Two-Part Shroud for Work Roll Cooling in Rolling Mills
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Solution Overview
Problem
Conventional work roll cooling systems in rolling mills face challenges such as fire risks with kerosene coolants, damage to aluminum finishes with water, and difficulties in sealing and maintaining the shroud for liquid nitrogen systems, which affect the efficiency and accuracy of the rolling process, especially during roll changes.
Innovation Solution
A two-part shroud design for the work roll cooling apparatus, where the first part is attached to the chock and the second part is detachable, allowing for axial removal of the work roll and shroud without disconnecting coolant and gas supplies, maintaining a consistent gap for effective sealing and facilitating easy cleaning and equipment mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shroud is used to seal against the rotating roll with a gas curtain, then condensation is prevented, but the gap tolerance becomes difficult to maintain across the full roll length
Solution Approach 1:
The shroud is divided into a first part attached to the chock and a second part that is detachable. This segmentation allows the first part to maintain the critical gap for sealing while the second part can be removed separately, preventing tolerance accumulation across the full length and ensuring consistent sealing effectiveness.
2Productivity
If the shroud is mounted to the chocks, then it provides cooling during operation, but it cannot be removed with the rollers during roll changes
Solution Approach 1:
The shroud is segmented into a first part that remains with the chock during operation and a second part that is detachable. During roll changes, the second part can be removed along with the roller, while the first part stays on the chock. This segmentation resolves the contradiction by allowing both continuous cooling capability and easy roll removal.
Solution Approach 2:
The first part of the shroud serves dual functions: it provides cooling during operation when attached to the chock, and it remains mounted on the chock during roll changes to be ready for the next roller installation. This multi-functionality allows the system to maintain cooling capability while facilitating easy roll changes.
3Reliability
If a physical contact seal is used between the shroud and roll, then sealing is achieved, but the mirror surface of the foil is damaged
Solution Approach 1:
A gas curtain is introduced as an intermediary between the shroud and the rotating roll to provide sealing. The gas curtain creates a barrier that prevents condensation ingress without requiring physical contact, thus protecting the mirror surface of the foil while maintaining effective sealing.
4Ease of manufacture
If the shroud is made as a single piece, then assembly is simple, but disassembly and cleaning become difficult
Solution Approach 1:
The shroud is divided into a first part attached to the chock and a second part that is detachable. This segmentation maintains relative assembly simplicity while enabling easy disassembly for cleaning. The second part can be removed to provide access to internal surfaces that would otherwise be difficult to reach, resolving the contradiction between assembly simplicity and cleaning accessibility.
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 design enables faster roll changes, maintains sealing consistency, and allows for effective cleaning and equipment access, improving operational efficiency and reducing downtime by ensuring the correct gap size is maintained during assembly and disassembly, thus enhancing the rolling process's accuracy and safety.
Implementation Method 1
a gas curtain or air knife type effect is used
Implementation Method 2
coolant is brought into contact with the work roll
Data Source
Figure 1
Figure 2
AI summary
Work roll cooling apparatus for a rolling mill comprises: at least one chock (200) which is configured to support a work roll (100) in the rolling mill, the work roll (100) having an axis (X) about which it is rotatable; and a shroud (300) for positioning adjacent the work roll (100) when in use so as to provide a cooling space within which a coolant is brought into contact with the work roll (100), the shroud including a first part (301) disposed on the chock (200) so as to provide a predetermined gap (G) between the first part (301) and the work roll (100), a second part (302), and a connection for releasably connecting the first and second parts (301, 302). In a connected condition the first and second parts (301, 302) are joined so as to provide the cooling space within the shroud (300), and in a disconnected condition each of the at least one chock (200), the first part (301) of the shroud (300) and the work roll (100) may be axially removed from the rolling mill and second part (301) of the shroud (300).