Electromagnetic Channelling for Hot-Rolled Bar Braking
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Solution Overview
Problem
Existing systems for channelling and unloading hot-rolled materials are costly due to high-power electric equipment required for braking, result in deformation of bars, and have issues with synchronism and maintenance, leading to inefficiencies and increased costs, especially in plants with multiple rolling lines.
Innovation Solution
The system employs electromagnet elements integrated into the travel channels to support, guide, and brake hot-rolled materials, eliminating the need for costly motor-driven tail brakes and flaps, allowing for controlled magnetic activation and deactivation of the channels to manage the movement and unloading of bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-power electric motors are used to brake the hot-rolled bars in tail brake devices, then the deceleration time is reduced and productivity is improved, but the construction cost and energy consumption increase significantly
Solution Approach 1:
The patent replaces the mechanical/electric braking system (motors driving tail brake rolls) with a magnetic braking system. Electromagnet elements are activated to create magnetic fields that interact with the ferromagnetic bars, producing braking force without mechanical contact. This substitution eliminates the need for high-power motors and associated electric equipment while achieving rapid deceleration.
Solution Approach 2:
The patent changes the physical state or properties used for braking. Instead of using mechanical friction through pressed rolls, the system utilizes magnetic field interaction by activating electromagnet elements. This parameter change allows for rapid deceleration without the energy consumption and cost associated with mechanical braking systems.
2Productivity
If high braking force is applied to reduce deceleration time, then productivity is improved, but the bars undergo deformation
Solution Approach 1:
The patent replaces mechanical contact braking with magnetic field-based braking. The electromagnet elements create a magnetic field that interacts with the ferromagnetic bars to produce braking force without physical contact. This eliminates the mechanical pressure and friction that cause bar deformation while still achieving rapid deceleration.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the braking system and the bars. Instead of direct mechanical contact between brake rolls and bars, the magnetic field serves as the mediating force that transfers braking action to the bars. This intermediary approach allows for effective braking without the deforming contact forces of mechanical systems.
3Productivity
If motor-driven tail brake devices are used for forced braking, then braking efficiency is improved, but the construction cost and device complexity increase
Solution Approach 1:
The patent replaces the complex mechanical system of motor-driven rolls with a simpler electromagnetic system. Electromagnet elements can be directly activated to create braking force without requiring motors, transmissions, or mechanical drive mechanisms. This substitution maintains high braking efficiency while significantly reducing device complexity and construction cost.
Solution Approach 2:
The patent extracts and eliminates the motor and associated mechanical equipment from the tail brake system. By using electromagnet elements that can be directly activated, the system removes the need for high-power electric motors and their associated control equipment, thereby reducing device complexity while maintaining braking efficiency.
4Device complexity
If natural friction braking is used in guideways, then device simplicity is improved, but the braking efficiency is insufficient and unloading time increases
Solution Approach 1:
The patent replaces passive friction-based braking with active magnetic braking. Electromagnet elements are activated to create controlled magnetic fields that provide consistent and efficient braking force. This active magnetic system maintains device simplicity while dramatically improving braking efficiency and reducing unloading time compared to reliance on natural friction.
Solution Approach 2:
The patent employs periodic or controlled activation of electromagnet elements along the guideway. By selectively activating electromagnets at different positions and times, the system provides controlled braking action that is more efficient than continuous friction braking, thereby reducing unloading time while maintaining system simplicity.
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 solution reduces energy consumption, construction costs, noise levels, and maintains high rolling speeds while preventing bar deformation, ensuring efficient and synchronized unloading without the need for complex synchronizing systems.
Implementation Method 1
The system employs electromagnet elements integrated into the travel channels to support, guide, and brake hot-rolled materials
Implementation Method 2
electromagnet elements integrated into the travel channels to support, guide, and brake hot-rolled materials
Implementation Method 3
The system employs electromagnet elements integrated into the travel channels to support, guide, and brake hot-rolled materials, eliminating the need for costly motor-driven tail brakes
Data Source
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AI summary
A system for channelling and unloading hot-rolled materials downstream of a unit for cutting to size and upstream of a cooling bed (11), in which a rolled material (13) is fed at high speed inside at least one channelling unit (14) and unloaded by the latter onto the cooling bed (11), the channelling unit (14) comprising a supporting structure (15) having at least one travel channel (16) which is open downwards and with which at least one electromagnet element (17) is associated. Preferably the at least one travel channel (16) is shaped in the manner of an overturned U. Preferably the system has at least one pair of adjacent and parallel travel channels (16).