Plate Straightening Control with Patterned Cooling for Flatness
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Solution Overview
Problem
Existing straightening systems for materials face challenges in achieving accurate flatness due to temperature deviations and varying material shapes, particularly in thick plate processing lines, where the shape pattern is not considered during the straightening process, leading to limitations in ensuring excellent flatness and preventing material deformation.
Innovation Solution
A straightening system that includes a cooling device with a nozzle assembly capable of spraying cooling fluid in a predetermined pattern across different regions of the material, a controller that adjusts the flow rate based on the material's shape pattern and temperature data, and a flatness measuring system to enhance flatness by controlling the straightening device and cooling device accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a predetermined amount of cooling fluid is sprayed in the width direction of the material, then the edge portion has enhanced cooling effect, but the central portion has degraded cooling effect due to small contact area
Solution Approach 1:
The cooling device divides the material width into multiple regions (edge portions and central portion) and applies different cooling fluid flow rates to each region. The edge portions receive higher flow rates for enhanced cooling, while the central portion receives optimized flow rates to prevent insufficient cooling, thereby achieving uniform temperature distribution across the material width.
2Ease of operation
If straightening process is performed once in the same straightening condition in longitudinal direction, then the process is simple, but there is a limit in ensuring excellent flatness due to varying material shape
Solution Approach 1:
The straightening device dynamically adjusts straightening conditions (such as roll gap, rolling force, or speed) based on the detected shape pattern of the material. The controller divides the material length into multiple regions and applies different straightening parameters to each region, enabling the system to adapt to varying material shapes while maintaining operational simplicity through automated control.
Solution Approach 2:
The system uses a shape detection device to measure the actual shape pattern of the material before straightening. This detected information is fed back to the controller, which then determines the appropriate straightening conditions based on the detected shape, enabling closed-loop control that ensures excellent flatness while maintaining process simplicity.
3Productivity
If straightening operation condition is determined before material rolling is terminated, then the process is efficient, but accurate straightening cannot be performed because temperature change and material shape after rolling and cooling are not considered
Solution Approach 1:
The system performs preliminary detection of the material's shape pattern after rolling and cooling, before the straightening operation begins. This preliminary detection allows the controller to pre-determine the appropriate straightening conditions based on the actual material state, ensuring both processing efficiency and straightening accuracy by avoiding trial-and-error adjustments during the straightening process.
Solution Approach 2:
The shape detection device measures the actual temperature and shape of the material after rolling and cooling, providing feedback to the controller. The controller uses this real-time information to determine the optimal straightening conditions, ensuring accurate straightening while maintaining processing efficiency through automated, data-driven decision-making.
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 effectively reduces temperature deviations across the material's width direction and enhances flatness by adjusting the straightening roll interval, straightening speed, and cooling fluid flow rate based on the material's shape pattern, ensuring accurate straightening and preventing material deformation.
Implementation Method 1
a cooling device configured to spray a cooling fluid in a predetermined pattern with respect to a plurality of regions of a material, divided in a width direction, to cool the material
Data Source
AI summary
A straightening system is provided to perform straightening in conformity with a shape pattern of a the material. The straightening system includes a cooling device configured to spray a cooling fluid in a predetermined pattern with respect to a plurality of regions of the material, divided in a width direction, to cool the material that is heated in a heating furnace and then passes through a rolling mill. The straightening system also includes a straightening device configured to straighten the material passed through the cooling device. The straightening system further includes a flatness measuring system configured to measure flatness of the material passed through the cooling device and a controller configured to receive data of the flatness of the material from the flatness measuring system and to control the cooling device in response to the data to enhance the flatness of the material.