Full Cone Spray Nozzle Vane Structure for Steel Cooling
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Solution Overview
Problem
Full cone spray nozzles used in steel sheet production face challenges in achieving uniform spray impact and water flow rate distribution across the entire sprayed region, particularly due to issues with dimensional tolerances and pressure fluctuations, leading to inadequate cooling and potential over-cooling.
Innovation Solution
A full cone spray nozzle design with a vane structure lacking a center bore, featuring channel grooves of specific width and depth on the circumference and a downstream projecting part with a combination of columnar and conical shapes, optimized to reduce pressure loss and enhance spray impact without increasing inflow pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a center bore is provided in the vane structure to achieve uniform flow rate distribution, then the flow rate distribution improves, but the spray impact becomes weak and the cooling ability deteriorates
Solution Approach 1:
The invention applies local quality by providing different structural features at different locations: the upstream end has a center bore for uniform flow distribution, while the downstream end has an enlarged diameter section for generating strong spray impact. This localized differentiation allows each section to optimize its function without compromising the other.
Solution Approach 2:
The vane structure is segmented into distinct functional zones: an upstream portion with center bore for flow distribution, a downstream portion with enlarged diameter for impact generation, and intermediate vanes for swirl creation. This segmentation allows independent optimization of each zone's characteristics.
2Force
If the vane structure does not have a center bore to increase spray impact, then the spray impact strengthens, but the flow rate distribution becomes non-uniform with excessive center flow
Solution Approach 1:
The center bore is positioned only at the upstream end where it serves flow distribution purposes, while the downstream end deliberately lacks a center bore to maximize spray impact. This spatially differentiated design allows each location to have the quality it needs for its specific function.
Solution Approach 2:
The vane structure divides the flow path into segments with different characteristics: the upstream segment with center bore controls flow distribution, the intermediate segment with vanes creates swirl, and the downstream segment with enlarged diameter generates impact.
3Area of stationary object
If the spray angle is increased to cover a wider region, then the coverage area improves, but the spray impact at the center becomes weak
Solution Approach 1:
The nozzle creates dynamic swirl flow that naturally distributes spray at an optimized angle. The rotating vanes generate centrifugal force that propels droplets outward at approximately 30 degrees, creating a balance between coverage and impact that static geometries cannot achieve.
Solution Approach 2:
The invention changes the flow parameters through the swirl mechanism, transforming the liquid into rotating droplets with optimized velocity and angle. This dynamic parameter change achieves both wide coverage and strong impact without the trade-off present in conventional fixed-angle nozzles.
4Force
If the inflow pressure is increased to strengthen spray impact, then the spray impact improves, but the pressure loss in the system increases
Solution Approach 1:
The nozzle performs preliminary acceleration and swirl generation within the nozzle body itself, creating high-velocity rotating droplets before exit. This preliminary action reduces the need for high inflow pressure, thereby minimizing pressure loss in the supply system.
Solution Approach 2:
The dynamic swirl flow mechanism converts pressure energy into rotational kinetic energy efficiently, creating strong spray impact without requiring excessive inflow pressure. The centrifugal propulsion of droplets achieves high velocity with minimal pressure loss.
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 design achieves a strong, uniform spray impact and flow rate distribution, reducing pressure loss and improving cooling efficiency across the entire spray area, ensuring consistent steel sheet cooling without over-cooling.
Implementation Method 1
the swirl flow generating means of the vane structure makes it swirl and form an eddy current
Data Source
Figure 1(a)~1(b)
Figure 2(a)~3
Figure 4
AI summary
A full cone spray nozzle comprising: a nozzle body (1) having a liquid inlet (3) at its upstream end and a spray orifice (4) at its downstream end; a vane structure (2) of an axial direction length (W) and diameter (D) arranged with its outer circumferential surface in contact with the inside of the nozzle body (1); has a plurality of channel grooves (6) of width (T) and depth (H) at the outer circumferential surface of the vane structure (2); an upstream side projecting part (8) of a length (U) in the axial direction of the nozzle body (1) at an upstream side of the vane structure (2); a downstream side projecting part (9) of a length (P) in the axial direction of the nozzle body (1) at a downstream side of the vane structure (2); and a swirl flow chamber (5) of an axial direction length (L) which is a space formed by an inside wall surface of the nozzle body (1), the vane structure (2) and the spray orifice (4), wherein 0.25≤T/D≤0.30, 0.25≤H/D≤0.30, and 1.5≤L/W≤3.5 are satisfied.