Patent Description:
During metal processing, rolling may be used to reduce a thickness of a metal substrate (such as stock sheets or strips of aluminum, aluminum alloys, or various other metals) by passing the metal substrate through a pair of work rolls. Depending on the desired properties of the final metal product, the metal substrate may be hot rolled, cold rolled, and/or warm rolled. Hot rolling generally refers to a rolling process where the temperature of the metal is above the recrystallization temperature of the metal. Cold rolling generally refers to a rolling process where the temperature of the metal is below the recrystallization temperature of the metal. Warm rolling generally refers to a rolling process where the temperature of the metal is below the recrystallization temperature but above the temperature during cold rolling.

The line speed of the metal substrate exiting the last stand of a rolling mill is often limited by the temperature of the metal substrate as it exits the rolling mill because the exit temperature influences the material properties of the metal substrate and/or aspects of a coil of the metal substrate such as flatness. Operating a rolling mill at higher speeds or reductions may lead to a situation where the cooling from the work rolls of the rolling mill cannot remove enough deformation energy to maintain the metal product below a critical softening temperature, and the metal substrate above the critical softening temperature may be susceptible to substrate quality issues such as water staining, sagging, or off flatness. Accordingly, rolling mills are typically run at reduced speeds, but such reduced speeds limit the capacity of the rolling mill. <CIT> discloses a quenching system for quenching a rolled metal substrate. To quench the metal substrate, the quenching system distributes a cooling agent thereon. Specifically, the system includes multiple top nozzles and bottom nozzles for distributing the cooling agent to reduce the metal strip temperature from an initial temperature to an intermediate temperature. Thereafter, once the intermediate temperature is reached, the top nozzles stop distributing the cooling agent and the bottom nozzles continue distributing the same, until the strip's temperature declines from the intermediate temperature to a target temperature. <CIT> discloses a cooling device for a hot-rolled steel sheet, which cools a top surface of the sheet conveyed on conveyor rolls after hot rolling. The cooling device includes a first set of cooling nozzles that j et/spray cooling water vertically downwards over a top surface of a hot-rolled steel sheet and a second set of cooling nozzles jet cooling water vertically upwards on a bottom surface of the hot-rolled cooling sheet. First and second measuring devices are provided in a row in the width direction of the strip for measuring the temperature of the sheet in the width direction on the upstream side and the downstream side of the first and second sets of cooling nozzles. A control device controls the operations of the first and second nozzle sets based on either or both of measurement results of the first measuring devices and measurement results of the second measuring devices.

Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

The present invention provides a cooling system for a metal processing system according to the subject matter of independent claim <NUM>, a cold rolling mill with such a cooling system according to claim <NUM> and a cold rolling mill with such a cooling system according to claim <NUM>.

According to various embodiments, a cold rolling mill includes an exit stand and a cooling system downstream from the exit stand. The cooling system includes a cooling header configured to selectively dispense a coolant onto a metal substrate exiting the exit stand.

According to some embodiments, a cold rolling mill includes an exit stand and a cooling system downstream from the exit stand. The cooling system includes a cooling header that includes a plurality of nozzles. Each nozzle of the plurality of nozzles is configured to selectively dispense a coolant onto a metal substrate exiting the exit stand. The cooling system also includes a controller that is communicatively coupled with the cooling header and is configured to individually control each nozzle of the plurality of nozzles.

Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure.

The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as "up," "down," "top," "bottom," "left," "right," "front," and "back," among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

Described herein are cooling systems and methods for cooling a metal substrate such as aluminum or aluminum alloys during metal processing. Metal processing systems may include, but are not limited to, hot rolling mills, cold rolling mills, and warm rolling mills. As such, while the following description refers to cold rolling mills, the embodiments described herein are not limited to such metal processing systems and may be utilized in various other types of metal processing systems as desired. Moreover, the embodiments are not limited to use on aluminum or aluminum alloys, but may be used with any desired metal including, but not limited to, For example, the substrate may include steel, steel-based materials, magnesium, magnesium-based materials, copper, copper-based materials, or any other suitable metal.

In some aspects, the cooling system for the metal processing system such as cold rolling is positioned downstream from a last (or exit) stand of the rolling mill. In various aspects, the cooling system is between the last stand of the rolling mill and a rewinder of the metal processing system and may be used to control the exit temperature of the metal substrate before coiling at the rewinder.

The cooling system may include a cooling header, an exhaust system, one or more temperature sensors, and a controller. The cooling header may include one or nozzles, and each of the one or more nozzles may be independently controlled such that a cooling profile of the coolant across a width of the metal substrate can be selectively controlled. The cooling header may selectively dispense a coolant onto the metal substrate as a super fine mist or micronized droplets. In certain examples, to maximize the duration and/or amount of cooling from the coolant, the cooling header may be positioned proximate to the last stand of the rolling mill. In various aspects, the cooling header may be positioned proximate to the last stand to maximize the allowed time for coolant evaporation. Additionally, placing the cooling header proximate to the roll could reduce the chance of decrease in cooling efficiency due to the laminar air flow generated by the high speed surface (e.g., because laminar air flow need time to accelerate).

