Welding Device Jaw Shoes for Continuous Casting Bars
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Solution Overview
Problem
Existing welding devices for continuous casting of metallic materials suffer from significant heat loss and the formation of 'black spots' due to large contact areas between the jaws and the hot bars, leading to uneven microstructure, mechanical property inconsistencies, and increased wear on rolling mill equipment.
Innovation Solution
A welding device with clamping means that minimize the contact area between the jaws and the bars, using smaller shoes with a longitudinal extension of less than 0.67 times the length of the bar's side, and employing cooling only during the welding stage to reduce thermal stress and heat loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If large contact area jaws are used to withstand forces and compensate for surface irregularities, then the ability to compensate for surface irregularities improves, but heat loss from the cast product increases
Solution Approach 1:
The jaw shoes are designed with a localized contact approach, concentrating the clamping force on specific high-point areas of the bar surface rather than distributing it across a large area. This allows the jaws to compensate for surface irregularities through targeted contact points while minimizing the overall contact area and associated heat loss.
2Strength
If large contact area jaws are used to withstand forces and compensate for surface irregularities, then the ability to withstand forces improves, but heat loss from the cast product increases
Solution Approach 1:
The invention changes the parameters of the jaw shoe contact area by reducing its longitudinal extension to less than 0.67 times the bar side length. This parameter modification allows the jaws to maintain sufficient clamping force through increased pressure concentration while reducing the contact area that causes heat loss.
3Duration of action of moving object
If jaw shoes remain in contact with bar surface for long time to complete welding, then welding completion is ensured, but local cooling effects and black spots are produced
Solution Approach 1:
The jaw shoes are designed to contact only the essential high-point areas of the bar surface rather than the entire surface. This partial contact approach is sufficient to complete the welding operation while minimizing the area subjected to harmful cooling effects and black spot formation.
4Temperature
If cooling means are applied to jaws during welding, then temperature control of jaws is improved, but thermal stress and heat loss from bar increase
Solution Approach 1:
The cooling of the jaw shoes is applied periodically or selectively during specific phases of the welding process rather than continuously. This allows temperature control of the jaws when necessary while minimizing the overall heat loss from the bar to the cooling system.
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 configuration reduces the extent of black spots, enhances temperature uniformity, extends the life of the shoes, and improves the mechanical and metallurgical properties of the welded product, while minimizing cooling water consumption and maintenance needs.
Implementation Method 1
the contact between the jaw shoes, having a lower temperature than the temperature of the bars, and the surface of the bars, which are at substantially higher temperatures, produces local cooling effects
Implementation Method 2
electrical power supply means for supplying an electrical current to the first and second elongated elements to be end-to-end welded
Data Source
Figure 1~4
Figure 2~3
AI summary
A welding device for the end-to-end welding of bars, billets or blooms produced by continuous casting, comprising a roller table and a self-moving trolley, in which the welding means are housed, that accompanies the product to be welded along a stretch of the roller table, seizing jaws for seizing the bars and electrical power supply units that are brought into contact with the surface of the two bars to carry out a welding operation.