Rolling System Temperature Control via Induction Heating
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Solution Overview
Problem
In a rolling line, maintaining the material's temperature within a desired range at the exit side of the finishing mill is challenging due to temperature fluctuations caused by heat conduction, air convection, and heat escape, which are not effectively controlled by existing methods.
Innovation Solution
A rolling system that includes an induction heater, temperature detectors, and a power setting calculation device to accurately control the material's temperature at the entry side of the finishing mill by calculating the necessary electric power based on temperature distribution patterns and heat transfer considerations, ensuring the material reaches an optimal temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the material temperature is controlled at the entry side of the finishing mill, then the temperature stability at the exit side is improved, but the temperature fluctuation during conveyance remains due to heat conduction and air convection
Solution Approach 1:
The system performs preliminary heating adjustment at the entry side of the finishing mill based on detected temperature distribution. By calculating the required heating amount in advance and applying it before the material enters the finishing mill, the system compensates for anticipated temperature drops during conveyance, thereby maintaining temperature stability at the exit side.
Solution Approach 2:
The system uses temperature detectors to continuously monitor the material temperature at the entry side, feeds this information back to the power setting calculation device, and adjusts the induction heater output accordingly. This closed-loop feedback mechanism enables real-time compensation for temperature fluctuations caused by heat conduction and air convection.
2Temperature
If the induction heater power is increased to compensate for heat loss, then the temperature at the entry side is maintained, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts the induction heater power parameters based on the detected temperature distribution pattern and calculated heating requirements. Instead of using fixed high power, the system optimizes the heating parameters to apply only the necessary amount of energy required to achieve the target temperature, thereby reducing unnecessary energy consumption while maintaining temperature control precision.
3Stability of the object's composition
If the distance between the induction heater and finishing mill is reduced to minimize heat loss, then the temperature stability is improved, but the system layout flexibility is reduced
Solution Approach 1:
The system introduces an intermediary control mechanism (power setting calculation device with temperature distribution analysis) between the induction heater and the finishing mill. This intermediary calculates the optimal heating strategy based on detected temperature patterns, enabling effective temperature control even over longer distances, thereby maintaining temperature stability while preserving layout flexibility.
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 stabilizes the material's temperature at the entry side of the finishing mill, enhancing the precision and quality of the rolling process by accurately adjusting the induction heater's power to maintain the desired temperature.
Implementation Method 1
an induction heater (6) which heats a material (1) that is conveyed by a conveying table (2)
Implementation Method 2
an induction heater (6) which heats a material (1)
Implementation Method 3
the temperature of the material results in changing due to heat conduction in the inside of the material
Implementation Method 4
escape of heat to a table roll of a conveying table, air convection
Data Source
AI summary
A rolling system includes an induction heater, temperature detectors, a finishing mill, and a power setting calculation device. The power setting calculation device generates a temperature distribution pattern in a plate thickness direction of a steel material at a temperature control position in an upstream side. The power setting calculation device calculates a volume average temperature of the steel material at a temperature control position in a downstream side, at a time when the steel material moves to the temperature control position in the downstream side from the temperature control position in the upstream side, based on the generated temperature distribution pattern. Then, the power setting calculation device calculates an electric power necessary for the induction heater so that the calculated volume average temperature follows a target temperature of the steel material at the temperature control position in the downstream side.