The exhaust system includes one or more removal devices that remove coolant after the coolant has been dispensed from the cooling header and removed at least some of the heat from the metal substrate. In certain aspects, the one or more removal devices are positioned a predetermined distance downstream from the cooling header. The predetermined distance may optionally correspond to a duration of cooling at a predetermined line speed. Optionally, the predetermined line speed may be a maximum line speed, although it need not be in other examples. In some non-limiting examples, the maximum line speed may be about <NUM>/min, although it may be other line speeds as desired and as discussed in detail below. Additionally or alternatively, the predetermined distance may optionally correspond to an amount of cooling or heat transfer of the coolant at a predetermined rate at which the coolant is dispensed from the cooling header. In other examples, the one or more removal devices may be positioned as desired relative to the cooling header.

The one or more temperature sensors may be positioned downstream from the cooling header and/or optionally upstream from the cooling header. Each temperature sensor may detect a temperature profile of the metal substrate across the width of the metal substrate. The controller may be communicatively coupled to the one or more temperature sensors and the cooling header. In various examples, the controller may control the cooling header based on a detected temperature profile from the one or more temperature sensors such that the cooling header provides a desired cooling profile. Optionally, the cooling profile may be an amount of cooling at a predetermined line speed such that the exit temperature of the metal substrate is at or below a critical softening temperature of the metal substrate and/or a desired coiling temperature of the metal substrate. In some cases, the predetermined line speed may be <NUM>/min, although it need not be in other examples. The critical softening temperature is the temperature at which the metal substrate starts to overheat and becomes susceptible to surface problems such as off flatness, water staining, etc. In various examples, the critical softening temperature may depend on the material composition of the metal substrate and/or a gauge of the metal substrate.

<FIG> illustrates an example of a metal processing system <NUM> that includes at least one work stand <NUM> of a rolling mill <NUM> and a cooling system <NUM> according to various embodiments. In the example of <FIG>, the rolling mill <NUM> is a cold rolling mill, although in other examples, the rolling mill <NUM> may be a warm rolling mill and/or a hot rolling mill as desired. While a single work stand <NUM> is illustrated, it will be appreciated that in other examples the rolling mill <NUM> may include a plurality of work stands <NUM>, such as two work stands <NUM>, three work stands <NUM>, four work stands <NUM>, or any other desired number of work stand <NUM>. The work stand <NUM> includes a pair of vertically aligned work rolls 108A-B. In the example of <FIG>, the work stand <NUM> also includes backup rolls 106A-B that support the work rolls 108A-B. In other examples, the work stand <NUM> may also include intermediate rolls. A roll gap <NUM> is defined between the work rolls 108A-B, and metal substrate <NUM> such as an aluminum or aluminum alloy sheet is passed through the roll gap <NUM> along a passline in a processing direction (represented by arrow <NUM>). In various examples, the work stand <NUM> is the last or exit stand of the rolling mill <NUM>, and the metal substrate <NUM> exiting the work stand <NUM> is passed to the cooling system <NUM> before it is coiled as a coil <NUM> with a rewinder. <FIG> illustrates the metal substrate <NUM> being coiled into the coil <NUM> in an over-wind configuration, but it will be appreciated that in other examples, the metal substrate <NUM> may be coiled in an under-wind configuration (see <FIG>).

The cooling system <NUM> includes a cooling header <NUM>, an exhaust system <NUM>, a temperature sensor <NUM>, and a controller <NUM>. In various examples, and as illustrated in <FIG>, the cooling system <NUM> may be between the exit stand <NUM> and a rewinder that forms the coil <NUM> of the metal substrate <NUM>.

The cooling header <NUM> may selectively dispense a coolant <NUM> onto the surface of the metal substrate <NUM> after it has exited the work stand <NUM>. The coolant <NUM> may be various suitable materials for removing heat from the metal substrate <NUM>. As one non-limiting example, the coolant <NUM> may be water or a cooling gas, although other suitable coolants may be utilized. In one non-limiting example, the cooling header <NUM> may be an atomizing spray header, although various other suitable types of headers may be utilized. In various examples, to maximize the allowed coolant evaporation time, the cooling header <NUM> may be positioned downstream of and proximate to the work stand <NUM> of the rolling mill <NUM>. In various examples, the cooling header <NUM> is positioned on one side of the passline of the metal substrate <NUM>. In the example of <FIG>, the cooling header <NUM> is positioned above the passline of the metal substrate <NUM>, although in other examples, the cooling header <NUM> may be positioned below the passline of the metal substrate <NUM>. In various examples, the cooling header <NUM> is positioned on the side of the passline of the metal substrate <NUM> that is opposite from the coil <NUM>. For example, in the over-wind configuration illustrated in <FIG>, the cooling header <NUM> is positioned above the passline of the metal substrate <NUM> while in an under-wind configuration, the cooling header <NUM> may be positioned below the passline of the metal substrate <NUM> (see <FIG>). In various examples, positioning the cooling header <NUM> on one side of the passline (and optionally on the side opposite from the coil <NUM>) may maximize an amount of time for heating and removal of the coolant from the metal substrate <NUM>. In other examples, the spray header may be positioned on both sides of the metal substrate.

