TECHNICAL FIELD

[0001] The present disclosure relates generally to conveying mechanisms for transferring materials from one location to another.In particular, the present disclosure relates to run-out tables used to transfer metal components from a heating unit of a rolling mill to a cooling station in order to allow cooling of the metal component.

BACKGROUND OF THE INVENTION

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] A run-out table is a material handling device that enables transfer of metal components such as metal bars, plates and sheets from one station of a rolling mill to another station so as to perform an intended function at the second station. Run-out tables are used in rolling mills to enable spray impingement cooling of metal plates. Such run-out tables covey the metal plates from a heating unit of the rolling mill to a cooling station where a plurality of sprayers/nozzles spray a coolant over heated surfaces of the metal plates.

[0004] Spray impingement cooling is the process of cooling of heated surfaces of a metal strip by spraying a fluid/coolant over the heated surfaces of the metal strip placed on a run-out table with the help of nozzles at the cooling section arranged along the run-out table. The run-out table supports the metal strip as it moves at high speeds from heating unit of the rolling mill to the cooling section. Temperature of the metal strip issuing from the heating unit however is too high for direct quenching and it is therefore necessary to cool the strip in its path along the run-out table to avoid undesired metallurgical changes in the strip.

[0005] Metal strip issuing from heating unit of the rolling mill is travelling at high speed and therefore rapid cooling on the run-out table is required to avoid the necessity of an abnormally or unacceptably long run-out table. Cooling is usually accomplished at a plurality of water spray stations or banks located along the run-out table, with cooling water being applied both to the top and bottom surfaces of the strip. The bottom surface is cooled by spray bars positioned closely adjacent the strip, with the cooling water serving also to cool the metal surface of the run-out table. However, accurate positioning and movement of the strip along the run-out table should be realized in order to prevent uneven cooling of the strip and undesired changes in physical as well as chemical characteristics of the strip.

[0006] Thus, there exists a need in the art to provide apparatus and system to automate movement and positioning of a run-out table in order to provide for accurate movement and positioning of a metal strip configured on the run-out table to enable optimal spray impingement cooling of the metal strip.

[0007] As used in the description herein and throughout the claims that follow, the meaning of“a,”“an,” and“the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of“in” includes“in” and“on” unless the context clearly dictates otherwise.

[0008] In some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0009] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g.“such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0010] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

OBJECTS OF THE DISCLOSURE

[0011] A general object of the present disclosure is to improve quality of a heat treated metal component.

[0012] An object of the present disclosure is to improve quality of a heat treated metal component by exercising better control on cooling parameters during heat treatment process.

[0013] An object of the present disclosure is to provide a desired environment to control various parameters of a run-out table installed in cooling section of a rolling mill.

[0014] An object of the present disclosure is to provide an automatic run-out table for accurate movement and positioning of heated metal components such as a metal strip for optimal spray cooling during heat treatment of the component, and thereby exercise better control on cooling parameters during heat treatment process.

SUMMARY

[0015] Aspects of the present disclosure relate to an apparatus and system for automation of handling of metal components from a heating unit of a rolling mill to a cooling station and during heat treatment of the component at the cooling station. The present disclosure provides apparatus and system for accurate movement and positioning of the metal component, such as a metal strip, configured on a run-out table to enable optimal spray cooling of the metal strip.

[0016] In an aspect, the present disclosure provides for automation of run-out table mechanism to achieve optimal cooling of the metal strip. The proposed technique/mechanism not only improves physical as well as chemical properties of the metal strip, but also minimizes space requirement for the apparatus because the required cooling can occur in a shorter time period as compared to time taken using the conventional run-out table mechanisms.

[0017] In an aspect, the present disclosure provides a run-out table for handling of heated metal components, the run-out table comprising; a run-out platform configured on a support structure and adapted to move in vertical direction; a movable platform for holding the heated metal component, and mounted on the run-out platform for linear movement in a horizontal direction; the movable platform comprising at least one rotary device to linearly move the movable platform; and a microcontroller to compute one or more movement parameters and control operation of the rotary device to move the movable platform to achieve the one or more computed movement parameters.

