Rolling Mill Exit Cooling Control for Residual Coolant Discharge
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Solution Overview
Problem
Conventional hot rolling mill exit side temperature control systems experience rapid cooling of materials due to excess coolant discharge, leading to decreased temperature control accuracy and thickness control precision.
Innovation Solution
A temperature control system with a cooling apparatus and control unit that includes spray nozzles, valves, and flow rate detectors, allowing for the precise control of coolant flow to prevent excess coolant discharge before the material reaches the rolling mill, ensuring the instructed amount of coolant is applied only after the material has passed, thereby maintaining target temperatures and improving thickness control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the spray valve is opened at the same timing as the cooling instruction, then the cooling response is fast, but the material is rapidly cooled by remaining coolant causing temperature control inaccuracy
Solution Approach 1:
The system performs preliminary discharge of remaining coolant from the passage before the material arrives. The control unit opens the spray valve earlier than the cooling instruction timing to discharge remaining coolant, then closes it before the material reaches the spray position. This preliminary action removes the harmful remaining coolant that would otherwise cause rapid unintended cooling and temperature control inaccuracy.
Solution Approach 2:
The system applies preliminary anti-action by discharging remaining coolant in advance to prevent the harmful effect of rapid cooling. By opening the spray valve before the cooling instruction and discharging remaining coolant, the system counteracts the potential harmful effect of excess coolant on the material, ensuring that only the instructed amount of coolant is applied when the material passes.
2Ease of operation
If a simple open/close valve control is used, then the system is simple to operate, but the coolant flow rate cannot be precisely controlled
Solution Approach 1:
The system introduces feedback control by installing a flow rate detector in the coolant passage and using a control unit that adjusts the spray valve opening based on detected flow rate. The control unit opens the spray valve in advance, detects the flow rate of remaining coolant, and closes the valve when the flow rate becomes small. This feedback mechanism enables precise control of coolant flow rate while maintaining ease of operation through automatic control.
Solution Approach 2:
The system replaces simple mechanical open/close valve control with an automated control system that uses a flow rate detector and control unit. Instead of relying solely on mechanical valve positioning, the system uses electronic sensing and control to precisely manage coolant flow rate, substituting mechanical simplicity with automated precision 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
This solution effectively suppresses rapid cooling, enhancing the accuracy of temperature control and thickness control by ensuring the coolant is applied only as needed, thereby stabilizing the material's temperature and passability.
Implementation Method 1
a spray nozzle spraying coolant onto the material to be rolled
Data Source
AI summary
A rolling mill exit side temperature control system includes the following features. A second valve control unit controls a valve opening of a second valve to cause a flow rate actual value detected by a flow rate detector to coincide with a flow rate target value. A remaining coolant discharging section controls a first valve to an open state and the second valve to a closed state by setting the flow rate target value to zero, before a material to be rolled reaches a rolling mill. A flow rate target value setting section sets the flow rate target value to a value corresponding to a target temperature of the material to be rolled on the entry side and the exit side of the rolling mill after the control by the remaining coolant discharging section.