The cooling header <NUM> may optionally include one or more nozzles that collectively extend across a width (or a portion of a width) of the metal substrate <NUM>. The nozzles are configured to dispense the coolant as micronized droplets or a super fine mist and may be various suitable types of nozzles for dispensing the coolant as micronized droplets or the super fine mist. Without being bound by any theory, it is believed that the micronized droplets increase the heat transfer efficiency (and thus cooling rate) of the coolant, provide a more uniform coolant distribution on the metal substrate <NUM>, and reduce the Leidenfrost effect, which may occur when material having a temperature higher than the boiling temperature of the coolant is immersed or contacted with the coolant. In other examples, the micronized droplets may provide improved heat transfer at a line speed less than about <NUM>/min.

In some embodiments, and as discussed in the following examples, the metal processing system <NUM> may use various other techniques or methods for dispensing the coolant to overcome the Leidenfrost effect. In such embodiments, the metal processing system <NUM> and/or the cooling system <NUM> includes one or more cooling features that modify (e.g., increase or decrease) a Leidenfrost point of the coolant to minimize or prevent the Leidenfrost effect at these temperatures and/or while the metal substrate is cooled from a first temperature (to a second temperature that is less than the first temperature. In some non-limiting examples, the cooling features may modify the Leidenfrost point to be up to about <NUM>, although in other embodiments it may be controlled to other temperatures as desired. Such cooling features may include, but are not limited to, controlling a coolant droplet size, providing an electrical charge of the coolant and/or the metal substrate, and/or providing a predetermined surface geometry of the metal substrate. In certain aspects, the cooling feature may modify the Leidenfrost point to reduce and/or prevent the formation of a vapor layer while the metal substrate is at the aforementioned temperatures and/or being cooled from a first temperature to a second temperature that is less than the first temperature.

In some embodiments, one or more of the cooling features may be controlled to increase the Leidenfrost point of the coolant. In such embodiments, the increased Leidenfrost point may allow the liquid coolant to rapidly cool a metal substrate through nucleate boiling at higher temperatures and reduce the time window in which unfavorable phase-transformations are occurring. The increased Leidenfrost point may also allow for lower volumes of liquid to be used for quenching to achieve a desired cooling rate. In various embodiments, the cooling feature(s) may be selectively controlled during metal processing such that quenching efficiency is improved while reducing the total volume of coolant needed to obtain a desired metal substrate temperature. In some aspects, the cooling system <NUM> with cooling feature(s) may promote rapid cooling of the metal substrate compared to traditional cooling systems. The cooling feature(s) may minimize and/or prevent problems with the metal substrate such as off flatness, water staining, etc. by controlling the amount of coolant dispensed on the metal substrate. Furthermore, such methods can mitigate the damaging impact of the Leidenfrost effect on cooling by ensuring a liquid coolant goes through nucleate boiling rather than sit suspended above a vapor layer on the surface of the metal substrate.

In one non-limiting example, the metal processing system <NUM> may form droplets of coolant having a reduced size, such as from about <NUM>-<NUM>, such as about <NUM>, such as less than or equal to <NUM>. The metal processing system <NUM> may form the droplets having the reduced size using various techniques or systems as desired, including but not limiting to mixing the coolant with air, ultrasonic techniques, providing the coolant through small physical holes, using a rotating disc, using vibration, various combinations thereof, or other techniques or systems as desired. <FIG> illustrates an example of the metal substrate <NUM> with micronized droplets <NUM> that are able to reach the surface of the metal substrate <NUM> without being suspended above a vapor layer. In some cases, due to the reduced volume and surface profile of the micronized droplets <NUM>, a vapor layer capable of supporting a larger volume of water is not able to form and the micronized droplets <NUM> are able to cool the surface of metal substrate <NUM>.

In another non-limiting example, the metal processing system <NUM> may use non-neutral electrical charges when applying the coolant. In such examples, the metal processing system <NUM> may induce an electrical charge on the surface of the metal substrate <NUM> prior to applying coolant to the metal substrate <NUM> using the cooling system <NUM>, and the coolant applied to the metal substrate <NUM> may have an electrical charge that is opposite the electrical charge on the surface of the metal substrate <NUM>. <FIG> illustrates an example of the metal substrate <NUM> when the cooling feature includes a non-neutral electric charge <NUM> of the coolant <NUM> and an opposite non-neutral electric charge <NUM> of the surface of the metal substrate <NUM>. In one non-limiting embodiment, the non-neutral electric charge <NUM> may be induced in the coolant <NUM> by passing the coolant through a means of electrostatic induction prior to application to the metal substrate <NUM>. Alternatively, the coolant <NUM> may be a naturally occurring, polar fluid, where a net charge is present throughout the coolant <NUM>. The non-neutral electric charge <NUM> may be induced in the metal substrate <NUM> by means of electrostatic induction, application of an electric field, or any other method or combinations of methods wherein a charge can be held present at a surface boundary of the metal substrate <NUM>. In some cases, the charge <NUM> may be induced prior to receiving the metal substrate <NUM> in the cooling system <NUM>, or may be applied at the time of cooling. In <FIG>, the electric charge <NUM> of the coolant <NUM> is negative and the electric charge <NUM> of the surface of the metal substrate <NUM> is positive, although embodiments exist where the charge profile is reversed. In these embodiments, the attractive forces that form between coolant electric charge <NUM> and metal substrate electric charge <NUM> modify the Leidenfrost point of the coolant <NUM>, changing the temperature at which a trapped vapor layer forms.