[0018] In an aspect, the microcontroller is wirelessly linked to a computing device to get inputs required to determine the one or more movement parameters.

[0019] In an aspect, the one or more movement parameters may include location to which the metal component is to be moved and speed with which the metal components is to be moved.

[0020] In an aspect, the support structure for the run-out platform may comprise at least two metal stands rigidly fixed to a base, and the run-out platform incorporates at least two rails that are spaced apart in a horizontal plane; wherein the two rails are slidably configured with the at least two metal stands for vertical movement of the run-out platform.

[0021] In an aspect, the two rails may be configured to sidably support the movable platform.

[0022] In an aspect, the movable platform may include a movable bed and at least two shafts configured with a plurality of rollers that engage with the at least two rails of the run-out platform for horizontal movement of the movable bed along a path defined by the at least two rails; and wherein the metal component is fixed on the movable bed with one or more of jigs, fixtures and clamps.

[0023] In an aspect, the rotary device may be any of a DC motor, stepper motor or a servo motor.

[0024] An aspect of the present disclosure relates to a system for controlled cooling of a heated metal component in a rolling mill, the system comprising: a run-out table comprising a movable platform configured for vertical movement and linear movement in a horizontal direction; a cooling station having a plurality of spray nozzle configured to spray a cooling media on one or more surfaces of the metal component at controlled flow rates; a plurality of temperature sensors to determine temperature profile of the metal component; and a microcontroller configured to control vertical and horizontal movements of the movable platform to maintain relative position of the metal component in relation with the plurality of spray nozzles based on the determined temperature profile of the metal component, and control flow rates of the cooling media being sprayed through the plurality of spray nozzles to achieve various desired cooling parameters.

[0025] In an aspect, the microcontroller is wirelessly coupled to a computing device to get inputs regarding various cooling parameters.

[0026] In an aspect, the various cooling parameters may be one or more of temperature of the one or more surfaces that is to be achieved and associated cooling rate.

[0027] In an aspect, the computing device may be selected from a group consisting of a network device, a mobile phone, a computer, a laptop, a PDA and a controller.

[0028] In an aspect, the cooling station may comprise one or more of, water pump, air compressor, pressure regulators, valves; and wherein their operation is controlled by the microcontroller to achieve desired flow rate of the cooling media through the plurality of spray nozzles.

[0029] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0031] In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0032] FIG. 1 illustrates an exemplary perspective view representation of proposed run-out table in accordance with an embodiment of the present disclosure.

[0033] FIG. 2 illustrates an exemplary representation of movable platform of the proposed run-out table in accordance with an embodiment of the present disclosure. [0034] FIG. 3 illustrates an exemplary representation of proposed system to automate movement and positioning of the movable bed of the proposed run-out table in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0035] If the specification states a component or feature“may”,“can”,“could”, or

“might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[0036] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This disclosure may however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the disclosure, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).

[0037] Various terms as used herein. To the extent a term used in a claim is not defined herein, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[0038] The present disclosure relates to run-out tables used to transfer metal components from a heating unit of a rolling mill to a cooling station in order to allow cooling of the metal component. The present disclosure provides apparatus and system to automate movement and positioning of a run-out table to provide for accurate movement and positioning of a metal strip configured on the run-out table to enable optimal spray cooling of the metal strip. In an aspect, the proposed system provides for accurate control over movement and positioning of the metal strip, configured on a movable bed of the run-out table, which is to be cooled during heat treatment of the strip, for instance, the proposed system can provide for control over movement of a steel strip fixated on the movable bed of the run-out table which is to be cooled in a steel rolling mill by spraying a coolant over at least one heated surface of the strip with the help of a plurality of nozzles at a cooling station. In an aspect, the steel strip can be fixed on the movable bed with the help of any or a combination of jigs, fixtures and clamps.

