Patent Application
20230257842
Not Applicable
The present invention relates to the field of systems for coating flat products made of a ferromagnetic material, e.g. metal strips, in particular strips made of steel. More specifically, the invention relates to a correction apparatus, and to a related correction method, for correcting the planarity of a strip made of a ferromagnetic material moving during a molten metal coating process, e.g. a galvanizing process. The present invention further relates to a system for coating a metal strip with molten metal comprising such a correction apparatus.
As known, strips made of a ferromagnetic material are externally coated by means of a plurality of coating processes, e.g. by galvanizing.
The zone of the tank containing the bath of molten metal, e.g. zinc, is the heart of the coating process and affects system operation, process productivity, product quality, and zinc consumption.
In such coating processes, the moving metal strip is normally subject to deformations and vibrations, which are corrected by using some devices in order to improve the process productivity and optimize the zinc consumption.
A known example of a system for coating a metal strip is shown in
The sink deflector roll 3, which is proximal to the connection duct 17 considering the strip feeding path, deflects the strip exiting the annealing furnace 10 from an oblique position to a vertical position, defining the position of the air knives 15.
The other two sink rolls 60, 50, known as stabilizer rolls and having a smaller diameter than the sink deflector roll 3, are positioned on the vertical stretch of the strip feeding path, thus in series with respect to said sink deflector roll 3, and define a correction device for correcting the planarity of the strip.
In particular, the sink stabilizer roll 50 is distal from the sink deflector roll 3 and in a fixed position with respect to the feeding path of the metal strip 1. The sink stabilizer roll 50 is arranged on a first side of the feeding path, which is the same side on which the sink deflector roll 3 is arranged.
The sink stabilizer roll 60 is instead proximal to the sink deflector roll 3 and is positionable along a horizontal direction, transverse to the feeding path of the metal strip, so as to bend it in the opposite direction to the bending imparted by the sink deflector roll 3. In fact, the sink stabilizer roll 60 is arranged on a second side, opposite to the first side, of the feeding path, and is capable of performing a penetration with respect to the theoretical strip passage plane.
Disadvantageously, as shown in
Furthermore, the duration over time of the sink rolls is about two or three weeks. The main causes imposing the replacement of the sink rolls are:
Stopping the system to replace the several sink rolls in the tank, in addition to generating a large amount of waste material because part of the material is not processed correctly, results in a production loss and increased production costs of the system due to the energy consumption for the annealing furnace and the tank during the stop.
The need is thus felt to manufacture an innovative correction apparatus for correcting the planarity of the strip which allows the aforesaid drawbacks to be overcome.
It is the object of the present invention to manufacture a correction apparatus for correcting the planarity of a metal strip, advancing into a coating system, which is capable of reducing as much as possible, until almost eliminating, the crossbow effect of the strip caused by the combined effect of winding the strip about the sink deflector roll and applying a pull to said strip.
It is another object of the invention to manufacture a correction apparatus which allows reducing the number of sink rolls, and therefore reducing the stops of the system due to the replacement of said sink rolls, thus minimizing the production losses and energy costs associated with these stops.
It is another object of the invention to carry out a related method for correcting the planarity of the metal strip.
Therefore, the present invention aims to achieve the above-discussed objects by manufacturing a correction apparatus for correcting the planarity of a metal strip advancing into a coating system for coating said metal strip with a layer of molten metal, said apparatus comprising
wherein said correction device comprises at least two motorized rolls arranged outside the tank,
where a first motorized roll of said at least two motorized rolls is distal from said bridle roll, in a fixed position with respect to the metal strip feeding path, said first motorized roll being arranged on a first side of said feeding path;
where said bridle roll is also arranged on said first side;
and wherein a second motorized roll of said at least two motorized rolls is arranged on a second side, opposite to the first side, of said feeding path, is proximal to said bridle roll and movable along a trajectory which intersects a plane A, defined by the rotation axes X, Y of the bridle roll and the first motorized roll, respectively, in an intermediate position between said rotation axes X, Y, so as to bend the metal strip in the opposite direction to the bending imparted by said bridle roll.