In yet another non-limiting example, the metal processing system <NUM> may use a surface geometry of the metal substrate <NUM> to modify the Leidenfrost point of the coolant. In such examples, the surface geometry of the metal substrate <NUM> (e.g., a roughness, surface profile, flatness distribution, etc.) may be modified prior to applying the coolant to the metal substrate <NUM> using various techniques. <FIG> illustrates an example of the metal substrate <NUM> when the cooling feature includes surface texture <NUM> on the metal substrate <NUM>. In this embodiment, the surface texture <NUM> provides a roughness profile of metal substrate <NUM> that may lend itself to breaking up a vapor layer that may form when metal substrate <NUM> is above a Leidenfrost point of the coolant <NUM> and without surface modifications. The surface of metal substrate <NUM> may be modified at any point prior to cooling using various means or techniques, including but not limited to textured rolls, imparting abrasions, or other means not limited by this disclosure. The modifications may occur at a point upstream of the cooling system <NUM>. In these examples, altered surface properties or geometries that help alleviate the Leidenfrost effect include, but are not limited to, a roughness, a distribution of micro-valleys, and/or other surface-area altering modifications. In certain embodiments, modifying the surface geometry may mitigate the effects of the Leidenfrost effect by creating greater amounts of surface area for the coolant <NUM> to interface with the metal substrate <NUM>. In some cases, the surface profile allows downward surface tension to overcome some of the effects of an upwards vapor layer, resulting in the desired nucleate boiling, and thus, rapid cooling.

The previous examples are provided for illustrative purposes and should not be considered limiting as other techniques may be used as desired in other embodiments. Moreover, the cooling system <NUM> need not necessarily use any of the aforementioned techniques to dispense coolant on the metal substrate <NUM>.

As discussed in detail below, each of the nozzles of the cooling header <NUM> may be independently controlled by the controller <NUM> to provide a desired cooling profile.

Referring back to <FIG> and <FIG>, the exhaust system <NUM> is positioned downstream from the cooling header <NUM>. In some optional examples, the exhaust system <NUM> is a predetermined distance downstream from the cooling header <NUM> that corresponds to a desired cooling rate and/or cooling duration at a predetermined line speed. In other examples, the exhaust system <NUM> may be positioned at various distances relative to the cooling header <NUM> as desired.

The exhaust system <NUM> includes a removal device <NUM> that is positioned below the passline of the metal substrate <NUM>. In some cases, the removal device <NUM> is on the same side of the passline as the cooling header <NUM>, although it need not be in other examples. In the example of <FIG>, the removal device <NUM> and cooling header <NUM> are positioned on opposing sides of the passline. The removal device <NUM> may be various suitable devices that may selectively generate a suction or vacuum force (represented by arrow <NUM>) that gathers or otherwise collects coolant after it has been heated by the metal substrate <NUM>. In one non-limiting example, the removal device <NUM> may be a vacuum nozzle and/or vacuum system. In certain embodiments, the removal device <NUM> may be at least a <NUM> CFM vacuum, such as a <NUM> CFM vacuum, although in other embodiments, the air flowing through vacuum system may be other rates as desired. In some non-limiting examples, the vacuum may further assist with cooling of the metal substrate <NUM>. In other cases, other suitable removal devices <NUM> may be utilized. In one non-limiting example, the coolant is water, and the removal device <NUM> is configured to remove the heated coolant in the form of steam. The removal device <NUM> may be dimensioned to extend across the width (or a portion of the width) of the metal substrate <NUM> such that the heated coolant may be removed across the width (or a portion of the width) of the metal substrate <NUM>.

The exhaust system <NUM> optionally includes a removal device <NUM>. In various cases, the removal device <NUM> may be above the passline of the metal substrate <NUM>. In various aspects, the removal device <NUM> is proximate to the top surface to remove any residue coolant that may sit on the metal. Optionally, one or more edge removal devices (such as blowers or other suitable devices) may be provided at the bottom side to prevent any top surface coolant from wrapping around the metal edges and wetting the bottom side. Compared to the removal device <NUM>, the removal device <NUM> may be any suitable device that may selectively generate a directing or guiding force (represented by arrow <NUM>) onto coolant that at least directs coolant off the metal substrate <NUM> and optionally towards the removal device <NUM>. In one non-limiting example, the removal device <NUM> is an air mover or a blower, although other suitable removal devices may be utilized. In some cases, the removal device <NUM> may be vertically aligned with the removal device, although it need not be in other examples.

As illustrated in <FIG>, the temperature sensor <NUM> may be downstream from the cooling header <NUM>. The temperature sensor <NUM> is adapted to detect a temperature profile of the metal substrate <NUM> across the width of the metal substrate <NUM> during processing. The temperature sensor <NUM> may positioned on either side of the passline of the metal substrate <NUM> as desired. If more than one temperature sensor <NUM> is used, they may be positioned on the same or opposite sides of the passline of the metal substrate <NUM>.

