March. 2001

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TOYO-SUN MACHINERY CO., LTD. 1-1-19, Matsugashima-nishi, Ichihara-shi

Chiba 290-0036 JAPAN TEL 0436-25-6411 FAX 0436-25-6414

U R L http://www.toyo-sun.com/ e-mail toyosun@mb.infoweb.ne.jp

Digital Spraying System of Roll Coolant Control for Ferrous and NF Industries

Features TOYO SUN MACHINERY Co., Ltd. was

established by the group of experts who

engaged in hydraulic technology for long time

in 1978. We have developed a lot of new

products for mainly water hydraulic

equipment for over 20 years, and extended to

what we are now.

MACHINERY

From 1978 to 1985 we supplied over 2000

units of water HYD valves, directional, flow

control and pressure control valves to steel

mill and NF industry in Japan. Including

imported from REXNORD INC.USA. During

this period we also engaged in those

maintenance works at site and TOYO-SUN

factory. After that we have been

manufacturing TOYO-SUN design water

HYD valves and system. We took advantage

of these technology in making water HYD

valves, and succeeded in developing

TOYO-SUN Digital Zone Control Coolant

Valves instead of conventional analog roll

coolant control system.

REXNORD

KNOCK DOWN

maker aluminum maker

analog TOYO SUN design

Digital Zone Control Roll Coolant

We supplied 3 rows, 52mm pitched, 23 zone

coolant control header for (138 valves 6

tandem cold direct mill at KAWASAKI (KSC)

CHIBA works in June 1989, as well as plural

rows, Multi-zone control for cold mill at

KOBE KAKOGAWA, NIPPON (NSC) steel

KIMITSU, and SUMITOMO WAKAYAMA,

KASHIMA.

/ tandem direct cold mill 3

52mm 138

/ Cold mill / cold

mill / cold mill /

Hot stand coolant DC coolant F5

F6 stand

1

Supplied coolant zone control header for Hot

Rolling Mill to NSC HIROHATA’S F4, F5

stands and KSC CHIBA’S F4, F5, F6, F7

stands. We have contributed their quality and

productivity of ferrous and non ferrous

industry.

/ 3HOT F4 F7 stand

TOYO-SUN’s fundamental thought about roll coolant is on the followings. At first the analog coolant controls are still being used for thicker plate mills or less required flatness control of the surface. A lot of steel makers installs rows of nozzles

having a fixed area of opening on a coolant.

Then they divide one header into several

zones and they provide a throttle valve

considerably apart for each zone to change

the pressure to vary the flow rate. In this way,

they can control the roll coolant.

(See Figure 1.)

MACHINERY Roll coolant

system

Coolant spray analog

mill

Hot rolling mill

coolant header

nozzle one header

zone zone

roll

coolant control

Fig

However, this method has the following

problems.

Fig 1

Throttle valve

a. When the coolant oil is controlled by an in-line

throttle valve, the following phenomenon takes

place : the flow rate and the pressure change at

the same time and the fluid sprayed from a

nozzle that has only a fixed opening area

changes the IMPINGEMENT on the roll

surface ; therefore, a linear cooling effect cannot

be obtained and the cooling effect cannot be

improved even if the pressure is raised to

increase the flow rate.

(See Figure 2.)

a. Coolant oil control line

nozzle spray

roll impingement

linear

Fig

c. The cooling effect cannot be improved unless the

spray area of a subject is increased in proportion

to the increase in the spraying flow rate. But,

when the flow rate of a nozzle having a fixed

opening area is increased by changing the

pressure, the cooling area is decreased (See Figure

3); consequently, the amount of heat dissipation

does not increase even if the flow rate is increased.

c. Spray

spray

nozzle

Fig

Pressure ( kgf/cm2 )

b. When the pressure is changed to vary the flow

rate, an even spray over the width of the

board cannot be obtained because as the

spray angle changes, the width of overlap

with the adjacent nozzles will also change.

b. spray angle

nozzle lap

spray

d.The matters mentioned above are explained

by the following examples. An example of

sprayed thickness.

d.

