Roll Cooling Gap Control via Coolant Pressure Feedback
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Solution Overview
Problem
Existing cooling systems for rolls in rolling mills face challenges in accurately adjusting the gap between the cooling shell and the roll surface, leading to measurement inaccuracies and potential damage due to unreliable position sensors and indirect distance measurement methods.
Innovation Solution
The method involves regulating the gap height between the cooling shell and the roll surface based on measurements of coolant pressure or volume flow, allowing for precise determination of the gap distance and automatic detection of roll position changes, thereby preventing collisions and overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If distance sensors are used to measure the gap height between cooling shell and roll surface, then the gap distance can be measured, but the measurement is difficult or imprecise due to flow conditions and sensor reliability issues under rolling mill conditions
Solution Approach 1:
The patent introduces coolant pressure or volume flow as an intermediary parameter to indirectly determine the gap height. Instead of directly measuring the gap with unreliable distance sensors, the system uses the coolant flow characteristics (which are easily measurable and reliable) as a mediator to infer the gap distance, thereby achieving both precision and reliability
Solution Approach 2:
The patent replaces mechanical/optical distance measurement systems with a fluid-based measurement approach. By substituting the mechanical sensor system with coolant flow measurement, the system achieves more reliable and precise gap determination under the harsh rolling mill environment where traditional sensors fail
2Measurement precision
If indirect distance measurement methods are used by measuring piston travel path, then the gap distance can be determined, but measurement inaccuracies and positioning errors occur
Solution Approach 1:
The patent uses coolant pressure or volume flow as a direct intermediary that correlates with gap height, replacing the indirect piston travel path measurement. This provides a more accurate and reliable indication of the actual gap distance, eliminating the cumulative errors associated with mechanical linkage measurements
3Ease of operation
If the gap between cooling shell and roll surface is not accurately regulated, then the system is simpler to operate, but roll collision or overheating damage occurs
Solution Approach 1:
The patent implements a feedback control system where coolant pressure or volume flow measurements continuously monitor the gap height, and the cooling shell position is automatically adjusted to maintain the optimal gap. This closed-loop control prevents roll collision and overheating while keeping the operation simple, as the system self-regulates based on real-time feedback
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 approach provides a reliable and robust system for cooling rolls by ensuring precise gap adjustment, reducing the risk of damage and production losses, and maintaining roll quality through accurate control of the cooling process.
Implementation Method 1
water or a coolant is guided past between a cooling shell and a roller
Implementation Method 2
thermal energy is introduced into the rolls, depending on the temperature of the rolling stock and the forming work performed
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a method for cooling a roll (1), in particular a working roll (1) of a hot-rolling system, comprising the steps of feeding coolant (3) by means of a nozzle (5) into a gap (7) between at least a part of the roll surface and a cooling shell (9, 11) that can be placed against the part of the roll surface and adjusting the gap height (h) between the cooling shell (9, 11) and the roll surface. According to the invention, the adjustment of the gap height (h) comprises either measuring the pressure (Pactual) of the fed coolant (3) or measuring the volumetric flow rate (Vactual) of the fed coolant (3). The invention further relates to a corresponding device (10) for cooling a roll (1).