The controller <NUM> is communicatively coupled to the temperature sensor <NUM> and receives the detected temperature profile of the metal substrate <NUM> from the temperature sensor <NUM>. The controller <NUM> is also communicatively coupled to the cooling header <NUM>. In various examples, the controller <NUM> may control the cooling header <NUM> based on the detected temperature profile and/or such that the cooling header <NUM> dispenses the coolant pursuant to a cooling profile. In some cases, the controller <NUM> may determine the cooling profile by comparing the detected temperature profile from the temperature sensor <NUM> with a predetermined temperature profile. Optionally, the predetermined temperature profile may be the critical softening temperature of the metal substrate <NUM> and/or a desired coiling temperature of the metal substrate, although it need not be in other examples. In various examples, the cooling profile may correspond to a cooling rate or amount of cooling that the coolant provides at a predetermined line speed. In various aspects, the predetermined line speed is an increased line speed compared to a typical line speed. In some non-limiting examples, a typical line speed may be less than or equal to about <NUM>/min, and the increased line speed may be line speeds greater than about <NUM>/min, such as about <NUM>/min. In other examples, the predetermined line speed may be less than about <NUM>/min or greater than about <NUM>/min. In various aspects, the cooling profile may be controlled by controlling one or more of a spray pattern of coolant from one or more nozzles individually, a spray pattern of the coolant being dispensed across the width of the metal substrate <NUM>, a flow rate of coolant from one or more nozzles, a duration at which the coolant is dispensed from one or more nozzles, how many of the one or more nozzles are activated or turned on, or other suitable characteristics or controls as desired. Accordingly, controlling the cooling header <NUM> such that the coolant is dispensed pursuant to the cooling profile may include one or more of controlling an air pressure in one or more of the nozzles of the cooling header <NUM>, controlling a coolant (or water) pressure of one or more nozzles of the cooling header <NUM>, controlling a flow rate of the coolant from one or more nozzles of the cooling header <NUM>, controlling a duration at which the coolant is dispensed, controlling a spray pattern of one or more nozzles individually, controlling a spray pattern across the width of the metal substrate <NUM>, controlling how many of the one or more nozzles are activated or turned on, or various other suitable controls. In one non-limiting example, the cooling header <NUM> may be controlled such that a flow rate of the coolant is at least <NUM> liters/minute, such as <NUM> liters/minute, although in other examples the flow rate may be adjusted as desired. In some optional examples, the cooling header may be utilized to correct a tight edges problem based on flatness input from a shape roll.

<FIG> illustrates a metal processing system <NUM> with the rolling mill <NUM> and a cooling system <NUM> according to various embodiments. Compared to the metal processing system <NUM>, the metal substrate <NUM> is coiled in an under-wind configuration.

The cooling system <NUM> is substantially similar to the cooling system <NUM> except that the cooling system <NUM> includes the cooling header <NUM> below the passline of the metal substrate <NUM> and on the same side of the passline as the removal device <NUM>. Compared to the cooling system <NUM>, the cooling system <NUM> also includes a temperature sensor <NUM> that is substantially similar to the temperature sensor <NUM> but is upstream from the cooling header <NUM>. In various cases, the controller <NUM> may be communicatively coupled to the temperature sensor <NUM> and may control the cooling header <NUM> based at least partially on a detected temperature profile from the temperature sensor <NUM>. As one non-limiting example, the temperature sensor <NUM> may detect a temperature profile across the width of the metal substrate <NUM> after it exits the work stand <NUM> and prior to cooling with the cooling system <NUM>. In this example, the controller <NUM> may compare the detected temperature profile from the temperature sensor <NUM> with the detected temperature profile from the temperature sensor <NUM> to determine an actual rate of cooling that the coolant from the cooling header <NUM> provides. In some cases, the controller <NUM> may control the cooling header <NUM> based on a difference between the actual rate of cooling and a desired rate of cooling (e.g., such that the metal substrate has a desired temperature profile).

<FIG> and <FIG> illustrate a metal processing system <NUM> with a rolling mill <NUM> and a cooling system <NUM> according to various embodiments. The rolling mill <NUM> is substantially similar to the rolling mill <NUM> and includes at least one work stand <NUM> that has work rolls 308A-B and intermediate rolls 306A-B. As best illustrated in <FIG>, the work stand <NUM> includes a coolant containment box <NUM> that may collect any coolant that may be directed onto the intermediate rolls 306A-B to limit or prevent the coolant from contacting the metal substrate <NUM>. Similar to the metal processing system <NUM>, the metal substrate <NUM> processed by the metal processing system <NUM> is coiled in an under-wind configuration to form a coil <NUM> of the metal substrate <NUM>.

The cooling system <NUM> is substantially similar to the cooling system <NUM> and includes a cooling header <NUM>, an exhaust system <NUM> with the removal device <NUM> and the removal device <NUM>, and a temperature sensor <NUM> downstream from the cooling header <NUM>. As represented by the triangle <NUM>, the temperature sensor <NUM> may detect a temperature profile of the metal substrate <NUM> across the width of the metal substrate <NUM>. Although not illustrated in <FIG> and <FIG>, the cooling system <NUM> also includes a controller that is communicatively coupled with the cooling header <NUM> and the temperature sensor <NUM>. Compared to the cooling system <NUM>, the cooling system <NUM> does not include a temperature sensor upstream from the cooling header <NUM>.