Ratio

Pressure 2kg/cm2 10kg/cm2

Flow rate 16.3L/min 36.5L/min 2.2

Spraying angle 113 120 1.06

Cooling area 29.6cm2 17.2cm2 0.58

Flow rate per square centimeter of cooling area

0.55L/cm2 2.12L/cm2 3.8

Table

When the spray pressure is increased from

2kg/cm2 to 10kg/cm2, the flow rate is

increased 2.2 times, but even if the spraying

angle is changed from 113 degrees to 120

degrees, the sprayed thickness becomes half

and the area is decreased to about a half.

The spray flow rate of the unit area is

increased by 3.8 times, resulting in that it is

incompatible with the formula for the amount

of heat dissipation, which is shown later.

Spray kg cm kg cm

2.2 spray

113 120 spray 1

2 1 2

spray 3.8

That is, it can be said that this cooling control system does not agree with the theory that changing the pressure will change the spray impingement and the spray angle and will decrease the cooling area even if the flow rate is increased. There, it is impossible to increase the cooling efficiency by this method.

sprayspray angle

control system

Pressure (kg /cm2)

Fig 3

Example of sprayed thickness

in vertical characteristics

What is an ideal coolant system?

An ideal coolant system that is suitable for the current computer control must agree with the information obtained by the following formula and by experiments of William Roberts.

computer control coolant system DR

William Roberts

The amount heat dissipation, Q, is obtained by the following formula.

Q = h A ( TR TC ) ( 1 ) Where , h : coefficient of heat transfer A : cooled area TR : temperature of subject TC : temperature of coolant fluid The effective method to increase the amount of the heat dissipation by formula (1) is to increase the coefficient of heat transfer and the cooled area. Besides, the following information can be obtained concerning the coefficient of heat transfer by the experiments of Dr. Roberts ( Cold rolling of Steel, Marcel Deckker New York Basel Issue ).

( 1 )

Dr. Roberts (Cold rolling of steel, Marcel Deckker New York Basel )

1 ) The larger amount of plate-out of the coolant oil on the surface of a subject , the better the coefficient of heat transfer. 2 ) If the velocity of the coolant is more than the specified value, the coefficient of heat transfer is almost constant.

1 ) Coolant oil plate out

2 ) Coolant

Conclusion The most effective coolant system is one in which the rate of flow of the coolant is constant ( that is, the pressure or the impingement is constant ), the cooling area changes in proportion to the changes in flow rate a lower viscosity and lower temperature coolant oil is used.

coolant systemcoolant

coolant oil

Configuration of TOYO-SUN Coolant Valve

TOYO SUN 1. Simple is best

The structure of TOYO-SUN coolant valve is extremely simple based on our past over 20 years experiences. The poppet lies always opening position loaded by spring in the valve. It can be certainly opened compared with favorably with the one that can be opened by the pressure of coolant fluid.

1. TOYO-SUN coolant 20

simplePoppet spring

air

2.Easy maintenance 2.Refer to drawing 4, main parts of poppet , seat , sleeve , and spring can be easily pulled out of the body by screwing the M6 cap screws into the poppet from nozzle side. You can call their parts “cartridge”.

body partspoppet seat sleeve spring nozzle

poppet handle M6 screw

cartridge

3. Material : All stainless steel 3. All SUS We use basically all stainless steel as the material of the coolant valve. O-rings made of vition#70, are usually utilized as our standard. According to specification, some engineering plastic can be used for seat or poppet, however you have to take care of permanent deformation, chemical swelling and discoloration because of chemical reaction.

sus O-ringviton#70

engineering plasticemulsion

crack

In some cases, chemical cleaning or steam cleaning is necessary for coolant system, so we utilize stainless steel for this system as our standard.

steamsus

4. Poppet with different dia, and breathing

4. poppet

Poppet has both smaller and larger diameter in itself. The former is for dealing with coolant fluid, the latter is for pneumatics. Every time the poppet strokes, it makes always breathes because the volume of different diameters. Breathing means invading foreign particles into valve inside from outside. TOYO-SUN coolant valve has prevention system to refrain from invading foreign particles. Therefore it has pipe which leads to the volume. The pipe is installed within the rear cover of the header. It is very important for permanent reliability in operation.

poppetON OFF

TOYO-SUN coolant valve

cover pipe

5. Flexible composite arrangement 5. Refer to Fig 4, there is easy versatile arrangement of coolant valves, header plate andpneumatic tubing position corresponding to the space inside rolling mill.

