapts its function based on operational requirements, providing versatility without requiring duplicate systems.
4Adaptability or versatility
If additional tanks or complex pressurized systems are added for pre-heating, then pre-heating capability is improved, but device complexity worsens
Solution Approach 1:
The atmospheric tank serves dual purposes: it is both the storage reservoir and the pressure reference for the system. By utilizing the tank's atmospheric pressure as a reference point and adding only a pressurization pump for pre-heating operations, the system achieves pre-heating capability while minimizing additional complexity.
Solution Approach 2:
The system recovers thermal energy by circulating fluid from the die back to the atmospheric tank, where heat is dissipated to the environment. This recovered thermal energy is then reused during pre-heating operations, creating an efficient thermal cycle without requiring additional heating infrastructure.
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
The system effectively pre-heats and cools dies using a single fluid, reducing energy consumption and safety concerns, while maintaining operational efficiency and safety by using an open storage tank and pressurizing the pre-heating fluid to prevent vapor formation, thus enhancing the die forming process.
Implementation Method 1
a heat exchanger to be cooled in its turn before its return to the tank
Implementation Method 2
the fluid intended for the pre-heating having the possibility of being generated under pressure out of the storage tank to obviate to the vapor formation at the required temperatures
Data Source
AI summary
The invention concerns a system for the thermoregulation of dies for die-casting, dies for chill casting and the like. It comprises a tank (11) containing a cooling fluid; a primary hydraulic circuit (12) for a circulation of the cooling fluid from the tank to the die to be cooled and from this to the tank through a heat exchanger (SC); a secondary pneumatic circuit (13) connected to the primary hydraulic circuit (12) for the circulation of an aeriform fluid in the die to be cooled both in alternative, and in a mixed form with the liquid cooling fluid; and a pre-heating hydraulic circuit (112) integrated with the primary hydraulic circuit (12) and assigned to the production and circulation of a hot liquid fluid for pre-heating the die to be thermoregulated.