Wire Rod Cooling Nozzles with Imaging Feedback
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Solution Overview
Problem
Conventional wire rod cooling apparatuses fail to uniformly cool wire rods wound in non-concentric rings due to temperature unevenness caused by sparseness and denseness variations in both the width and transfer directions, leading to inadequate coolant control and inefficient cooling.
Innovation Solution
A wire rod cooling apparatus with multiple jet nozzles arranged along the conveyor's width direction, equipped with an imaging device to capture images of the wire rod and extract sparseness, denseness, and temperature information, allowing for individual control of coolant flow rates based on these parameters to selectively cool specific portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a slit nozzle is provided over the entire area in the width direction of the conveyor to cool the wire rod uniformly, then the cooling coverage is improved, but the temperature unevenness between dense-in-width-direction portions and sparse-in-width-direction portions worsens because coolant cannot pass through the dense portions effectively
Solution Approach 1:
The cooling apparatus divides the cooling area into multiple regions corresponding to dense-in-width-direction portions and sparse-in-width-direction portions. Separate nozzles are provided for each region, allowing independent control of coolant supply to each segment, thereby addressing the temperature unevenness caused by differential coolant penetration
Solution Approach 2:
The apparatus applies different cooling conditions to different parts of the wire rod. Specifically, coolant is supplied to both dense and sparse portions with adjusted flow rates or timing based on their respective cooling requirements, ensuring uniform temperature distribution across the entire wire rod width
2Ease of operation
If coolant is sprayed uniformly to both dense-in-width-direction and sparse-in-width-direction portions, then the cooling process is simplified, but the temperature difference between these portions increases due to reduced coolant penetration in dense areas
Solution Approach 1:
The cooling apparatus dynamically adjusts coolant flow rates or spray timing for different nozzle regions based on real-time detection of wire rod density distribution. This dynamic control enables differentiated cooling for dense and sparse portions while maintaining operational simplicity through automated adjustment
Solution Approach 2:
The system incorporates detection means to monitor the density distribution of the wire rod and uses this information to adjust coolant supply to various nozzles. This feedback mechanism ensures that cooling is optimized for each portion's actual condition, reducing temperature differences while keeping the control system manageable
3Ease of manufacture
If the wire rod is wound in non-concentric rings with varying ring pitch, then the winding process is simplified, but temperature unevenness occurs in the transfer direction due to varying coolant penetration
Solution Approach 1:
The cooling apparatus segments the cooling area in the transfer direction into multiple zones along the conveyor. Each zone has independently controlled nozzles that can be activated based on the local density conditions caused by non-uniform ring pitch, thereby addressing temperature unevenness without complicating the winding process
Solution Approach 2:
The system dynamically activates or adjusts coolant flow in different transfer-direction zones based on detected density variations. This dynamic response allows the cooling apparatus to adapt to the varying ring pitch conditions while maintaining uniform temperature distribution
4Manufacturing precision
If multiple nozzles are provided to address density variations, then cooling precision is improved, but the device complexity increases
Solution Approach 1:
The cooling apparatus uses a unified control system that manages multiple nozzles through a single integrated controller. The detection means and control unit coordinate all nozzle operations, allowing the system to achieve precise cooling uniformity while keeping the overall device architecture relatively simple and manageable
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 solution enables precise control of coolant flow to address temperature differences, reducing temperature unevenness and enhancing the uniformity of the wire rod's mechanical properties and surface conditions, thereby improving cooling efficiency and reducing the need for additional heat treatments.
Implementation Method 1
an imaging device that is provided on a transfer-line upstream side of a jet nozzle row composed of the plurality of jet nozzles and captures an image of the wire rod being transferred
Implementation Method 2
jet coolant toward the wire rod... the flow rate of coolant jetted from the jet nozzles is controlled individually for each jet nozzle
Implementation Method 3
coolant is sprayed from the slit nozzle toward the ring-shaped wire rod; thereby, the cooling of the ring-shaped wire rod is performed
Data Source
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AI summary
A wire rod cooling apparatus that cools a wire rod wound in a ring shape by a wire rod winder while transferring the wire rod on a conveyor includes: a plurality of jet nozzles that are arranged along a width direction of the conveyor and jet coolant toward the wire rod; an imaging device that is provided on a transfer-line upstream side of a jet nozzle row composed of the plurality of jet nozzles and captures an image of the wire rod being transferred; and a control unit that extracts sparseness and denseness information and temperature information of the wire rod from the captured image. The control unit is configured to control a flow rate of coolant jetted from the jet nozzles individually for each jet nozzle on the basis of the sparseness and denseness information and the temperature information of the wire rod in conformity with a timing when a specified portion corresponding to the information arrives at the jet nozzle.