Coolant Fig 4 header ass’yvalve

Standard type

Optional type

Fig 4

Fig 5-1

SPRAYING CONDITION

Fig

Fig 5-1

Fig 5-2

SPRAYING CONDITION

6.Open and shut detector ( OSD, Option )

6.

It is difficult for an operator to confirm the malfunction of coolant valves instantly during rolling operation. It is not until wrong flatness of the plate that an operator doesn’t notice coolant valve malfunction.

Fig

There are so many coolant valves installed on the header. Maintenance people are usually forced to have a lot of trouble with finding the causes of trouble with finding the causes of malfunction.

TOYO-SUN open and shut detector ( OSD ) can easily find which valves are under malfunction at their cockpit. OSD also plays important role in maintaining coolant valves. When one of the coolant valves happens to malfunction, there are several reasons, which cause the nozzles clogging, coil burning and tube failure etc, however, if OSD is installed, they can easily check the causes of trouble promptly, in addition proceeding to shoot them in the right order.

7.Installation of buffer plate (Fig7) 7.Buffer plate

The spray impingement to roll face exerts direct influence on its cooling efficiency. In many cases, however, we have been making light of or paying no attention to the fact.

Spray rollimpingement

factor

(Fig 7)

8.Nowadays steel technology has made the precision roll face flatness controlled with supersonic or laser by using computer. TOYO-SUN thinks the automated flatness control ( AFT ) requires an even flow coolant spray pattern to make thinner plates. TOYO-SUN installs the buffer plates inside semi-circled pipe welded to header plate due to even spray impingement and even cooling to the roll face.

8. flatness control computer on line grinder

Lasereven

TOYO-SUN coolant system

coolant bufferFig roll even

10

11

Fig 7

Digital Roll Coolant System Technical Report

1.Outline of the system 1.SYSTEM

In order to perform effective profile control of a thin plate, a number of nozzles, each equipped with a remotely controllable shut-off valve, are lined up vertically, and at the same time they are lined up horizontally according to the width of the plate at a specified pitch ( standard: 50 millimeters ). An upper header and a lower header are interlocked by combining nozzles with different sizes and, by controlling the shut off valves digitally, this system controls the flow rate without controlling the pressure: that is, without changing the impingement

against the roll. system profile

ON OFF valvenozzlepitch

nozzle headervalve ON,OFF digital

rollimpingement control

2.Header ( See Fig 8 ) 2.Header Fig 8 Both the upper and lower headers have 72 nozzles in three rows and 24 zones as shown in the following drawing. When the flow rates of nozzles, No.1, No.2, and No.3, are 30L/min, 50L/min, and 60L/min respectively, the preset flow rate of each zone are be as shown in Table 2.

Header 24 372 nozzle Nozzle No.1 No.2 No3

30L/min 50L/min 60L/minzone ( Table )

Header Surface Fig 8

Nozzle Pitch : 50mm / 24zones 3

12

3 Method for Setting the Flow Rate of Each Zone 3

Nozzle No Specified flow rate CH1 CH2 CH3 CH4 CH5 CH6 CH7 CH8

No.1 30L /min OFF ON ON ON ON

No.2 50L /min OFF ON ON ON ON

No.3 60L /min OFF ON ON ON ON

Total throughput of Each zone

0 L /min

30L /min

50L /min

60L /min

80L /min

90L /min

110L /min

140L /min

Table 2

4.Specifications and Equipment configuration of the Digital System roll Coolant

4.

Main Specifications

Total flow rate ( ) : 6.8 M3/min Pressure ( ) : 5 kgf/cm2 Kind of Fluid ( ) : Industrial water , soluble oil and mineral oil Max Flow rate Of each zone ( ) : 140L/min

Booster

Dryer

Terminal box

Solenoid Valve and Pressure Switch StandSolenoid valves for pneumatics ( 3 way, 2 positions directional control ) 72 pcs

Pressure switches ( for low pressure ) 24 Booster ( 4 9 kg/cm ) 1 Dryer ( 1 unit, 3 piece sets ) ( built in ) Multiple Quick connector ( for 12 pieces ) 12

( for air tubes )

Header ass’y 24zones(both upper and lower) Nozzle pitch : 50mm

Coolant Pilot air

Coolant Header Assembly Operation Panel(No.2) on Machine

Overall and each zone control for operation and maintenance.

