Galvanized-Wire Cooling Device Vacuum Purge System
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Solution Overview
Problem
Existing wire cooling systems in continuous hot-dip galvanizing processes face challenges in safely stopping water spraying to prevent molten metal splashes during size changes or maintenance, posing risks to operators and requiring complex shutdown procedures.
Innovation Solution
A cooling system with a power supply, spray heads, and a vacuum-based purge means that allows instantaneous stopping of water spraying by evacuating fluid from the spray heads, preventing water from falling into the molten metal bath and ensuring operator safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional water spray cooling systems are used in continuous hot-dip galvanizing, then cooling effectiveness is achieved, but rapid shutdown capability is insufficient leading to safety risks when water drops fall into molten metal
Solution Approach 1:
The system divides the water supply control into two independent parts: service valves for normal operation and purge means for emergency shutdown. Each spray head has its own service valve and purge means, allowing independent control and rapid evacuation of water from individual heads without affecting the entire system.
Solution Approach 2:
The purge means is pre-configured with evacuation paths (purge pipes leading to collection trays) and vacuum generation capability. When triggered, it immediately evacuates water from the internal passages of spray heads before water can fall into the molten metal, preventing the harmful effect in advance.
2Ease of operation
If service valves are closed to stop water supply during maintenance or size changes, then water spray is stopped, but residual water in internal passages continues to spray creating safety hazards
Solution Approach 1:
The purge means extracts and removes residual water from the internal passages of spray heads through evacuation paths. This extracted water is directed to collection trays away from the molten metal bath, eliminating the harmful projection of water droplets that would otherwise occur when service valves are closed.
Solution Approach 2:
The purge means acts as an intermediary between the service valve and the environment. When the service valve closes, the purge means activates to evacuate residual water through intermediate evacuation paths before it can become a harmful projectile, mediating the transition from pressurized spray to safe containment.
3Productivity
If water supply is stopped by closing service valves, then spraying ceases, but pressure loss in internal passages is not immediate allowing water to continue projecting
Solution Approach 1:
The system uses periodic or on-demand activation of the purge means rather than continuous operation. The purge means is activated immediately when emergency shutdown is required, creating a sudden pressure change that rapidly evacuates water from internal passages, achieving immediate stoppage when needed most.
Solution Approach 2:
The system replaces the purely mechanical valve-closing mechanism with a vacuum-based purge system. Instead of relying only on mechanical pressure reduction from valve closure, the purge means uses vacuum generation to actively and rapidly evacuate water, substituting passive mechanical pressure loss with active vacuum-driven removal for faster response.
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 provides immediate and safe shutdown of water spraying, preventing splashes and enhancing safety and operational efficiency by allowing for rapid adjustments during maintenance or size changes without risking molten metal exposure.
Implementation Method 1
a vacuum-based purge means that allows instantaneous stopping of water spraying by evacuating fluid from the spray heads
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
A cooling system for a wire-coating installation comprises: a supply unit (12) with a chamber (14) for a cooling fluid and a plurality of fluid outlets (16); and a plurality of spray heads (18) each equipped with one or more orifices (20) for spraying the cooling fluid towards a wire (11) that is to be cooled, each spray head being connected to a respective fluid outlet (16) so as to supply fluid to an internal passage (54) of the spray head (18) extending as far as the spray orifice(s). A service valve (22) is associated with each spray head (18) so as to selectively control the supply of fluid to the internal passage (54) of the spray head. A purge means (30) is associated with each spray head (18), the triggering of which purge means allows fluid to be discharged from the internal passage (54), in order to stop the spraying of fluid through the spray orifice(s) (20).