As best illustrated in <FIG>, the cooling header <NUM> may include a plurality of nozzles <NUM>, and the cooling header <NUM> is dimensioned to extend across the width of the metal substrate <NUM>. The number, type, and arrangement of nozzles <NUM> should not be considered limiting. In various aspects, the controller of the cooling system <NUM> may independently control each nozzle <NUM> such that the cooling header <NUM> provides the desired cooling profile. In other examples, the controller of the cooling system <NUM> may control at least one nozzle <NUM> in conjunction with another nozzle <NUM>.

Referring to <FIG> and <FIG>, the removal device <NUM> of the exhaust system <NUM> is a vacuum nozzle and the removal device <NUM> of the exhaust system <NUM> is a blower. As best illustrated in <FIG>, the removal device <NUM> is dimensioned to extend across the width of the metal substrate <NUM>.

In some optional examples, the cooling system <NUM> includes a recirculation system <NUM> that is in fluid communication with the exhaust system <NUM> and the cooling header <NUM>. In these examples, coolant that is collected by the exhaust system <NUM> may be treated or otherwise prepared for subsequent cooling by the recirculation system <NUM>, and the recirculation system <NUM> may recirculate the treated coolant back to the cooling header <NUM>.

<FIG> and <FIG> illustrate a metal processing system <NUM> with the rolling mill <NUM> and a cooling system <NUM> according to various embodiments. The cooling system <NUM> is substantially similar to the cooling system <NUM> and includes a cooling header <NUM>, an exhaust system <NUM> with a removal device <NUM>, and the temperature sensor <NUM> downstream from the cooling header <NUM>. Similar to the cooling system <NUM>, the cooling system <NUM> may include a controller that is communicatively coupled with the cooling header <NUM> and the temperature sensor <NUM>.

Similar to the cooling header <NUM>, the cooling header <NUM> may include a plurality of nozzles <NUM>, and the cooling header <NUM> is dimensioned to extend across the width of the metal substrate <NUM>. The number, type, and arrangement of nozzles <NUM> should not be considered limiting. In some aspects, the nozzles <NUM> may are a different style and/or type compared to the nozzles <NUM>, although they need not be in other embodiments. Similar to the cooling system <NUM>, the controller of the cooling system <NUM> may control the nozzles <NUM> as desired, including independently from one another or nozzles may be controlled in conjunction.

Compared to the cooling system <NUM>, a distance between the cooling header <NUM> and the removal device <NUM> is reduced and/or minimized. Similar to the removal device <NUM>, the removal device <NUM> is a vacuum nozzle that optionally may extend across the width of the metal substrate <NUM>. Compared to the removal device <NUM>, where an opening of the device <NUM> is facing directly upwards, the removal device <NUM> includes a receiving portion <NUM> that is elongated in the direction of travel of the metal substrate <NUM> and optionally proximate to the cooling header <NUM> to increase coolant collection, which may be in the form of steam. In certain aspects, the cooling system <NUM> may avoid and/or minimize cooling at the edges of the metal substrate <NUM> to minimize or reduce the possibility that tight edges are created in the metal substrate <NUM>, which may lead to strip break.

A method of controlling the temperature of a metal substrate with a cooling system is also provided. While reference will be made to the cooling system <NUM>, it will be appreciated that the following description is applicable to any of the cooling systems described herein, as well as other cooling systems within this disclosure.

In various examples, the method of controlling the temperature of the metal substrate <NUM> includes receiving the metal substrate <NUM> at the cooling system <NUM> and with the metal substrate <NUM> moving at a predetermined line speed. In some optional examples, the predetermined line speed may be about <NUM>/min, although it need not be in other examples. The method may include detecting a temperature profile of the metal substrate <NUM> across the width of the metal substrate <NUM>. In various examples, the method may include comparing the detected temperature profile with a predetermined or desired temperature profile. In various examples, the predetermined desired temperature profile is a temperature profile that is less than or equal to the critical softening temperature of the metal substrate <NUM> and/or a desired coiling temperature of the metal substrate, although it need not be in other examples.

In certain aspects, the method may include determining a cooling profile for the cooling header <NUM> based on a difference between the detected temperature profile and the predetermined or desired temperature profile. The method may include controlling the cooling header <NUM> such that the cooling header <NUM> provides coolant pursuant to the cooling profile and such that the coolant cools the metal substrate <NUM> to have the predetermined or desired temperature profile at the predetermined line speed. In some cases, controlling the cooling header <NUM> may include controlling one or more of a spray pattern of coolant from one or more nozzles individually, a spray pattern of the coolant being dispensed across the width of the metal substrate <NUM>, a flow rate of coolant from one or more nozzles, a duration at which the coolant is dispensed from one or more nozzles, how many of the one or more nozzles are turned on, or other suitable characteristics or controls as desired.

A collection of exemplary embodiments, not according to the invention and present for illustration purposes only, are provided below, including at least some explicitly enumerated as "Illustrations" providing additional description of a variety of example embodiments in accordance with the concepts described herein.