Unit :min

13

Electrical Control Panel ( Power Room ) ( 1 set )

Operation Panel ( No. 1 ) in Operator room

5.Coolant Control System Diagram

Relay Sequencer NFB, etc (built-in)

14

.Functions and Purpose of Each Operation Panel

.

The layout of the switches and indicators on the front of the operation panel ( No. 1 ) installed in the operator room and the operation panel ( No. 2 ) installed on the machine are shown on 17 page.

Operator NO.1NO.2

17

The No. 2 operation panel is located on the machine and is used mainly for maintenance. The both ON/OFF valves in each crossways line can be operated individually by setting the AUTO/MANUAL switch to the neutral position on the operation panel in the operator room.

NO.2maintenancevalve zone ON OFF

ON OFF operator auto manual switch

No. 1 Operation Panel No.1 a. The pushbutton switches located in the

second row from the bottom of the operation panel in the operator room are used to set the flow rate of each zone individually in manual mode. They are of the one-push, one-up link mechanism as CH1 CH7 CH1.

a. Operatormanual zone

CH1 CH7CH1 one push one up link

b. The indicators display the currently preset flow rate. The flow rate pattern can be understand at a glance by the area of the lit indicators.

b. lamp pattern

c. For fail safe, the spray is turned off when the solenoid valve is energized, and the spray and indicator light are turned on when it is deenergized.

c. side spray OFFspray ON lamp

15

d. Manual, Neutral, Auto Switch Individual setting of the flow rate in each zone can be performed in the procedure of item a with switching in manual mode ( No.1 operation panel ). Nozzles No.1, No.2, and No.3 can be switched ON/OFF individually with the No.2 operation panel in neutral mode. When the auto on pushbutton switch with indicator is pressed with the switch in auto mode, both the upper and lower headers in each zone starts spraying in the preset flow rate pattern. The flow rate pattern can be changed from the host computer during spraying in auto. ( optional )

d. Manual Auto Manual zone

NO.2 NO.1

NO.2 NO.3 ON OFF Auto auto ON lamp PBS

zonepattern header spray Auto spray computerpattern

e. When the operator want to spray the flow rate of 30L /min or 50L /min in the crossways lines individually, in manual mode.( optional ) Press the pushbutton with the switch.

e. 30L min 50 L min PBS zonespray manual

f. Header valve malfunction detector ( optional )

f. Header valve

When the valve does not spray ( in MANUAL, AUTO mode ) even if the solenoid valve is deenergyed. By functioning of the malfunction detector mechanism shown in the header-valve cross section ( Fig 6 ), the indicators located at the top of the No.1 operation panel turn on. If any of the six valves in each zone malfunction, the lamp corresponding to the zone turns on.

Header valve Fig 6 valve spray

manual auto NO.1zone lamp

zone valve

zone lamp

16

This operation panel is located on the machine side and is provided to confirm the function of the header valves, pipings, and other troubles. First, turn on the power and type out the number of the zone to be operated by the ten key in the left two digits. Check this with the indicator. Then type out the flow rate in the right two digits. Also check this with the indicator. Press the ON button of the ten key to check the spray from the valve. When the selector switch common to each of the No.1, No.2, and No.3 zone is turned ON, the spray of one horizontal row can be functioned. END

valve piping trouble checkten key board zone

ten key board on button valve spray NO.1,NO2,NO.3 zoneswitch on spray

No.1 Operation Panel ( Operator Room )

No.2 Operation panel ( At Side )

Valve malfunction indicator

Flow rate Setting button

Flow rate pattern display

Flow rate indicator

Air pressure

Coolant pressure Auto Neutral Manual

Auto on (with lamp)

50L 30L

All spray,Power OFF, (SV demagnetization)

All stop, Spray OFF

Power switch indicator

Power PBS SSW common to each zone

Ten key board

Number of zones

Valve flow rate

ON (PBS)

OFF (PBS)

17