Rolling Contact Heat Transfer Simulation Under Variable Load
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Solution Overview
Problem
Current technologies lack the capability to accurately quantify the dynamic contact heat transfer coefficient and friction conditions in the heavy-load deformation zone during the rolling process, leading to inaccuracies in product quality and process control due to oversimplification of contact heat transfer processes.
Innovation Solution
A dynamic contact heat transfer simulation device is developed, incorporating a thermal insulation cover, hydraulic cylinder, control relay, pressure sensor, thermocouple, data acquisition system, heating furnace, motor, rotating chuck, and temperature-adjustable heat-conducting rod, which simulates real rolling conditions by adjusting pressure, lubrication, and friction conditions in real-time, allowing for precise measurement of dynamic heat transfer coefficients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional solid interface contact heat transfer devices are used, then device simplicity is maintained, but measurement precision deteriorates due to inability to simulate real rolling conditions
Solution Approach 1:
The patent applies the dynamics principle by transforming the traditional static contact heat transfer device into a dynamic simulation device. The key implementation includes: (1) The heating furnace and motor drive system enable the hot end to rotate at variable speeds, simulating the dynamic rolling process; (2) The hydraulic cylinder provides dynamically adjustable pressure to simulate rolling load; (3) The lubricant injection system dynamically controls oil film thickness during operation. These dynamic capabilities allow the device to accurately simulate real rolling conditions, significantly improving measurement precision of heat transfer coefficients under actual working conditions.
Solution Approach 2:
The patent implements parameter changes by enabling independent adjustment of multiple critical parameters: (1) Temperature parameters through the heating furnace and temperature-adjustable heat-conducting rod; (2) Pressure parameters through the hydraulic cylinder and pressure sensor; (3) Speed parameters through the motor and speed-adjustable rotating hot end; (4) Lubrication parameters through the lubricant injection system and oil film thickness control. This multi-parameter adjustability allows the device to replicate various rolling conditions and obtain accurate heat transfer coefficients across different operating scenarios.
2Reliability
If traditional static contact devices are used, then device complexity is reduced, but reliability deteriorates due to boundary condition errors in actual rolling conditions
Solution Approach 1:
The patent implements feedback mechanisms through: (1) Temperature feedback using thermocouples to measure temperatures at the contact interface and hot end, with data transmitted via temperature-measuring slip ring mechanism to the control system; (2) Pressure feedback using pressure sensors to monitor the contact pressure between hot end and cold end; (3) Speed feedback through encoder or sensor on the motor drive system. The control system processes this feedback data and adjusts heating power, hydraulic pressure, and motor speed in real-time to maintain accurate simulation of rolling conditions, ensuring reliability of heat transfer coefficient measurements.
Solution Approach 2:
The patent uses several intermediary elements to enable accurate measurement while managing system complexity: (1) The heat-conducting rod acts as an intermediary to conduct heat from the contact interface to the thermocouple measurement point; (2) The slip ring mechanism serves as an intermediary to transmit temperature signals from the rotating hot end to the stationary data acquisition system; (3) The hydraulic fluid acts as an intermediary to transmit and control pressure at the contact interface; (4) The lubricant serves as an intermediary to control oil film thickness and simulate lubrication conditions. These intermediaries enable reliable measurement and control functions.
3Adaptability or versatility
If traditional contact heat transfer devices are used, then ease of operation is maintained, but adaptability deteriorates due to inability to adjust for different rolling conditions
Solution Approach 1:
The patent implements universality by designing a multi-functional integrated system where: (1) The heating furnace provides thermal processing function; (2) The motor drive system provides both rotation and speed control functions; (3) The hydraulic cylinder provides pressure application and force measurement functions; (4) The lubricant injection system provides lubrication and oil film control functions; (5) The data acquisition system integrates temperature, pressure, and speed measurement. This multi-functional design enables the single device to simulate various rolling conditions (different speeds, pressures, temperatures, lubrication states) without requiring multiple separate apparatus, thereby achieving high adaptability while maintaining reasonable operational simplicity through centralized control.
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 device accurately simulates the dynamic heat transfer process under various rolling conditions, providing precise dynamic heat transfer coefficients and friction data, enhancing the accuracy of mathematical models and control systems in the rolling process.
Implementation Method 1
a heating furnace, used for heating the temperature-adjustable heat-conducting rod
Implementation Method 2
a thermocouple, installed on the pressure-adjustable fixed cold end for temperature measurement
Implementation Method 3
a hydraulic cylinder connected with the moving chuck, used for pushing the moving chuck to drive the pressure-adjustable fixed cold end to contact with the speed-adjustable rotating hot end
Implementation Method 4
lubricant is introduced into contact interface between the speed-adjustable rotating hot end and the pressure-adjustable fixed cold end... to ensure that a stable lubricating oil film is formed at the contact interface
Implementation Method 5
a motor, connected with the rotating chuck, used for driving the adjustable-temperature heat-conducting rod to rotate
Implementation Method 6
The dynamic contact heat transfer simulation device... is applicable to the simulation measurement of the dynamic contact heat transfer process
Data Source
AI summary
The present invention provides a dynamic contact heat transfer simulation device for rolling heavy-load deformation zone. The device includes a control system, a data acquisition system, a pressure-adjustable fixed cold end, a rotating chuck, a temperature-adjustable heat-conducting rod and an speed-adjustable rotation hot end; the device utilizes the rotating chuck and the speed-adjustable rotating hot end to adjust the rotation speed in real time according to the actual rolling conditions, simulate the working conditions of the actual rolling heavy-load deformation zone, and accurately obtain the dynamic heat transfer coefficient of the rotating contact interface under variable load pressure conditions.