Wire Cooling via High-Speed Liquid Jet in Inert Atmosphere
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Solution Overview
Problem
Existing cooling methods for wires during annealing and patenting processes are inefficient, leading to slow cooling rates, difficulty in handling long wires, dirt buildup, and risk of oxidation, particularly in high-speed galvanized steel wire production.
Innovation Solution
A high-speed cooling method using a cooling device with a first and second chamber for containing cooling liquid, where cooling liquid is projected onto the wire at a high speed in an inert gas atmosphere, preventing oxidation and improving cooling efficiency by minimizing vapor layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling tubes with water sleeve are used for cooling the wire, then the wire can be cooled, but the cooling rate is low and the line length increases significantly
Solution Approach 1:
The patent uses a hydraulic cooling system where water is sprayed through nozzles onto the wire surface. This hydraulic approach replaces the traditional tube-based cooling method, enabling more efficient heat transfer and faster cooling rates without requiring excessively long line lengths.
Solution Approach 2:
The patent changes the cooling parameters by using high-pressure water jets with controlled flow rates and angles. By adjusting these parameters, the system achieves optimal cooling efficiency and speed, resolving the contradiction between cooling rate and line length.
2Temperature
If cooling tubes are used for cooling the wire, then cooling can be achieved, but dirt builds up in the tubes
Solution Approach 1:
The patent extracts the cooling function from enclosed tubes and applies it directly to the wire surface through spray nozzles. This eliminates the confined tube structure where dirt accumulates, while maintaining effective cooling through direct contact with the wire.
Solution Approach 2:
The patent introduces spray nozzles as intermediaries between the cooling water source and the wire. These nozzles deliver cooling water precisely where needed without creating enclosed spaces where dirt could build up, thus resolving the contamination issue.
3Temperature
If cooling tubes are used for cooling the wire, then cooling can be achieved, but the wire may oxidize
Solution Approach 1:
The patent creates an inert atmosphere around the wire during cooling by using gas shielding or controlled environment systems. This prevents oxygen from reaching the hot wire surface, thereby preventing oxidation while maintaining effective cooling through the spray system.
4Productivity
If high-speed cooling is implemented, then processing speed increases, but cooling uniformity may be compromised
Solution Approach 1:
The patent applies local quality by positioning multiple spray nozzles at different locations and angles around the wire path. Each nozzle is optimized for its specific zone, ensuring uniform cooling distribution across the entire wire surface even at high processing speeds.
Solution Approach 2:
The patent uses dynamic control of the spray system, adjusting flow rates, pressures, and nozzle angles in real-time based on wire speed and temperature distribution. This dynamic adaptation maintains cooling uniformity regardless of processing speed variations.
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 method achieves faster cooling rates, reduces oxidation risk, and allows for higher processing speeds while maintaining wire quality, as the inert gas atmosphere prevents chemical reactions and oxidation.
Implementation Method 1
cooling liquid is projected onto the wire at a high speed in an inert gas atmosphere
Implementation Method 2
cooling liquid driving means fluidically connecting said first and second chambers for driving said cooling liquid from said first chamber to said second chamber through said at least one cooling liquid inlet
Implementation Method 3
means for introducing inert gas, functionally associated with said second chamber to create an inert gas atmosphere inside said second chamber during the cooling of said wire
Implementation Method 4
cooling liquid is projected onto the wire at a high speed in an inert gas atmosphere, preventing oxidation and improving cooling efficiency by minimizing vapor layer formation
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Cooling device (1) for cooling a wire (100), comprising a first chamber (2) and a second cooling chamber (4) through which the wire (100) passes. The device also comprises cooling liquid driving means (16) for driving the cooling liquid from the first chamber (2) to the second chamber (4) through at least one cooling liquid inlet (12). Through the driving means (16) and the cooling liquid inlet (12), a jet of cooling liquid is projected on the wire path at a mean speed of at least 0.6 m/s, and at a distance between 6 and 13 times the diameter of the wire (100). Cooling is performed in an inert gas atmosphere inside the second chamber (4). The invention also relates to a corresponding installation and a corresponding wire cooling method.