System and method for rapid substrate cooling

Abstract

Disclosed is a cooling system ( 104 ) and method for a metal processing system ( 100 ). The cooling system ( 104 ) includes a cooling header ( 114 ), an exhaust system ( 118 ), a temperature sensor ( 128 ), and a controller ( 130 ). The cooling header ( 114 ) selectively dispenses a coolant onto a metal substrate ( 110 ), and the exhaust system ( 118 ) removes heated coolant from the metal substrate ( 110 ). The temperature sensor ( 128 ) is downstream from the cooling header ( 114 ) and detects a temperature profile of the metal substrate ( 110 ) across a width of the metal substrate. The controller ( 130 ) is communicatively coupled to the cooling header ( 114 ) and the temperature sensor ( 128 ), and the controller ( 130 ) controls the cooling header ( 114 ) based at least on a detected temperature profile.

That which is claimed: 
     
         1 . 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.   
     
     
         2 . The cooling system of  claim 1 , wherein the cooling header is an atomizing spray header. 
     
     
         3 . The cooling system of  claim 1 , 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. 
     
     
         4 . The cooling system of  claim 3 , wherein the cooling header and the removal device of the exhaust system are below the passline. 
     
     
         5 . The cooling system of  claim 1 , 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. 
     
     
         6 . The cooling system of  claim 5 , wherein the first removal device is a vacuum device, and wherein the second removal device is a blower. 
     
     
         7 . The cooling system of  claim 5 , 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. 
     
     
         8 . The cooling system of  claim 7 , wherein the cooling header and the first removal device are below the passline, and wherein the second removal device is above the passline. 
     
     
         9 . The cooling system of  claim 1 , wherein the cooling header comprises a plurality of nozzles, and wherein each nozzle of the plurality of nozzles is independently controlled by the controller. 
     
     
         10 . The cooling system of  claim 1 , 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. 
     
     
         11 . The cooling system of  claim 1 , 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.   
     
     
         12 . The cooling system of  claim 11 , 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. 
     
     
         13 . The cooling system of  claim 1 , 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. 
     
     
         14 . A metal processing system comprising:
 an exit stand of a rolling mill, wherein the rolling mill is a cold rolling mill; and   the cooling system of  claim 1 , wherein the cooling system is downstream from the exit stand.   
     
     
         15 . The metal processing system of  claim 14 , 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.   
     
     
         16 . 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.   
     
     
         17 . The cold rolling mill of  claim 16 , further comprising:
 a rewind coiler, wherein the cooling system is between the exit stand and the rewind coiler; and   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.   
     
     
         18 . The cold rolling mill of  claim 16 , 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.   
     
     
         19 . 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. 
   
     
     
         20 . The cold rolling mill of  claim 19 , 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.