Rolling Mill Cooling Section With Pump-Based Coolant Flow Control
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Solution Overview
Problem
Existing cooling systems in rolling mills face challenges with valves that cause pressure surges, slow response times, flow losses, and high energy consumption, leading to inaccurate temperature control and increased wear, particularly in intensive cooling applications.
Innovation Solution
A control method that dynamically adjusts the pump's operation based on target coolant flow rates, eliminating the need for valves in the supply line, and incorporating features like return lines and check valves to maintain precise coolant application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If control valves are used to adjust coolant flow, then continuous adjustment is possible, but pressure surges and slow response times occur
Solution Approach 1:
The invention extracts and eliminates the valve component from the coolant supply line, replacing it with a pump-based flow control system. The pump directly controls coolant flow rate without requiring intermediate valve components, thereby eliminating pressure surges and improving response time while maintaining continuous adjustment capability.
Solution Approach 2:
The invention replaces the mechanical valve-based flow control system with an electronically controlled pump system. The pump's rotational speed can be precisely controlled via electronic means, enabling rapid and accurate flow adjustment without the mechanical delays and pressure fluctuations inherent in valve operation.
2Ease of operation
If valves are installed in supply lines, then coolant flow can be controlled, but flow losses and increased wear occur
Solution Approach 1:
The invention removes valves from the supply line configuration, replacing valve-based flow control with direct pump control. This eliminates the flow losses and energy dissipation that occur when coolant passes through valve restrictions, while maintaining the ability to control flow rate through pump speed regulation.
3Extent of automation
If switching valves are used for coolant application, then binary control is achieved, but precise temperature control is limited
Solution Approach 1:
The invention transitions from static binary valve control to dynamic pump speed control. The pump's rotational speed can be continuously varied in real-time, enabling precise modulation of coolant flow rate to achieve accurate temperature control, unlike fixed-position switching valves that can only provide on/off 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
Achieves rapid and precise temperature control with reduced energy consumption and minimized wear, enhancing the efficiency and reliability of cooling processes in rolling mills.
Implementation Method 1
a respective pump (10) delivers a respective actual flow (F) of the liquid, water-based coolant (7) to a respective application device (6)
Implementation Method 2
the respective actual flow (F) of the coolant (7) is applied to the hot rolled material (1) by means of the respective application device (6)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a cooling section (2) arranged within a rolling train or upstream or downstream of the rolling train. A hot-rolled product (1) made of metal is cooled by means of the cooling section (2). Application devices (6) of the cooling section (2) are supplied with a respective actual current (F) of a water-based liquid coolant (7) via a respective supply line (8) and a respective pump (10). The respective actual current (F) of the coolant (7) is applied to the hot-rolled product (1) by means of the respective application device (6). The hot-rolled product (1) is transported within the cooling section (2) in a horizontal transport direction (x) during the application of the coolant (7). A controller (11) of the cooling section (2) dynamically ascertains a respective target actuation state (S*) for each pump (10) on the basis of a respective target current (F*) of the coolant (7) to be applied onto the hot-rolled product (1) by means of the respective application device (6) and controls the respective pump (10) in a corresponding manner such that the respective actual current (F) delivered by each pump (10) approximates the respective target current (F*) as much as possible at any time.