Electromagnetic Wiping Device for Plated Steel Sheet Edge Control
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Solution Overview
Problem
High-speed steel sheet plating processes face challenges in maintaining productivity while reducing scattered particles and dross formation, which increases with higher line speeds and gas wiping pressures, affecting plating quality and equipment longevity.
Innovation Solution
An electromagnetic wiping device is introduced to preliminarily remove a portion of the plating layer at the edge regions of the steel sheet using a varying magnetic field, followed by a gas wiping operation to adjust the plating layer thickness, reducing the load on gas wiping and minimizing particle scattering and dross formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high line speed is used to increase productivity, then productivity is improved, but scattered particles and dross formation increase
Solution Approach 1:
The electromagnetic wiper preliminarily removes excess plating layer from the steel sheet surface before the gas wiping stage. By pre-thinning the plating layer in the edge regions and center region, the subsequent gas wiping operation requires lower pressure and flow rate, thereby reducing particle scattering and dross formation even at high line speeds
Solution Approach 2:
The patent replaces part of the mechanical gas wiping system with an electromagnetic wiping mechanism. The electromagnetic wiper uses magnetic field interaction to remove plating material without requiring high-pressure gas flow, thus reducing the mechanical stress that causes particle scattering and dross when operating at high line speeds
2Manufacturing precision
If high gas pressure is used to remove plating layer at high line speed, then plating thickness control is improved, but particle scattering and dross formation increase
Solution Approach 1:
The electromagnetic wiper performs preliminary plating layer removal before gas wiping. By pre-thinning the plating in edge regions and center region, the gas wiping stage operates at lower pressure while still achieving target thickness, thus maintaining manufacturing precision without generating excessive particles or dross
Solution Approach 2:
The electromagnetic wiper applies localized magnetic field action to different regions of the steel sheet (edge regions and center region). This enables region-specific plating control where excess plating is selectively removed in areas prone to overplating, allowing precise thickness control with reduced overall gas pressure requirements
3Manufacturing precision
If gas wiping is performed to control plating thickness, then plating quality is improved, but gas wiping load increases at high line speeds
Solution Approach 1:
The electromagnetic wiper removes a portion of the plating layer before gas wiping, reducing the amount of material that needs to be removed during gas wiping. This preliminary removal significantly decreases the gas pressure and flow rate required, thereby reducing energy consumption and gas wiping load while maintaining plating quality
Solution Approach 2:
The electromagnetic wiping mechanism replaces part of the gas wiping function, using electromagnetic forces instead of high-pressure gas flow to remove plating material. This substitution reduces the energy demand of the gas wiping system while achieving the same plating thickness control objective
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 approach allows for controlled plating thickness, reduced gas pressure and flow rate, decreased particle scattering, and improved plating quality and equipment lifespan, enabling higher line speeds without increasing dross formation.
Implementation Method 1
an electromagnetic wiper (30) disposed on the device base (10) for controlling a thickness of a plating layer of the steel sheet by generating a varying magnetic field
Data Source
AI summary
There are provided an electromagnetic wiping device, a plated steel sheet wiping apparatus including the electromagnetic wiping device, and a method for manufacturing a plated steel sheet. A portion of a plating layer of a steel sheet having passed through a plating bath is preliminarily removed at least in an edge region of the steel sheet, and a gas wiping operation is performed. Therefore, overplating is prevented at least in the edge region of the steel sheet. In addition, since the load of gas wiping can be reduced while maintaining the line speed of the steel sheet, the quantity of scattered particles and the formation of dross can be reduced for improving the plating quality of the steel sheet and the productivity of a manufacturing process.