Decentralized Nozzle Mixer for Roll Nip Lubrication
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Solution Overview
Problem
Centralized roll gap lubrication systems in roll stands suffer from saponification and demixing issues in long pipelines, leading to clogging and increased maintenance needs, which impair the surface quality of rolled strips and require frequent cleaning.
Innovation Solution
Decentralizing the mixing and spraying units by integrating each spray nozzle with a mixer, eliminating long pipelines and reducing residence time of the emulsion, and using non-return valves and quick-change devices to minimize contamination and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a centralized mixing device with long pipelines is used to distribute emulsion to multiple spray nozzles, then the system can cover a large rolling mill area, but saponification forms in the pipelines and causes clogging requiring frequent maintenance
Solution Approach 1:
The centralized mixing system is segmented into multiple decentralized nozzle-mixer units, each independently producing emulsion at the spray location. This eliminates long distribution pipelines where saponification occurs, while still covering the entire rolling mill area through distributed placement of multiple units.
Solution Approach 2:
The system transitions from a single central mixing point to multiple distributed mixing points across the rolling mill space. This spatial redistribution maintains comprehensive coverage while eliminating the harmful effect of long pipeline residence times that cause saponification.
2Reliability
If the emulsion residence time in pipelines is reduced by shortening connecting paths, then saponification is minimized, but the system becomes more complex with multiple mixer units
Solution Approach 1:
The mixer and spray nozzle are merged into a single integrated nozzle-mixer unit. This combines the emulsion production and delivery functions in one compact component, eliminating the need for separate connecting pipelines and thus reducing system complexity while minimizing residence time.
Solution Approach 2:
Each nozzle-mixer unit is self-contained and independently operational, producing its own emulsion supply without relying on centralized distribution infrastructure. This self-sufficiency reduces the overall system complexity by eliminating interconnecting pipelines between central mixer and nozzles.
3Reliability
If cleaning is performed frequently to remove saponification deposits, then the lubrication effectiveness is maintained, but maintenance effort and downtime increase
Solution Approach 1:
The problematic element (long pipelines where saponification forms) is extracted and removed from the system. By eliminating the pipelines between mixer and nozzles, the source of saponification deposits is removed, dramatically reducing cleaning frequency and maintenance downtime.
Solution Approach 2:
The old centralized mixing system with long pipelines is discarded in favor of decentralized nozzle-mixer units. This paradigm shift eliminates the recurring maintenance problem of pipeline cleaning while preserving the lubrication function.
4Object-affected harmful factors
If hot water cleaning is used instead of hazardous chemicals, then safety is improved, but cleaning effectiveness may be reduced
Solution Approach 1:
The extremely short residence time of emulsion in the nozzle-mixer unit (benefit) naturally prevents severe saponification (harm converted to benefit). This reduces cleaning requirements to minimal hot water flushing, making hot water cleaning sufficiently effective without hazardous chemicals.
Solution Approach 2:
The residence time parameter is changed from minutes/hours in pipelines to seconds in the integrated unit. This parameter change fundamentally alters the degree of saponification, transforming it from a severe cleaning problem requiring harsh chemicals to a minor issue manageable with hot water.
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
Significantly reduces maintenance effort and frequency, prevents clogging, and maintains surface quality by minimizing saponification and allowing for efficient cleaning with hot water, eliminating the need for hazardous chemicals.
Implementation Method 1
a mixture of water and oil is produced by means of a mixing and spraying device
Implementation Method 2
the mixture of water and oil is sprayed onto the work rolls of the roll stand and/or onto the surface of the metal strip
Data Source
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AI summary
The invention relates to a device for lubricating the cylinders of a roll stand, in particular for roll nip lubrication in a roll stand for strip-shaped rolling stock. A mixture made out of water and oil is produced by means of a mixing and spraying device (1). Said mixture is sprayed onto at least one of the cylinders (2) of the roll stand and/or to the surface of the rolling stock (3). The mixer and the spraying device (1) consists of an arrangement consisting of several nozzle mixer units (4), water being guided thereto by means of a first supply line (5) and oil being guided thereto by means of a second supply line (6).