Illustration <NUM>. A cooling system for a metal processing system, the cooling system comprising: a cooling header configured to selectively dispense a coolant onto a metal substrate; an exhaust system downstream from the cooling header, wherein the exhaust system comprises a removal device that is configured to remove coolant dispensed by the cooling header; a temperature sensor downstream from the cooling header, wherein the temperature sensor is configured to detect a temperature profile of the metal substrate across a width of the metal substrate; and a controller communicatively coupled to the cooling header and the temperature sensor, wherein the controller is configured to control the cooling header based at least on a detected temperature profile.

Illustration 1a. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the cooling header is an atomizing spray header.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the cooling header and the removal device of the exhaust system are positioned relative to a passline of a metal substrate through the cooling system, and wherein the cooling header and the removal device of the exhaust system are on opposing sides of the passline.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the cooling header and the removal device of the exhaust system are positioned relative to a passline of a metal substrate through the cooling system, and wherein the cooling header and the removal device of the exhaust system are on a same side of the passline.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the cooling header and the removal device of the exhaust system are below the passline.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the removal device of the exhaust system is configured to generate a vacuum force.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the removal device of the exhaust system is a first removal device, and wherein the exhaust system further comprises a second removal device downstream from the cooling header.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the first removal device is a vacuum device, and wherein the second removal device is a blower.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the cooling header, the first removal device, and the second removal device are positioned relative to a passline of a metal substrate through the cooling system, wherein the cooling header and the first removal device are on a first side of the passline, and wherein the second removal device is on a second side of the passline opposite from the first side.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the cooling header and the first removal device are below the passline, and wherein the second removal device is above the passline.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the second removal device is vertically aligned with the first removal device.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the cooling header comprises a plurality of nozzles, and wherein each nozzle of the plurality of nozzles is independently controlled by the controller.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the temperature sensor is a first temperature sensor, and wherein the cooling system further comprises a second temperature sensor upstream from the cooling header.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, further comprising a flatness sensor configured to detect a flatness profile of the metal substrate across a width of the metal substrate, wherein the controller is communicatively coupled to the flatness sensor and is configured to control the cooling header based at least on a detected flatness profile.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the controller is further configured to: determine a desired exit temperature profile of metal substrate; receive the detected temperature profile from the temperature sensor; determine a cooling profile for the coolant at a predetermined line speed based on the desired exit temperature profile and the detected temperature profile; and control the cooling header such that the cooling header dispenses the coolant pursuant to the cooling profile.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the desired exit temperature profile is a coiling temperature of the metal substrate.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein controlling the cooling header comprises controlling at least one of a spray pattern across the width of the metal substrate or a flow rate of the coolant from the cooling header.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the desired exit temperature profile is predetermined.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the controller is configured to determine the desired exit temperature profile based at least partially on a material composition of the metal substrate.

Illustration <NUM>. The cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the predetermined line speed is about <NUM>/min.

Illustration <NUM>. A metal processing system comprising: an exit stand of a rolling mill; and the cooling system of any preceding or subsequent illustrations or combination of illustrations, wherein the cooling system is downstream from the exit stand.

Illustration <NUM>. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the cooling header is positioned proximate to the exit stand.

Illustration <NUM>. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the exhaust system is a predetermined distance downstream from the cooling header, and wherein the predetermined distance is based on a desired cooling rate of the metal substrate at a predetermined line speed of the metal substrate exiting the exit stand.

Illustration <NUM>. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the controller is further configured to: determine a desired exit temperature profile of metal substrate prior to coiling; receive the detected temperature profile from the temperature sensor; determine a cooling profile for the coolant at a predetermined line speed based on the desired exit temperature profile and the detected temperature profile; and control the cooling header such that the cooling header dispenses the coolant pursuant to the cooling profile.

Illustration <NUM>. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the predetermined line speed is about <NUM>/min.

Illustration <NUM>. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the rolling mill is a cold rolling mill.

Illustration <NUM>. A method of cooling a metal substrate using the cooling system of any preceding or subsequent illustrations or combination of illustrations, the method comprising: receiving the detected temperature profile from the temperature sensor; determining a cooling profile for the coolant at a predetermined line speed based on a desired exit temperature profile of the metal substrate before coiling and the detected temperature profile; and controlling the cooling header such that the cooling header dispenses the coolant pursuant to the cooling profile.

Illustration <NUM>. A cold rolling mill comprising: an exit stand; and a cooling system downstream from the exit stand, the cooling system comprising a cooling header configured to selectively dispense a coolant onto a metal substrate exiting the exit stand.

Illustration <NUM>. The cold rolling mill of any preceding or subsequent illustrations or combination of illustrations, further comprising a rewind coiler, wherein the cooling system is between the exit stand and the rewind coiler.

Illustration <NUM>. The cold rolling mill of any preceding or subsequent illustrations or combination of illustrations, further comprising an exhaust system downstream from the cooling header, wherein the exhaust system comprises a removal device that is configured to remove coolant dispensed by the cooling header.

Illustration <NUM>. The cold rolling mill of any preceding or subsequent illustrations or combination of illustrations, further comprising: a temperature sensor downstream from the cooling header, wherein the temperature sensor is configured to detect a temperature profile of the metal substrate across a width of the metal substrate; and a controller communicatively coupled to the cooling header and the temperature sensor, wherein the controller is configured to control the cooling header based at least on a detected temperature profile.

