Electromagnetic Strip Stabilizer for Ferromagnetic Coating

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Solution Overview

Problem

Existing coating processes for ferromagnetic metal strips face issues with vibrations and static deformation, leading to non-uniform coating thickness and reduced productivity, due to mechanical guide members and electromagnetic levitation systems, which also cause liquid metal splashes and alloy composition variations.

Innovation Solution

An electromagnetic device with first and second electromagnets aligned parallel to a theoretical pass-line, generating independent magnetic fields that create continuous magnetic fields along the strip's transverse direction, using connection elements to distribute forces uniformly across the strip's width, minimizing deformation and vibrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mechanical guide members (rolls) are used to guide the metal strip, then the strip trajectory is controlled, but vibrations and static deformation (crossbow) occur leading to non-uniform coating thickness

Engineering Contradiction:

Improvecoating thickness uniformityVSAvoidvibrations and deformation

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical guide members (rolls) with an electromagnetic stabilization system that uses magnetic fields to control and stabilize the metal strip trajectory through the molten metal bath, eliminating mechanical contact that causes vibrations and deformation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system dynamically adjusts electromagnetic field parameters (strength, distribution) to compensate for strip deformation and maintain uniform coating thickness, changing the physical state of control from mechanical to electromagnetic

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If the metal strip is supported vertically between two points, then the strip remains tensioned, but the distance between support points (30-50 meters) creates static deformation

Engineering Contradiction:

Improvestrip tension stabilityVSAvoidstatic deformation (crossbow)

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The patent replaces the mechanical support system with electromagnetic fields that provide distributed stabilization along the strip length, eliminating the need for long-span mechanical supports that cause sagging and deformation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If jet-coolers and knives are used for coating removal and cooling, then the coating process is completed, but these components are sources of vibrations affecting strip stability

Engineering Contradiction:

Improvecoating process efficiencyVSAvoidvibrations from processing components

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical processing components (jet-coolers, knives) with electromagnetic fields for strip stabilization during these operations, maintaining processing efficiency while eliminating vibration sources

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution effectively stabilizes the metal strip, reduces over-coating requirements, increases production line speed, and improves coating quality by uniformly distributing forces across the strip's cross-section, adapting to varying widths and reducing electromagnetic saturation.

Implementation Method 1

first electromagnets aligned along a direction parallel to a first theoretical pass-line of said metal strip and orthogonal to a transportation direction of the strip... generating independent magnetic fields that create continuous magnetic fields along the strip's transverse direction

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

connection elements to distribute forces uniformly across the strip's width, minimizing deformation and vibrations

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Data Source

PatentUS9968958B2Electromagnetic device for stabilizing and reducing the deformation of a strip made of ferromagnetic material, and related process

Publication Date: 2018.05.15 DANIELI & C OFFICINE MECCANICHE SPA

AI summary

An electromagnetic device (1) for stabilizing and minimizing the deformation of a strip (4) made of ferromagnetic material during its feeding in a system for coating the same strip with molten metal, by applying a distribution of force which is continuous in the direction transversal to the strip regardless of the width thereof. The device comprises first electromagnets and second electromagnets mirroring the tirst electromagnets with respect to said theoretical pass-line (50) of said strip (4). Each electromagnet includes a core comprising one pole and one feeding coil wound about the pole. The electromagnetic device comprises a connection element (26) made of ferromagnetic material which connects the cores of the first electromagnets (15, 15′, 15″, 15′″) and a connection element (26′) made of ferromagnetic material which connects the cores of the second electromagnets (16, 16′, 16″, 16′″). The connection elements (26, 26′) mirror the theoretical pass-line (50) of the strip (4).