Another aspect of the invention relates to a method for correcting the planarity of a metal strip advancing into a coating system for coating said metal strip with a layer of molten metal, the method being carried out by the aforesaid correction apparatus and comprising the following steps:
a) modifying, by means of the bridle roll, the direction of the feeding path of the metal strip exiting an annealing furnace;
b) modifying again, by means of the sink roll, the direction of the feeding path of the metal strip immersed in the tank;
wherein the step of correcting the planarity of the metal strip by means of the at least two motorized rolls of the correction device is provided between step a) and step b), by moving the second motorized roll along a trajectory which intersects the plane A, defined by the rotation axes X, Y of the bridle roll and the first motorized roll, respectively, in an intermediate position between said rotation axes X, Y, so as to bend said metal strip in the opposite direction to the bending imparted by said bridle roll.
Advantageously, the correction device is installed outside the molten metal tank, preferably immediately after the hot roll of the annealing furnace and before a connection duct of the furnace with the tank of the molten metal bath. Alternatively, the correction apparatus of the invention is installed downstream of the hot roll of the annealing furnace, but at least partially inside the connection duct of the furnace with the tank of the molten metal bath.
Therefore, the sink stabilizer rolls in the tank are no longer necessary with an apparent simplification of the system, and thus apparent benefits in terms of reducing the Capex and Opex.
The provision of the device for correcting the planarity of the strip equipped with at least two motorized rolls, of which one movable along the aforesaid trajectory which intersects the theoretical strip feeding plane, and of the fixed bridle roll on said theoretical feeding plane, allows correcting, in a more efficient manner, the crossbow effect of the coated strip, caused by the combined effect of winding the strip about the sink roll and applying a pull to said strip.
In particular, as shown in
A further improvement in the planarity of the strip is obtained by providing a correction device with three motorized rolls, of which the central motorized roll is movable along the trajectory which intersects the plane A, defined by the rotation axes X, Y of the bridle roll and the first motorized roll, respectively, in an intermediate position between said rotation axes X, Y, while the two lateral motorized rolls are fixed on said theoretical feeding plane. The two lateral motorized rolls are arranged on the same side as the bridle roll with respect to the path of the strip, while the central motorized roll is arranged on the opposite side.
Preferably, due to the aid of a measurement device for measuring the planarity of the metal strip, arranged downstream of the tank along the feeding path and communicating with a control system, which, in turn, can act in feedback on the second motorized roll to adjust the position thereof along the aforesaid trajectory, it is possible to adjust the planarity correction in case of the presence of residual errors downstream of the tank.
A further improvement in the correction of the planarity of the strip coated with molten metal can be obtained by providing, downstream of the tank, along the strip feeding path, at least one pair of electromagnetic stabilizer devices. At least one further measurement device for measuring the planarity of the metal strip, for example comprising position transducers based on the eddy currents or at least one laser scanning system, can be arranged close to said stabilizer devices and communicating with the aforesaid control system, which can thus further act in feedback on the second motorized roll to adjust again the position thereof along said trajectory, allowing the optimization of the planarity correction.
Other advantages of the invention are:
The dependent claims describe preferred embodiments of the invention.
Further features and advantages of the invention will become more apparent in the light of the detailed description of preferred, but not exclusive, embodiments of an apparatus shown by way of non-limiting example, with the aid of the accompanying drawings, in which:
The same reference numerals in the figures identify the same elements or components.
With reference to
In all embodiments of the invention, such a correction apparatus comprises
Advantageously, only one correction device 4 is provided, arranged between the bridle roll 2 and the sink roll 3. In particular, according to the invention, the presence of further correction devices is excluded; in particular, the presence of a further correction device comprising sink rolls inside the tank 11 and/or other rolls arranged downstream of said tank 11 is excluded.
Two bridle rolls 2, 2′ are shown in
Advantageously, the correction device 4 comprises at least two motorized rolls 5, 6 arranged outside the tank 11, therefore never immersed in the molten metal, e.g., zinc. Said at least two motorized rolls 5, 6 are not bridle rolls.
A first motorized roll 5 of said at least two motorized rolls is distal from the bridle roll 2 and in a fixed position with respect to the feeding path of the metal strip 1, said first motorized roll 5 being arranged on a first side of said feeding path. The bridle roll 2 is also arranged on said first side. A second motorized roll 6 of said at least two motorized rolls is arranged on a second side, opposite to the first side, of the feeding path, is proximal to the bridle roll 2 and movable along a trajectory which intersects a plane A, defined by the rotation axes X, Y of the bridle roll 2 and the first motorized roll 5, respectively, in an intermediate position between said rotation axes X, Y so as to bend the metal strip in the opposite direction to the bending imparted by the bridle roll 2 (
In a variant, the longitudinal axis of the second motorized roll 6 can move along a transverse plane, e.g. perpendicular, to the theoretical strip feeding plane, and which intersects said theoretical strip feeding plane between the bridle roll 2 and the fixed motorized roll 5.
