Rolling Stand Lubrication via Pneumatic Atomization
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Solution Overview
Problem
Existing roll lubrication methods in both hot and cold rolling processes are complex and inefficient, requiring extensive preparation and large amounts of lubricant, with limited adjustability and increased fire risks in hot rolling.
Innovation Solution
A method that mixes lubricants with air and water shortly before application using multi-substance nozzles, allowing for adjustable oil concentration and reduced lubricant usage, with separate supply lines for water and lubricants, and control valves for precise distribution, minimizing lubricant waste and optimizing lubrication effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lubricant is applied in large amounts to ensure adequate lubrication, then lubrication effect is improved, but lubricant consumption increases and fire risk increases
Solution Approach 1:
The patent uses gas (air) to transport and distribute the lubricant through pneumatic nozzles, creating a lubricant-laden air stream that is conveyed to the rolling mill. This pneumatic delivery system enables precise control of lubricant application, allowing adequate lubrication with minimal lubricant consumption compared to traditional direct application methods
Solution Approach 2:
The patent changes the physical state and delivery parameters of the lubricant by mixing it with gas to create a sprayable mixture. The lubricant is transformed from a bulk liquid into a fine spray distributed through air streams, enabling uniform application at optimized concentrations that reduce overall consumption while maintaining effective lubrication
2Reliability
If oil and water are mixed in advance in a circulation system, then lubrication coverage is improved, but system complexity increases
Solution Approach 1:
The patent performs preliminary mixing of lubricant and water in a simple mixing chamber before the gas transport stage, creating a pre-mixed lubricant solution that is then carried by air streams. This preliminary action ensures adequate mixing and coverage without requiring complex circulation systems, separators, or multiple processing stages
Solution Approach 2:
The patent extracts the complex circulation and separation system from the lubrication process, replacing it with a simplified gas-phase transport system. The lubricant-water mixture is created briefly and then immediately carried by air streams directly to the application point, eliminating the need for complex recirculation loops and separation equipment
3Reliability
If pure oil is used for lubrication in hot rolling, then lubrication effect is improved, but fire risk increases
Solution Approach 1:
The patent creates a composite lubricant system by combining water and lubricant in a mixed solution that is then transported and applied as a spray. This water-lubricant composite provides effective lubrication while the water content significantly reduces fire risk compared to pure oil, especially in hot rolling applications where fire hazard is a concern
Solution Approach 2:
The patent uses gas (air) as an intermediary medium to transport and apply the lubricant-water mixture. The gas phase acts as a carrier that delivers the lubricant components to the rolling mill surface, enabling effective lubrication delivery while the dispersed spray pattern and water content reduce fire hazards associated with pure oil application
4Adaptability or versatility
If lubricant concentration is adjusted frequently for different materials and conditions, then lubrication optimization is improved, but process complexity increases
Solution Approach 1:
The patent implements a dynamic lubrication system where the composition and concentration of the lubricant-gas mixture can be easily adjusted by changing the lubricant feed rate or water-to-lubricant ratio in the mixing chamber. This dynamic adjustment capability allows optimization for different materials and rolling conditions without complex reconfiguration, as the system can be quickly tuned by adjusting flow rates rather than changing physical components
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 simplifies the lubrication process, reduces lubricant consumption, enhances adjustability, and provides effective lubrication with minimal oil usage, while ensuring fire safety in hot rolling by using air and water mixtures, and allows for optimal adjustment based on material and rolling conditions.
Implementation Method 1
applied in atomizer nozzles
Implementation Method 2
water, at least one lubricant and the gas are mixed
Implementation Method 3
sprayed in 2, 3 or 4 substance nozzles
Implementation Method 4
lubricant is applied to the rolled strip and/or the work roll
Data Source
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AI summary
The invention relates to a method for lubricating rollers, in particular the working rollers (2, 3) on a rolling stand and a rolled strip (6) which has been rolled between the above working rollers and transported onwards, in which a lubricant/gas mix, a lubricant/water/gas mix, a lubricant/water mix and/or a grease/media mix is applied onto the rollers (2, 3) or the rolled strip (6) on the input side of the stand, characterized in that the mixture is prepared by means of at least one mixing device (14, 17, 27, 29, 31, 35) in the region upstream of the rolling stand.