Continuous Wire Annealer Extends Recrystallization Time
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Solution Overview
Problem
Continuous wire annealers face high energy consumption due to immediate cooling of wires after recrystallization, which reduces dwell time and necessitates higher heat input, leading to inefficient energy use.
Innovation Solution
A continuous annealer design that extends the recrystallization time by moving the cooling zone further downstream, allowing for a second partial recrystallization process without additional heat, thereby increasing the total recrystallization time and reducing energy input, while optionally using conductive or inductive heating and a protective gas atmosphere.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the wire is immediately cooled after recrystallization, then the cooling process is efficient and surface tarnishing is prevented, but the dwell time at temperature is reduced and energy consumption increases
Solution Approach 1:
The patent divides the thermal process into three distinct zones: an annealing zone for heating and initial recrystallization, a recrystallization zone for extended recrystallization without cooling, and a cooling zone for final cooling. This segmentation allows the wire to undergo recrystallization in two stages, extending the effective dwell time at temperature while controlling energy consumption through localized heating.
Solution Approach 2:
The patent applies preliminary heating in the annealing zone to raise the wire temperature to the recrystallization range, then maintains this temperature in the recrystallization zone to allow extended recrystallization before final cooling. This preliminary thermal action ensures sufficient recrystallization time without requiring continuous high energy input throughout the entire process.
2Duration of action of moving object
If the cooling zone is positioned immediately after the annealing zone, then the wire is cooled quickly to prevent surface tarnishing, but the total recrystallization time is reduced
Solution Approach 1:
The patent segments the process into an annealing zone, a dedicated recrystallization zone, and a cooling zone. The recrystallization zone is specifically designed to extend the recrystallization time without immediate cooling, while the cooling zone is positioned downstream to provide final cooling and prevent surface tarnishing. This spatial segmentation resolves the contradiction by separating the recrystallization function from the cooling function.
Solution Approach 2:
The patent maintains continuous useful action by keeping the wire in the recrystallization zone at elevated temperature for an extended period, allowing the recrystallization process to continue uninterrupted. The cooling action is applied continuously but is separated in space from the recrystallization zone, enabling both extended recrystallization time and surface protection without compromising either function.
3Reliability
If higher heat input is applied to compensate for reduced dwell time, then the recrystallization effectiveness is maintained, but energy consumption increases
Solution Approach 1:
The patent applies segmented heating through distinct zones: the annealing zone provides initial heating to recrystallization temperature, while the recrystallization zone maintains this temperature for extended time without additional heat input. This spatial segmentation of thermal processing allows the wire to achieve effective recrystallization through time extension rather than increased heat input, reducing overall energy consumption.
Solution Approach 2:
The patent changes the processing parameters by extending the dwell time at temperature in the recrystallization zone rather than increasing the heat input. By maintaining the wire at recrystallization temperature for a longer period in the second zone, the patent achieves effective recrystallization through time extension, which is more energy-efficient than compensating for reduced time with higher heat input.
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 approach achieves energy savings of up to 20% while maintaining the same degree of recrystallization, allowing operators to choose between energy savings and improved residual strain, and can enhance wire ductility without increasing energy input.
Implementation Method 1
annealing means for annealing the first wire portion in the annealing zone
Implementation Method 2
a first partial recrystallization process takes place in the first wire portion in the annealing zone
Implementation Method 3
a cooling zone downstream of the recrystallization zone... a third wire portion... passes through the cooling zone
Data Source
AI summary
A continuous annealer for wire is disclosed, and specifically for annealing and recrystallizing a wire in a continuous process. The continuous annealer for wire comprises: two contact discs for contacting a first wire portion extending therebetween; an annealing zone situated between the two contact discs; and annealing means for annealing the first wire portion in the annealing zone, as a result of which a first partial recrystallisation process in the first wire portion takes place in the annealing zone. A recrystallisation zone is situated downstream of the second contact disc, wherein, downstream of the annealing zone, the first wire portion passes through the recrystallisation zone as the second wire portion, and a second partial recrystallisation process takes place in the second wire portion. The wire has the opportunity to recrystallize further after leaving the annealing zone without further heating. By extending the recrystallisation time, the recrystallisation temperature can be reduced accordingly. As a result, the same degree of recrystallisation can be achieved overall with a significantly lower input of energy than when the wire is cooled immediately after leaving the annealing zone.