[0039] In an aspect, the present disclosure provides for automation of run-out table mechanism to achieve optimal cooling of the metal strip. The proposed technique/mechanism not only improves physical as well as chemical properties of the metal strip, but also minimizes space requirement for the apparatus because the required cooling can occur in a shorter time period as compared to time taken using the conventional run-out table mechanisms.

[0040] In an aspect, the proposed apparatus and system aim to provide a desired environment to control various parameters of a run-out table installed in cooling section of a rolling mill. In an aspect, the proposed apparatus and system can be used to study and/or analyze effects of various parameters such on cooling rate of the metal strip. The apparatus and system also allows for easy handling and operation of various components of the cooling station.

[0041] In an aspect, the proposed apparatus and system can allow for measurement and analysis of various parameters pertaining to the cooling process such as, cooling rate of the metal strip, mass flow rate of the coolant, coolant pressure, inter-nozzle distance, strip to nozzle distance, strip movement speed and the likes.

[0042] In an aspect, the present disclosure further provides for wireless control of movement and positioning of the movable bed of the run-out table to prevent damage of hot metal strips due to improper alignment and/or positioning of the strips with respect to nozzles of the cooling station. In an aspect, the proposed system allows for a centralized control of various sub-systems and sub-units such as compressors, pumps, motors, etc.

[0043] In an aspect, the proposed apparatus includes a stand with rails on which a movable bed is configured to carry and move metal strips at a desired speed along a cooling station configured with a plurality of nozzles that spray a coolant, for instance, water over heated surfaces of the metal strip to allow for cooling of the heated surfaces of the metal strip.

[0044] It would be appreciated that nozzles can be configured at the cooling station such that they can provide for simultaneous cooling of more than one heated surface of the metal strip, and any such configuration and/or arrangement of nozzles is well within scope of the present disclosure. [0045] In an aspect, the proposed system acquires data pertaining to various parameters of the cooling process with a high degree of accuracy to minimize manual intervention and to enable efficient control of the parameters.

[0046] It would be appreciated that although the present disclosure is explained in terms of a run-out table used for spray impingement cooling of hot metal strips, the present disclosure is not limited to the same in any way whatsoever, and any other form of apparatus, device and mechanism that involve a conveying mechanism used for spray impingement cooling of hot metal strips is well within the scope of the present disclosure.

[0047] FIG. 1 illustrates an exemplary perspective view representation of proposed run-out table in accordance with embodiments of the present disclosure. In an aspect, the proposed run-out table (also referred to as“apparatus” hereinafter) 100 can include at least two metal stands 102 rigidly connected to a base 104, a run-out platform 106 comprising at least two rails 108 spaced apart in a horizontal plane, wherein the at least two rails 108 are supported by a supporting structure comprising at least two metal rods 110 suspended at one end of each of the at least two rails 108 to provide rigidity and to support movement of the run-out platform 106. The run-out platform 106 is movable in vertical direction along a path defined by the at least two metal stands 102. Further, the run-out platform 106 supports a movable platform 112 such that the movable platform 112 can linearly slide along length of the run-out platform 106.

[0048] .Referring to FIG. 2 the movable platform 112 comprises a movable bed

1 l4mounted over at least two shafts 116 configured with a plurality of rollers 118 that engage with the at least two rails 108 of the run-out platform 106 to allow horizontal/longitudinal movement of the movable bed 114 along a path defined by the at least two rails 108.

