Width-Zone Cooling Control for Thick Plate Straightening Flatness
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Solution Overview
Problem
Existing straightening systems in thick plate processing lines face challenges in achieving accurate flatness due to temperature deviations and varying material shapes, particularly in the width direction, which limits the effectiveness of the straightening process.
Innovation Solution
A straightening system that includes a cooling device with a nozzle assembly configured to spray cooling fluid in a predetermined pattern across the material's width, controlled by a controller that adjusts the flow rate based on shape pattern data and temperature measurements to enhance flatness, and a straightening device that adjusts its operation parameters in response to shape patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a predetermined amount of cooling fluid is sprayed uniformly across the material width, then the cooling device structure is simple, but temperature deviation between central and edge portions increases
Solution Approach 1:
The patent applies local quality by varying the cooling fluid flow rate across different width positions of the material. Specifically, the central portion receives a first flow rate while edge portions receive a second flow rate that is different from the first, creating localized cooling zones that account for the different thermal characteristics and contact areas of various material regions. This resolves the temperature deviation problem without requiring complex overall system redesign.
Solution Approach 2:
The cooling device is segmented into multiple independent flow rate control units corresponding to different width positions of the material. Each segment can independently adjust its cooling fluid flow rate, allowing the central portion and edge portions to receive customized cooling amounts. This segmentation enables precise temperature control across the material width while maintaining manageable device complexity.
2Device complexity
If straightening operation is determined before rolling is terminated, then the control process is simple, but accurate straightening cannot be performed due to unconsidered temperature changes and shape variations
Solution Approach 1:
The patent implements feedback control by measuring the actual temperature distribution and shape characteristics of the material after rolling and accelerated cooling, then using this measured data to determine the straightening operation parameters. The controller receives real-time information about temperature changes and shape variations, and adjusts the straightening process accordingly. This feedback mechanism ensures accurate straightening while keeping the control process systematic and manageable.
Solution Approach 2:
The system performs preliminary measurement and analysis of temperature distribution and shape characteristics immediately after rolling and cooling, before the straightening process begins. This preliminary action provides the necessary data foundation for determining optimal straightening parameters, enabling accurate straightening without requiring overly complex real-time control during the actual straightening operation.
3Ease of operation
If a single straightening condition is applied throughout the material length, then the operation is simple, but excellent flatness cannot be ensured due to varying material shapes at different longitudinal positions
Solution Approach 1:
The patent applies local quality to the straightening process by determining different straightening operation parameters for different longitudinal portions of the material. The fore-end portion, middle portion, and tail-end portion each receive customized straightening conditions based on their specific shape characteristics. This localized approach ensures excellent flatness across the entire material length while maintaining ease of operation through automated portion-based 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
The system significantly reduces temperature deviations across the material's width, ensuring improved flatness and accuracy in the straightening process by dynamically controlling the cooling fluid flow rate and straightening device operations based on real-time shape and temperature data.
Implementation Method 1
a cooling device configured to spray a cooling fluid in a predetermined pattern with respect to a plurality of regions of a material (M), divided in a width direction, to cool the material
Implementation Method 2
a shape adjusting device disposed in an upstream region of the cooling device and configured to spray a cooling fluid in the width direction of the material (M) to induce shape modification of the material
Data Source
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AI summary
The present invention relates to a straightening system and a straightening method, which can conduct straightening in conformity with the shape pattern of a material, the straightening system comprising: a cooling device for spraying a cooling fluid in a predetermined pattern, in order to cool a material that has been heated in a heating furnace and has passed through a rolling device, with regard to a plurality of areas split in the transverse direction of the material; a straightening device for straightening the material that has passed through the cooling device; a flatness gauge for measuring the flatness of the material that has passed through the cooling device; and a control unit for receiving data regarding the flatness of the material from the flatness gauge and controlling the cooling device in response thereto, thereby improving the flatness of the material. This configuration is advantageous in that the flatness of the material can be improved by setting the interval between straightening rolls and the rate of straightening in conformity with the shape pattern of the material and by controlling the cooling flow rate with regard to the transverse direction of the cooling device.