Metal Sheet Quenching Tank Water-Level Control for Shape Stability
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Solution Overview
Problem
Existing quenching methods for metal sheets in continuous annealing facilities face challenges in stabilizing the cooling performance and restraining rolls' effectiveness due to variations in temperature ranges and cooling fluid management, leading to shape defects like warps and deformations.
Innovation Solution
A quenching apparatus with a cooling tank, restraining rolls, and a water-level adjustor that controls the cooling fluid's surface height to set a precise cooling start position, ensuring the metal sheet is restrained within a target temperature range, using nozzles to stabilize cooling and prevent shape variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the position of restraining rolls is fixed based on a standard temperature range (TMs+150) to (TMf−150), then the device structure is simple, but the manufacturing precision deteriorates because the temperature range varies depending on manufacturing conditions
Solution Approach 1:
The restraining roll position is made adjustable rather than fixed. The position control device allows dynamic repositioning of the restraining roll along the metal sheet conveyance direction to match the actual temperature range where martensitic transformation occurs, resolving the contradiction between simple structure and precise control
Solution Approach 2:
The system changes the positional parameter of the restraining roll based on detected temperature range variations. By adjusting the roll position according to actual manufacturing conditions, the system maintains precise shape control without requiring complex predetermined positioning
2Measurement precision
If water is jetted through nozzles at a lower portion of a movable masking member, then masking control is improved, but cooling performance becomes unstable because water hits the masking member and interferes with jetted water
Solution Approach 1:
The nozzle arrangement is changed from a lower portion configuration to an upper portion configuration relative to the masking member. This spatial repositioning in the vertical dimension prevents water interference while maintaining masking control functionality
Solution Approach 2:
The masking member is positioned to serve as an intermediary structure that separates the water jetting zone from the cooling zone. By placing nozzles above the masking member, the system uses the masking member itself as a structural element that prevents water interference rather than being interfered with
3Manufacturing precision
If masking is performed for each nozzle individually, then precise local control is achieved, but device complexity increases and cooling capacity varies in steps
Solution Approach 1:
Multiple nozzles are grouped into nozzle groups rather than treating each nozzle separately. The masking member controls water flow for entire groups simultaneously, reducing the number of independent control elements while maintaining effective cooling coverage through combined nozzle action
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 solution effectively suppresses shape variations in metal sheets by accurately controlling the cooling process, maintaining the metal sheet within a stable temperature range during quenching, thereby reducing deformations and ensuring consistent product quality.
Implementation Method 1
a cooling tank in which a cooling fluid is to be stored and the metal sheet is cooled by being immersed in the cooling fluid
Implementation Method 2
a water-level adjustor that adjusts a height of a fluid surface of the cooling fluid inside the cooling tank
Implementation Method 3
sudden thermal contraction and transformation expansion occur at the same time
Data Source
AI summary
A metal-sheet quenching apparatus cools a metal sheet while conveying the metal sheet and includes a cooling tank in which a cooling fluid is to be stored and the metal sheet is immersed in the cooling fluid to be cooled; restraining rolls that are installed inside the cooling tank and convey the metal sheet that has been cooled in the cooling tank while restraining the metal sheet in the thickness direction; a water-level adjustor that adjusts the height of a fluid surface of the cooling fluid inside the cooling tank; and a position control device that adjusts the height of the fluid surface of the cooling fluid inside the cooling tank by controlling the operation of the water-level adjustor.