Dual-Axis Rotation Spill Box for Hot Dip Coating
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Solution Overview
Problem
Existing dip coating installations for metal strips face challenges in precise positioning and flow rate balancing, requiring large deflections and complicating the adjustment mechanism, which affects the quality and consistency of the coating.
Innovation Solution
A coating installation with a sheath that allows flexible and precise positioning of the metal strip relative to the liquid metal bath, utilizing a dual-axis rotation system for the spill box to maintain horizontality and balance flow rates, and incorporating overflow compartments to clean the liquid seal effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single axis of rotation near the upper end of the sheath is used, then the sheath can be adjusted, but relatively large deflections are necessary which are not desirable given the size of the area surrounding the sheath
Solution Approach 1:
The adjustment system is segmented into two independent rotational axes: the first axis (A1) rotates the entire sheath assembly, while the second axis (A2) rotates only the spill box relative to the sheath. This segmentation allows each axis to perform a specific function with minimal deflection, resolving the contradiction between adaptability and deflection amplitude.
Solution Approach 2:
The problem is solved by adding another dimension of rotation. Instead of relying on a single axis that requires large angular deflection, the invention introduces a second rotational degree of freedom. The spill box can be oriented correctly by combining rotations around both axes, thereby achieving the desired positioning with small deflections around each individual axis.
2Manufacturing precision
If two cylinders are used to adjust the position of the movable part, then positioning can be achieved, but the adjustment mechanism becomes complicated and does not allow very precise positioning
Solution Approach 1:
The complex mechanical adjustment system using two cylinders is replaced by a dual-axis rotational system. Each axis is driven by a simple rotary actuator, eliminating the need for complex cylindrical mechanisms. This substitution maintains positioning precision while significantly reducing mechanism complexity.
Solution Approach 2:
The system transitions from a static, complex mechanical linkage to a dynamic rotational system. The two independent rotational axes provide flexible, on-the-fly adjustment capabilities without the rigidity and complexity of pre-configured mechanical linkages. This dynamic approach simplifies the overall mechanism while enhancing positioning precision.
3Adaptability or versatility
If the lower part is connected to the upper part via a bellows, then movement is enabled, but the thermal deformation behavior of the upper part is modified
Solution Approach 1:
The bellows connection is extracted and replaced by a direct rigid connection between the upper and lower parts. The movability previously provided by the bellows is achieved instead through the controlled rotation around axis A1, which pivots the entire assembly. This extraction eliminates the thermal deformation issues introduced by the bellows while maintaining the required adaptability.
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 minimizes the amplitude of movement required for adjustment, enhances the precision of positioning, and reduces the risk of defects in the coating by maintaining a clean liquid seal and balanced flow rates, resulting in improved coating quality and reduced defect density on the metal strip.
Implementation Method 1
liquid metal from the bath overflows from the liquid seal in order to clean the liquid seal of impurities
Implementation Method 2
the connection of the lower part to the upper part via the bellows modifies the thermal deformation behavior of the upper part
Data Source
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AI summary
The invention concerns an apparatus for the continuous dip coating of a metal strip (1), comprising a vessel for containing a molten metal bath (12), a bottom roller (15) and a duct (13) in which the metal strip (1) runs. The duct (13) comprises an upper portion (45) and a lower portion (57), said lower portion (57) carrying an overflow container (49) delimiting at least two molten metal overflow compartments (25, 29), each overflow compartment (25, 29) being delimited internally by an inner wall comprising an upper edge. The duct (13) with the overflow container (49) is rotatably movable, relative to the metal strip (1), about a first axis of rotation (A1), and the overflow container (49) is rotatably movable, relative to the upper portion (45) of the duct (13), about a second axis of rotation (A2).