Instead, in a further variant, the longitudinal axis of the second motorized roll 6 can move along a curved surface which intersects the theoretical strip feeding plane between the bridle roll 2 and the fixed motorized roll 5.
In particular, in both variants, the longitudinal axis of the second motorized roll 6 is parallel to said theoretical feeding plane and can move with respect to the latter along said transverse plane or said curved surface in a first direction or in a second direction, opposite to the first direction, so as to adjust the aforesaid localized plastic deformation, the second motorized roll 6 more or less penetrating said theoretical plane, e.g., along the direction of the strip thickness.
In the zone between the bridle roll 2 and the sink roll 3, theoretical strip feeding plane means a tangent plane, in common with the bridle roll 2 and the sink roll 3, which is tangent in the zone where the strip leaves the bridle roll 2 and in the zone where the strip starts being wound onto the sink roll 3, respectively.
Since the sink roll 3 is the only roll immersed in the molten metal of the tank 11, the support arms (not shown) of the sink roll 3, which is preferably idle, are the only support arms partially immersed in the molten metal.
Preferably, the tank 11 is a tank internally coated with a ceramic material and internally provided with heaters (not shown), e.g., heaters based on the magnetic field obtained with suitable inductors, to melt the metal ingots, e.g., zinc, and keep the molten metal moving and at temperature.
In a first embodiment of the apparatus of the invention, shown in
In a second embodiment of the apparatus of the invention, shown in
In both embodiments, there can be provided
The measurement device 13 can comprise, or consist of, at least one laser scanning system.
At least one pair of air knives 15, e.g., only one pair of air knives, can be arranged downstream of the tank 11 along the feeding path. A first air knife is arranged at the first side of the feeding path and a second air knife is arranged at the second side of said feeding path. The air knives remove excess molten metal from the metal strip, thus allowing the coating thickness provided by the specifications of the coated product to be obtained.
The measurement device 13 is arranged upstream or downstream of the at least one pair of air knives 15 along the feeding path.
Preferably, there is provided at least one pair, e.g., only one pair, of electromagnetic stabilizer devices 16, arranged downstream of the tank 11 along the feeding path. A first electromagnetic stabilizer device is arranged at the first side of the feeding path and a second electromagnetic stabilizer device is arranged at the second side of said feeding path. This electromagnetic damping system has the dual purpose of removing or controlling the vibration of the strip, if the vibration level produced by the bearings of the sink roll 3 is not acceptable, and optionally correcting a residual planarity error of the strip profile.
If the electromagnetic stabilizer devices 16 are provided, the control system 14 is adapted to acquire further planarity data, from at least one further measurement device 13′ associated with the at least one pair of electromagnetic stabilizer devices 16, and adapted to send a further control signal to the correction device 4 to possibly adjust the position of the second motorized roll 6 along the aforesaid trajectory.
At least one pair of electromagnetic stabilizer devices 16 can be arranged downstream of the at least one pair of air knives 15 along the metal strip feeding path.
Therefore, the measurement device 13 close to the air knives 15 and the measurement device 13′ close to the optional electromagnetic stabilizer devices 16 are connected, by means of respective interfaces, to the control system 14 which automatically adjusts the position of the second motorized roll 6 along the trajectory intersecting plane A.
Preferably, the correction device 4 comprises a movement mechanism for moving the second motorized roll 6 along said trajectory. Therefore, the control system 14 sends the control signals to said movement mechanism. For example, such a movement mechanism can be selected from the following: pneumatic, hydraulic, mechanical, electromechanical actuators, or the like.
In the embodiments shown in the Figures, the bridle roll 2 and the two or three motorized rolls 5,6,7 are preferably arranged inside an end part of the annealing furnace 10, preferably upstream of a connection duct 17, which connects said end part of the annealing furnace 10 to the tank 11.
In a variant, the two or three motorized rolls 5, 6, 7 are arranged, at least partially, inside the connection duct 17.
In all embodiments of the invention, the two or three motorized rolls 5, 6, 7 are preferably coated with tungsten carbide or another suitable ceramic coating, which ensures a high wear resistance thereof.
The two or three rolls 5, 6, 7 are motorized in order to avoid any possible slippage with respect to the advancing strip.
The position of the second motorized roll 6 is detected by a convenient position transducer, or another suitable position sensor, and the signal containing the data of this position is sent to the control system 14.