Illustration <NUM>. A cold rolling mill comprising: an exit stand; and a cooling system downstream from the exit stand, the cooling system comprising: a cooling header comprising a plurality of nozzles, each nozzle of the plurality of nozzles configured to selectively dispense a coolant onto a metal substrate exiting the exit stand; and a controller communicatively coupled with the cooling header and configured to individually control each nozzle of the plurality of nozzles.

Illustration <NUM>. The cold rolling mill of any preceding or subsequent illustrations or combination of illustrations, further comprising: a temperature sensor configured to detect a temperature profile across a width of the metal substrate, wherein the controller is communicatively coupled with the temperature sensor is configured to control each nozzle of the plurality of nozzles based on a detected temperature profile from the temperature sensor.

Illustration <NUM>. A method of cooling a metal substrate with a cooling system, the method comprising: receiving a metal substrate at a first temperature, applying a coolant to a surface of the metal substrate by directing the coolant through at least one nozzle, the at least one nozzle configured to direct the coolant as micronized droplets; and controlling a droplet size of the coolant as it is directed through the at least one nozzle to modify a Leidenfrost point of the coolant.

Illustration <NUM>. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the metal substrate comprises an aluminum alloy.

Illustration <NUM>. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the first temperature is <NUM>.

Illustration <NUM>. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the at least one nozzle is at least one cone-shaped nozzle.

Illustration <NUM>. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the coolant comprises water.

Illustration <NUM>. The method of any preceding or subsequent illustrations or combination of illustrations, wherein receiving the metal substrate at the first temperature comprises receiving the metal substrate from a piece of metal processing equipment.

Illustration <NUM>. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the piece of metal processing equipment comprises a work stand of a rolling mill, and wherein the rolling mill comprises at least one of a hot rolling mill, a cold rolling mill, or a warm rolling mill.

Illustration <NUM>. The method of any preceding or subsequent illustrations or combination of illustrations, wherein: the surface of the metal substrate is an upper surface; the at least one nozzle comprises at least two nozzles; a first nozzle of the at least two nozzles is positioned above a passline of the metal substrate through the quenching system; a second nozzle of the at least two nozzles is positioned below the passline of the metal substrate; and applying the coolant comprises directing the coolant onto the upper surface of the metal substrate with the first nozzle and directing coolant onto a lower surface of the metal substrate with the second nozzle.

Illustration <NUM>. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the cooling feature comprises a flow-rate of coolant through the at least one nozzle, and wherein the flow rate of coolant comprises <NUM>/min.

Illustration <NUM>. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the coolant is selected from the group consisting of water, oil, air, a charged solution and/or other suitable liquid coolant.

Illustration <NUM>. The method water, oil, air, a charged solution and/or other suitable liquid coolant, wherein applying the coolant comprises applying the coolant such that the temperature of the metal substrate decreases at a rate of at least <NUM>/s, and optionally at least <NUM>/s.

Illustration <NUM>. The method <NUM>/s, wherein the at least one nozzle comprises at least one movable nozzle.

Illustration <NUM>. The method <NUM>/s, further comprising moving the at least one movable nozzle to a second surface of the metal substrate that is at the first temperature.

Illustration <NUM>. A method of quenching a metal substrate with a quenching system, the method comprising: receiving a metal substrate at a first temperature; inducing a non-neutral electric charge on a surface of the metal substrate; and applying a coolant to the surface of the metal substrate by directing the coolant through at least one nozzle, wherein the coolant comprises a complementary electrical charge to the electrical charge induced on the surface of the metal substrate to modify a Leidenfrost point of the coolant.

Illustration <NUM>. A method of quenching a metal substrate with a quenching system, the method comprising: receiving a metal substrate at a first temperature; modifying a surface of the metal substrate such that the surface geometry modifies a Leidenfrost point of a coolant; and applying the coolant to a surface of the metal substrate by directing the coolant through at least one nozzle towards the modified surface of the metal substrate.

Claim 1:
A cooling system (<NUM>) for a metal processing system (<NUM>), the cooling system comprising:
a cooling header (<NUM>) configured to selectively dispense a coolant (<NUM>) onto a metal substrate (<NUM>);
an exhaust system (<NUM>) downstream from the cooling header (<NUM>), wherein the exhaust system (<NUM>) comprises a removal device (<NUM>) that is configured to remove coolant (<NUM>) dispensed by the cooling header (<NUM>);
a temperature sensor (<NUM>) downstream from the cooling header (<NUM>), wherein the temperature sensor (<NUM>) is configured to detect a temperature profile of the metal substrate (<NUM>) across a width of the metal substrate (<NUM>); and
a controller (<NUM>) communicatively coupled to the cooling header (<NUM>) and the temperature sensor (<NUM>), wherein the controller (<NUM>) is configured to control the cooling header (<NUM>) based at least on a detected temperature profile,
wherein the controller (<NUM>) is further configured to:
determine a desired exit temperature profile of the metal substrate (<NUM>);
receive the detected temperature profile from the temperature sensor (<NUM>);
determine a cooling profile for the coolant (<NUM>) at a predetermined line speed based on the desired exit temperature profile and the detected temperature profile; and
control the cooling header (<NUM>) such that the cooling header dispenses the coolant pursuant to the cooling profile.