[0049] In an aspect, the movable platform 112 can include one or more bearings that support the movable bed 114 over the at least two shafts 116 to allow smooth and vibration free movement of the movable bed 114. In an aspect, movement of the movable bed 114 in the horizontal/longitudinal direction can be actuated by a rotary device, such as but not limited to, a servo motor or a stepper motor, to enable accurate positioning of the movable bed 114 in the longitudinal direction at high speed along the path defined by the at least two rails 108 of the run-out platform 106. In an aspect, rotary devices such as direct current (DC) motor, electric motors and the likes can also be used to allow movement of the movable bed, and use of any such devices is well within the scope of the present disclosure. [0050] In an aspect, the run-out platform 106 can move vertically along the path defined by the at least two metal stands 102 to allow positioning of the movable bed 114 in vertical direction. In an aspect, positioning of the movable bed 114 in vertical direction can allow for control of parameters pertaining to the cooling process, for instance, when a metal strip, say steel strip, clamped on the movable bed 114 is aligned with a nozzle of the cooling station, positioning of the movable bed 114 in vertical direction enables control and/or adjustment of distance between tip of the nozzle and the strip (also referred to as“strip to nozzle distance” hereinafter) that can provide for optimal cooling of the strip. In an aspect, the steel strip can be clamped on the movable bed with the help of any or a combination of jigs, fixtures and clamps.

[0051] In an aspect, operations of the rotary device can be controlled by a microcontroller (not shown) that can be wirelessly controlled so as to enable accurate control over movement and positioning of the movable bed 114 in the vertical as well as the longitudinal directions.

[0052] In an aspect, when at least one metal strip configured on the movable bedl l4 is in alignment with one or more nozzles of the cooling station, the one or more nozzles can spray/sprinkle a fluid, such as water, liquid nitrogen, helium, and the like cooling mediums over at least one heated surface of the metal strip to enable cooling of the at least one heated surface. In an aspect, the one or more nozzles can be located at specific locations above as well as below the rails of the apparatus 100, and any such arrangement and/or configuration of nozzles is well within the scope of the present disclosure.

[0053] In an aspect, at least one parameter pertaining to the cooling process, for instance, temperature of metal strip, cooling rate of the metal strip, mass flow rate of the fluid and the likes, can be recorded simultaneously, and at least one parameters pertaining to movement and positioning of the movable bed, for instance, speed of the movable bed, height of the movable bed 114 can be altered based on the at least one parameter pertaining to the cooling process.

[0054] In an exemplary implementation, the apparatus 100 can include two metallic stands 102 fixedly connected to a base 104 and a run-out platform 106 that includes two rails 108 extending in horizontal/longitudinal direction. The rails 108 can be spaced apart from each other and can define a path for the rollers 118 of the movable platform 112 to allow movement of the movable bed 114 in the longitudinal direction. The rails 108 can be supported by a supporting structure that can include two metal rods/bars 110 suspended at ends of the rails 108 so as to provide support and rigidity of the run-out platform 106.

[0055] In an aspect, the run-out platform 106 can be supported by an overhead supporting structure that includes two metallic rods suspended over an end of each of the at least two rails 108 to provide a rigid support to the run-out platform 106 and to allow movement and positioning of the run-out platform 106 without compromising rigidity of the run-out platform 106.

[0056] FIG. 2 illustrates an exemplary representation of movable platform of the proposed run-out table in accordance with an embodiment of the present disclosure. In an aspect, the movable platform 112 can include a movable bed 114 mounted over at least two shafts 116. The at least two shafts 116 can be configured with a plurality of rollers 118, at least one roller 118 configured at each end of the at least two shafts 116. In an aspect, the plurality of rollers 118 can roll over the at least two rails 108 of the run-out platform 106 such that rolling of the plurality of rollers 118 along the path defined by the at least two rails 108 of the run-out platform 106 can enable translatory movement of the movable bed 114 in the longitudinal direction.

[0057] In an aspect, vertical height of the movable platform 112 can be adjusted by moving the run-out platform 106 in the vertical direction along the path defined by the at least two metal stands 102.

[0058] In an exemplary implementation, the movable bed 114 can be mounted over two shafts 116 at the ends of which a roller 118 is provided that can roll over the rails 108 of the run-out platform 106 in order to provide translatory movement of the movable bed 114 in the longitudinal direction.

