Facing the dual demands of large-scale mass production and multi-specification flexible production, traditional bar cooling beds suffer from low efficiency, uneven cooling, poor adaptability, and high energy consumption. A targeted integrated skirt plate cooling bed solution has emerged—covering 10-40mm bars, integrating post-rolling cutting, high-speed conveying, and uniform cooling. It matches 12m/s high-rhythm rolling, adapts to small-batch orders, and cuts energy/operation costs, offering a practical upgrade path for the industry. Core highlights are as follows:
I. Core Project Positioning: A Dual-Driven Solution for “Flexible Production + Cost Reduction and Efficiency Enhancement”
Bar processing enterprises currently face three core challenges: Firstly, during the double-split rolling of small-sized bars (10-12mm), traditional cooling beds are prone to stacking and uneven cooling; secondly, during the single-line rolling of medium and large-sized bars (14-40mm), equipment switching is time-consuming; thirdly, high-rhythm production leads to high energy consumption and fast equipment wear.
This skirt plate cooling bed solution accurately targets the above pain points:
- Double-split rolling scenario: Optimized for 10-12mm small-sized bars, the parallel cooling design increases single-batch capacity by 40% compared with traditional cooling beds, solving efficiency loss and energy waste;
- Single-line rolling scenario: Compatible with 14-40mm bars, quick adaptation is achieved through parameter adjustment and fine-tuning, reducing equipment switching time from 30 minutes to less than 5 minutes;
- Rhythm matching and energy balance: Withstands a maximum rolling speed of 12m/s, seamlessly connecting with mainstream rolling mills; unit product energy consumption is reduced by 15%-20%, conforming to green development trends.
II. Key Technical Highlights: “Detail Innovation + System Collaboration” for Full-Process Precision Control
1. High-Temperature Stable Cutting System: “Millimeter-Level Precision + Long-Term Durability” at 850℃
As the first key process after rolling, the crank-type flying shear achieves three breakthroughs:
- High-temperature adaptation and precision control: Cuts hot bars at up to 850℃, with crop length ≤200mm and cut perpendicularity deviation ≤0.5mm/m, reducing subsequent processing losses;
- Dual-mode cutting and safety protection: Supports normal cutting and emergency shutdown, equipped with sensors for real-time monitoring and alarm;
- Power and durability optimization: Driven by a high-power DC motor with a precision planetary gearbox, the surface-hardened cutting edge has a service life twice that of traditional ones.
2. High-Speed Synchronous Pinch Roll: “Differential-Free Transmission + Flexible Clamping” at 13m/s
The pinch roll connecting rolling and cutting links features:
- Structural adaptation and flexible clamping: Symmetrical structure with adjustable clamping force (0.5-2.5MPa), rubber-coated roll surface avoids slipping and scratches, increasing product qualification rate by over 10%;
- Speed synchronization and precise feedback: Real-time speed collection and transmission ensure cutting length error within ±3mm, solving tail stall deviation;
- Maintenance convenience: Modular roll body design enables quick replacement, with an automatic lubrication system reducing manual workload.
3. High-Efficiency Uniform Cooling System: “Temperature Balancing + Smooth Transmission Chain” with 54m Width
Adopting a step rack-type design, the system realizes efficient cooling through multi-module collaboration:
(1) Input Roller Table: “Gradual Transition Design”
The 0°-12° gradual inclination angle avoids stacking and collision; independent motor drive ensures 98% equipment availability; chrome-plated 45# steel roll body is wear-resistant and corrosion-resistant.
(2) Cooling Bed Body: “Wide Intelligent Layout”
- Adjustable spacing design: Adapts to dense cooling of small-sized bars and heat dissipation of large-sized bars;
- Material and structural optimization: Q345 alloy steel racks withstand ≤950℃, with cooling uniformity deviation ≤15℃;
- Temperature closed-loop control: Multi-point thermometers monitor temperature, automatically adjusting parameters to ensure outlet temperature ≤200℃ for small and medium-sized bars.
(3) Alignment and Discharge System: “Smooth Connection Design”
- Alignment roller table: Low-speed operation with alignment error ≤5mm, facilitating subsequent packaging;
- Chain steel shifter: Heavy-duty chain with adjustable step pitch, avoiding bar collision;
- Discharge trolley: Hydraulic lifting with flexible contact pads, ensuring parking precision ≤3mm.
(4) Lubrication and Environmental Protection Design: Manual glycerin lubrication with oil recovery device, reducing costs and meeting environmental requirements.
4. Auxiliary System: “Guarantee System” for Intelligent Monitoring + Convenient Operation and Maintenance
- Intelligent monitoring system: PLC control and touch screen interface for real-time display and remote operation;
- Fault diagnosis and early warning: Built-in sensors for abnormal alarm and troubleshooting guidance;
- Wear part management: Standardized design of key parts with spare parts list and quick replacement guide.
III. Core Value of the Solution: Multi-Dimensional Empowerment for Cost Reduction and Efficiency Enhancement
1. Compatibility Upgrade
Covers 10-40mm full-specification bars, realizing “one equipment for multiple scenarios” and increasing equipment utilization rate to over 90%.
2. Precision Improvement
Full-process precision control reduces scrap rate by 15%-20%, improving product competitiveness.
3. Efficiency Optimization
Matching high rolling speed and reducing downtime, overall production efficiency is 30% higher than traditional solutions.
4. Cost Reduction
- Energy cost: Reduced by 15%-20% annually;
- Operation and maintenance cost: Reduced by about 25% with extended MTBF to over 8000 hours;
- Labor cost: Reduced by 1-2 people per shift through intelligent control.
5. Green and Environmental Protection
Lubricating oil recycling, no wastewater generation, and noise ≤85dB, creating a friendly working environment.
IV. Application Scenarios and Industry Value
This solution is suitable for:
- Production of 10-40mm round steel, deformed steel bars, and split bars;
- High-rhythm, large-batch, and multi-specification flexible production;
- High-end bar processing with strict precision and surface quality requirements.
Pilot application data shows that the solution increases product qualification rate to over 98%, shortens production cycle by 30%, and reduces comprehensive cost by about 20%. It provides a feasible path for the bar processing industry to transform towards refinement, high efficiency, and greenization, empowering enterprises of all sizes to enhance core competitiveness.
For more information on adaptation scenarios, customization, and application cases, further communication is welcome.
