Hydraulic Stopper Control Device for Steelworks
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Solution Overview
Problem
Existing control devices for stoppers in steelworks, both electromechanical and hydraulic, face issues with slow response times, complex components, high maintenance needs, and energy inefficiency, particularly due to clearance and the requirement for continuous hydraulic fluid circulation.
Innovation Solution
A hydraulic control device with a double-acting hydraulic cylinder and reversible hydraulic pump, connected directly to the stopper, which eliminates the need for servo valves and external hydraulic units, using a closed, pressurized circuit with minimal fluid volume and length, and a brushless electric motor for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If electromechanical devices with worm gear or pinion and rack are used to adjust stopper displacement, then the device structure is established, but response time becomes slow and device complexity increases
Solution Approach 1:
The patent applies hydraulic principles by using a hydraulic cylinder with piston and chamber system to replace the electromechanical worm gear and pinion-rack mechanism. The hydraulic actuation provides faster response time while reducing the number of mechanical components, directly resolving the contradiction between speed and device complexity.
2Measurement precision
If electromechanical devices with multiple mechanical components are used, then stopper displacement is achieved, but clearance increases leading to inaccurate position control and frequent maintenance
Solution Approach 1:
The hydraulic cylinder with piston provides direct linear actuation without intermediate mechanical transmission components like worm gears or pinions. This eliminates clearance issues in mechanical joints, ensuring accurate stopper position control and reducing maintenance requirements.
3Speed
If hydraulic devices with servo valves and continuous fluid circulation are used, then better response time is achieved, but energy consumption increases and device complexity increases
Solution Approach 1:
The hydraulic system uses periodic or demand-based actuation rather than continuous fluid circulation. The reversible pump operates only when stopper position adjustment is needed, consuming energy only during active control periods rather than continuously circulating hydraulic fluid, thus reducing overall energy consumption while maintaining fast response capability.
Solution Approach 2:
The reversible pump can recover and reuse hydraulic fluid by pumping it back to the reservoir or repositioning it for subsequent use. This reduces the need for continuous fluid supply and disposal, lowering energy consumption associated with continuous circulation systems.
4Ease of operation
If hydraulic devices with servo valves and external hydraulic units are used, then stopper control is achieved, but device dimensions increase and costs increase
Solution Approach 1:
The patent integrates the hydraulic pump, control valve, and cylinder into a single compact assembly mounted directly on the stopper holder. This merging of components eliminates the need for separate external hydraulic units and long fluid lines, significantly reducing device dimensions while maintaining full stopper control capability.
Solution Approach 2:
The integrated hydraulic assembly performs multiple functions within a single compact unit: the pump provides fluid power, the valve controls flow direction and pressure, and the cylinder actuates the stopper. This multi-functionality reduces the overall device volume compared to separate specialized components.
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 solution provides a compact, energy-efficient, and low-maintenance control system with high reactivity and accuracy, reducing energy consumption and maintenance needs while ensuring precise control of the stopper's position and steel flow.
Implementation Method 1
a hydraulic circuit including a double-acting hydraulic cylinder and a reversible hydraulic pump, said hydraulic cylinder having a first and a second chamber between which a piston slides, said hydraulic pump being connected to said first and second chamber
Data Source
AI summary
A control device (1) for a stopper (3) comprises: —an outer casing (10), —a control rod (6) sliding through the casing (10), rigidly attachable to the stopper (3), —a hydraulic circuit (20) including a double-acting hydraulic cylinder (21) and a reversible hydraulic pump (9), the hydraulic cylinder (21) having a first and a second chamber (21a, b) between which a piston (22) slides, the hydraulic pump (9) being connected directly to the first and second chamber (21a, b) by means of a first branch and a second branch (20a, b) of said hydraulic circuit (20, respectively, the piston being rigidly attached to the control rod (6), the hydraulic circuit (20) being entirely housed in the outer casing (10), —a control circuit (30) connected to the hydraulic circuit (20) to control the position of the piston (22).