[0059] FIG. 3 illustrates an exemplary representation of proposed system to automate movement and positioning of the movable bed of the proposed run-out table in accordance with an embodiment of the present disclosure. In an aspect, the proposed system 300 can include a run-out table 100, a cooling station 302 configured with at least one nozzle 304 and a microcontroller 306 that can control movement and positioning of a movable bed of the run-out table 100 in horizontal as well as in vertical direction to allow accurate adjustment of the movable bed with respect tip of the nozzle 304 in order to provide for optimal cooling of a metal strip 308, for instance, a steel strip or a cast iron strip, placed or fixated on the movable bed of the run-out table 100. In an aspect, the metal strip 308 can be fixated on the movable bed with the help of any or a combination of jigs, fixtures and clamps. [0060] In an aspect, the cooling station 302 can provide a fluid comprising any or a combination of water and air to be pumped to the at least nozzle 304 with the help of a pump. The nozzle 304 can spray the fluid onto the metal strip 308 either placed or fixated with the movable bed of the run-out table 100.

[0061] In an aspect, the metal strip 308 can initially be heated to a specific temperature, for instance, upper critical temperature of the metal strip, and can then be transferred to movable bed of the run-out table 100 that further transfers the strip 308 to the cooling station 302 such that when the strip 308 is in alignment with the nozzle 304, the nozzle can spray a fluid comprising any or a combination of water and air, over heated surface of the strip 308.

[0062] In an aspect, the cooling station 302 can include a plurality of components such as, but not limited to, pump, air compressor, pressure regulators, valves, etc., operations of which can be controlled by the microcontroller 306. For instance, a digital flow meter can be connected to the microcontroller 306 for accurate and real-time measurement of water flow rate during spraying of the fluid from the nozzle 304. The microcontroller 306 can also control timing of the spray.

[0063] In an aspect, the microcontroller 306 can be located at a desired distance from the cooling station 302 and the run-out table 100 and can wirelessly transmit signals to a computing device 312. The microcontroller 306 can wirelessly communicate with a computing device 312 such as a network device, a mobile phone, a computer, a laptop, a PDA, a controller and the likes to enable wireless and remote control as well as analysis of various parameters pertaining to the cooling process such as cooling rate of the metal strip, mass flow rate of the coolant, coolant pressure, inter-nozzle distance, strip to nozzle distance, strip movement speed and the likes.

[0064] In an aspect, a plurality of temperature sensors may be configured at various locations of the cooling station 302, the metal strip 308 and the run-out table 100 to enable automatic measurement of temperature at such locations, and temperature data can be automatically passed to the microcontroller 306 using a centrally controlled data logger.

[0065] In an aspect, control of the parameters pertaining to the cooling process and recording of temperature data as well as flow rate data can be carried out wirelessly through the computing device 312. The microcontroller 306 can include a wireless module which connects the microcontroller 306 to the computing device 312. In an aspect, a computer program is written and executed which sends operating signals to the components of the cooling station 302 and the mn-out table 100 such as, rotary devices, valves, gauges and the likes through the microcontroller 306. In an aspect, the microcontroller 306 can allow for high rate of data recording and analysis.

[0066] In an exemplary implementation, after the metal strip 308 is heated at a heating unit 310, the metal strip 308, at high temperature, is transferred to the run-out table 100, and the temperature of the strip 308 can be sensed by a thermocouple installed at a specific location of the run-out table 100. The temperature of the strip 308 can be recorded by the data logger and can be analyzed by the microcontroller 306 in order to process the temperature data, and to enable operation of the rotary device that can initiate movement of the movable bed of the run-out table 100 in longitudinal direction. Cooling process can be simultaneously started by the microcontroller 306 to enable spraying of the fluid over path of the run-out table 100. The microcontroller 306 can simultaneously check cooling rate of the strip 308 and can adjust speed of the movable bed by adjusting rotational speed of output shaft of the rotary device.

[0067] In an aspect, the proposed technique/mechanism can be retrofitted in existing run-out table mechanism without any major design iterations. It would be appreciated by a person skilled in the art that length of the proposed run-out table 100 is shorter than length of run-out tables used in conventional spray impingement cooling applications.

[0068] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms“comprises” and“comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C ....and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.

[0069] While embodiments of the present disclosure have been illustrated and described, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the disclosure, as described in the claims.