Contactless Electromagnetic Braking for Rolling Mill Bars
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for decelerating long products exiting a rolling mill, such as bars, often result in shape deformation and reduced braking performance due to mechanical contact, which compromises product quality and efficiency, while also requiring significant space and energy.
Innovation Solution
A contactless braking system utilizing a series of electromagnets with open magnetic cores and coils, inducing eddy currents to generate a drag force that slows down the products without physical contact, reducing the need for bulky machinery and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If motorized rotating rolls are used to mechanically brake the bar, then braking force is generated, but the bar undergoes unacceptable deformation altering its cross section shape
Solution Approach 1:
The patent replaces the mechanical braking system (motorized rotating rolls) with an electromagnetic braking system (electromagnets inducing eddy currents). This substitution eliminates direct mechanical contact between the braking device and the bar, thereby preventing deformation of the cross section shape while still generating sufficient braking force through electromagnetic drag.
Solution Approach 2:
The patent introduces eddy currents as an intermediary mechanism. The electromagnets do not directly contact the bar but instead induce eddy currents within the bar material, which then generate opposing magnetic fields that create the braking force. This intermediary approach allows force transmission without mechanical contact, preserving the bar's shape.
2Shape
If pinching force is limited to prevent deformation, then product quality is maintained, but the transmittable torque and braking performance are reduced
Solution Approach 1:
The patent replaces mechanical pinching with electromagnetic induction. The electromagnets generate braking force through induced eddy currents rather than mechanical contact, allowing full braking performance without the need to limit pinching force. This eliminates the trade-off between maintaining shape and achieving sufficient braking torque.
3Power
If multiple braking rolls are added to increase braking capacity, then braking performance improves, but device complexity and installation space increase
Solution Approach 1:
The patent replaces multiple mechanical braking rolls with a series of electromagnets. The electromagnetic system achieves the required braking capacity through controlled induction in each magnet, eliminating the need for multiple heavy mechanical rolls. This reduces device complexity, installation space, and maintenance requirements while maintaining or improving braking performance.
4Force
If mechanical contact braking is used, then braking force is applied, but product quality deteriorates due to surface contact and deformation
Solution Approach 1:
The patent substitutes mechanical contact braking with contactless electromagnetic braking. The electromagnets induce eddy currents within the bar material to generate braking force without physical contact. This eliminates surface contact issues, prevents deformation, and maintains manufacturing precision while still applying sufficient braking force.
Solution Approach 2:
The patent uses eddy currents as an intermediary to transmit braking force without mechanical contact. The electromagnets induce these currents within the bar, which then generate opposing magnetic fields that provide the braking effect. This intermediary mechanism preserves product quality by eliminating direct contact while still achieving the required braking force.
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 decelerates high-speed long products in a short distance without deforming them, significantly reducing braking cycle time and energy use, while minimizing space requirements and maintaining product quality.
Implementation Method 1
A contactless braking system for decelerating long products, such as bars bi, exiting from a rolling mill (100) comprises at least one braking module (6). The braking module comprises a multiplicity of electromagnets (60) arranged in a series along a braking line (lb). Each of the electromagnets (60) is configured to induce eddy currents when a long product bi contactlessly slides through the gaps (63) of their open magnetic cores (61).
Implementation Method 2
Each of the electromagnets (60) comprises an open magnetic core (61) and a coil (62) around the magnetic core (61). The electromagnets (60) are configured to induce eddy currents when a long product bi contactlessly slides through the gaps (63) of their open magnetic cores (61).
Implementation Method 3
Each of the electromagnets (60) is configured to induce eddy currents when a long product bi contactlessly slides through the gaps (63) of their open magnetic cores (61). A braking magnetic force (Fd), or drag force, is exercised on the long product bi by the electromagnets (60).
Data Source
Figure 1~2
Figure 3a~3b
Figure 3c~4
AI summary
A contactless braking system –and a related method- for decelerating long products (bi), such as bars, exiting from a rolling mill (100) configured to manufacture said long products (bi), said system comprising: at least one braking module (6) comprising a multiplicity of electromagnets (60) arranged in a series along a braking line (lb), each of said electromagnets (60) being configured to induce a magnetic field (B) and comprising an open magnetic core (61) and a coil (62) around said magnetic core (61), wherein the open magnetic core (61) comprises a gap formed by two opposed poles between which said magnetic field (B) flows, the electromagnets (60) of said braking module (6) being configured in a way that the gap of each open magnetic core (61) is apt to receive and let contactlessly slide therethrough each long product (bi) exiting from said rolling mill (100); and in a way that a braking magnetic force (Fd) is exercised on said long product (bi) by said electromagnets (60) when said long product (bi) contactlessly slides through said gap, said braking magnetic force (Fd) being opposite to the direction of movement of said long product (bi) exiting from said rolling mill (100).