Roll Cooling Containment Using Contactless Gas Seals
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Solution Overview
Problem
Existing roll cooling systems face issues with cross-contamination of processes and debris collection, which can damage work rolls and metal articles, and are inefficient in removing coolant, especially when processing is stopped or reversed.
Innovation Solution
A system comprising a housing with movable seals and gas delivery devices that create a contactless seal to contain viscous materials on rolling surfaces, preventing them from exiting and allowing for effective removal without damaging the rolls or articles, using a combination of flexible or rigid seals and forced gas delivery systems like air knives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate wiper is used to contain coolant on the work roll, then coolant containment is improved, but cross-contamination of processes occurs and debris collection damages the work roll
Solution Approach 1:
The patent replaces the mechanical wiper system with a gas flow-based containment system. Gas flows are used to contain and direct the coolant along the work roll surface without physical contact, eliminating the mechanical wear and debris collection problems associated with wipers while maintaining effective coolant containment.
Solution Approach 2:
The patent introduces gas flow as an intermediary medium between the coolant and the environment. The gas flow acts as a barrier that contains the coolant on the work roll surface without requiring direct mechanical contact, thereby preventing both cross-contamination and debris damage to the roll.
2Productivity
If a vacuum system is employed to remove coolant from the work roll, then coolant removal is attempted, but effectiveness is reduced when processing is stopped or reversed
Solution Approach 1:
The patent employs dynamic gas flow control that can adapt to different operating conditions. The gas flow system can be adjusted and remains effective whether the roll is rotating forward, reversed, or stationary, providing consistent coolant containment and removal capability across all operational states unlike fixed vacuum systems.
3Reliability
If a wiper is in constant contact with the roll surface, then coolant containment is improved, but debris collection occurs which damages the work roll and metal article surface
Solution Approach 1:
The patent substitutes the mechanical wiper contact system with a non-contact gas flow containment system. This eliminates the mechanical interaction that causes debris collection and surface damage, while still achieving effective coolant containment through aerodynamic control of the coolant flow.
Solution Approach 2:
The gas flow serves as an intermediary that contains the coolant without requiring direct contact with the work roll or metal article surfaces. This intermediate gas barrier prevents debris generation and surface damage while maintaining coolant containment effectiveness.
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 contains and removes viscous materials like coolants without cross-contamination, preventing debris from damaging the rolls and articles, and allows for efficient coolant management, even during process interruptions, enhancing the reliability and cleanliness of roll cooling processes.
Implementation Method 1
each of the plurality of gas delivery devices is configured to supply gas toward the contacting edge of at least one seal of the plurality of seals to move the at least one seal between the first and second positions
Implementation Method 2
when each of the plurality of seals is in the second position, the gas supplied by the plurality of gas delivery devices prevents the viscous material from exiting the housing by acting as a contactless seal
Implementation Method 3
a coolant delivery device to deliver a coolant to a surface of the work roll and the backup roll
Implementation Method 4
a coolant delivery device to deliver a coolant to a surface of the work roll and the backup roll
Implementation Method 5
cooling a roll in metal processing
Data Source
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AI summary
Provided herein are systems and methods for containing a viscous material, such as coolant, applied to cool a roll or a roll processed engineering material such as a metal strip. In particular, a viscous material containment system can include a housing, a viscous material delivery system, a plurality of movable seals and a plurality of gas delivery devices. A method for cooling a roll can include applying a vicious material, such as coolant, to the roll and containing the viscous material on the roll using the viscous material containment system. In some cases, the viscous material containment system can be used to facilitate removal of the viscous material from the roll.