In all embodiments of the invention, the sink roll 3 has a diameter D3 which is much greater than the diameter D1 of the two or three motorized rolls 5, 6, 7 of the correction device 4. The diameter D2 of the bridle roll 2 can have a value which is greater than or equal to D3 or can have an intermediate value between D1 and D3.
For example, in a first variant, the diameter D3 of the sink roll 3 can be between 600 and 1000 mm; the diameter D2 of the bridle roll 2 can be between 600 and 1200 mm; and the diameter D1 of the two or three motorized rolls 5, 6, 7 can be between 150 and 400 mm.
Preferably, the ratio D3/D1 is from 1.5 to 6.6, the ratio D3/D2 is from 0.5 to 1.6, and the ratio D2/D1 is from 1.5 to 8.
For example, instead, in a second variant, the diameter D3 of the sink roll 3 can be between 600 and 1000 mm; the diameter D2 of the bridle roll 2 can be between 400 and 900 mm; and the diameter D1 of the two or three motorized rolls 5, 6, 7 can be between 150 and 400 mm.
Preferably, the ratio D3/D1 is from 1.5 to 6.6, the ratio D3/D2 is from 0.6 to 2.5, and the ratio D2/D1 is from 1 to 6.
In alternative variants, the motorized roll 5 and the optional motorized roll 7 can have a different diameter than the diameter D1 of the motorized roll 6.
Preferably, with reference to the second embodiment, the distance along the strip feeding plane between the motorized rolls 5 and 7 is between 1.05 D1 and 2 D1, preferably between 1.5 D1 and 2 D1 (where, for example, 1.05 D1 means 1.05 times D1, and so on). The motorized roll 6, on the opposite side of the strip with respect to rolls 5, 7, is arranged within this distance.
Preferably, with reference to the first embodiment, the distance along the feeding path of the metal strip 1 between the first motorized roll 5 and the bridle roll 2 is between 1.05 D2 and 2 D2, preferably between 1.5 D2 and 2 D2, said second motorized roll 6 being arranged within this distance.
The sink roll 3, which is preferably idle, is preferably coated with tungsten carbide or another suitable ceramic coating, which ensures a high wear resistance thereof.
The bearings allowing the idle sink roll 3 to roll are designed so as to ensure a service life of more than three months of continuous working, in order to limit the vibrations generated by the sink roll 3 due to the wear of the bearings. Such bearings can be of the rolling type, for example made of metals or ceramics which are resistant to wear caused by the mechanical and chemical stresses of the tank.
A method for correcting the planarity of a metal strip 1 advancing into a coating system, such as that shown in
Such a method comprises the following steps:
wherein the correction of the planarity of the metal strip by means of the at least two motorized rolls 5, 6 of the correction device 4 is provided between step a) and step b), preferably only between step a) and step b), by moving the second motorized roll 6 along a trajectory which intersects the plane A, defined by the rotation axes X, Y of the bridle roll 2 and the first motorized roll 5, respectively, in an intermediate position between said rotation axes X, Y, so as to bend the metal strip in the opposite direction to the bending imparted by the bridle roll 2.
The sink roll 3 deflects the strip exiting the annealing furnace 10, in particular exiting the connection duct 17, from an oblique position with respect to the vertical to a substantially vertical position that defines the position of the possible air knives 15.
Preferably, in order to correct the planarity of the metal strip, the following steps are included:
The measurement of the planarity of the metal strip 1 can be carried out upstream or downstream of the at least one pair of air knives 15. At the outlet of the tank 11, the profile and therefore the planarity of the strip can be measured or detected by a suitable scanning system based on laser technology. The value of the static shape defects, such as the crossbow, present on the strip is then sent to the control system 14 for a possible feedback on the second motorized roll 6.
Furthermore, if the electromagnetic stabilizer devices 16 for correcting the planarity of the metal strip are provided, the following steps are also included:
The electromagnetic stabilizer devices 16 allow reducing the amplitude of the vibration of the strip in the zone of the air knives 15 and simultaneously improving the shape of the strip by reducing the amplitude of the static shape defects, such as the crossbow.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102020000016012 | Jul 2020 | IT | national |
This application claims priority to PCT International Application No. PCT/IB2021/055965 filed on Jul. 2, 2021, which application claims priority to Italian Patent Application No. 102020000016012 filed on Jul. 2, 2020, the entire disclosures of which are expressly incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2021/055965 | 7/2/2021 | WO |
