conceptual design of a multi-functional hot-dip galvanizing simulator
TRANSCRIPT
Conceptual Design of a Multi-functional Hot-Dip Galvanizing Simulator
Xiaodong Hao, Qifu Zhang
China Iron & Steel Research Institute Group, Beijing 100081, China [email protected]
Keywords: Hot-Dip Galvanizing, Simulator, function-behavior-structure, conceptual design
Abstract. Simulation techniques play a crucial role in determining a successful engineering design. A
multifunctional galvanizing simulator is the basic equipment for enterprise to acquire the process
information for producing annealed sheets, galvanized sheets and galvannealed sheets under
laboratory conditions. This paper extended Gero’s function-behavior-structure framework and used
this framework for the conceptual design of a multifunctional hot-dip galvanizing simulator.
Introduction
Galvanized sheet is the product with both high technology content and high additional value [1].
Due to the production of zinc coated steel sheet nearly runs through the whole process of steel
enterprise, most of the world level large steel enterprises are making continuous efforts to leverage
their product innovation in order to maintain their competitive edge [2]. Simulation techniques are
economical and efficient ways to investigate the processing conditions, the process and product
surface quality of strip continuous hot dip galvanizing. Continuous Annealing Galvanizing Simulator
is the most necessary laboratory equipment for study of coating technology [3]. This situation led to
an increasing need for the development of an innovative hot-dip galvanizing simulator. Conceptual
design is an important task in engineering design process, which plays a crucial role in determining a
successful product innovation [4, 5]. Therefore, it needs effort to develop conceptual design approach
for the design of hot-dip galvanizing simulator.
The existing research on the development of hot-dip galvanizing simulator has focused on
benchmark existed simulators and start the design from the detail design stage of simulators without
using any design methodology [2, 6]. As state by Pahl and Beitz [5], the design of complex product
should be started from product planning. In this stage, designers should acquire the knowledge about
customer need, environmental and competitors’ products. The acquired knowledge would be then
transferred into design requirements (includes functional knowledge). However, from the design
literature and research on the hot-dip galvanizing simulators, we know that few of current research
focus on acquiring such design requirements. In fact, identifying the requirements is the first step of a
successful design.
In this regard, this study aims to develop a framework for guiding the conceptual design of a hot-dip
galvanizing simulator. The Function-Behavior-Structure (FBS) model [7] is extended to construct a
systematical approach for the conceptual design of a Multifunctional Hot-Dip Galvanizing Simulator.
Conceptual Design Framework
2.1 Tasks in conceptual design phase
According to Pahl and Beitz [5], conceptual design is the key part of design process, which includes
several major steps.
Abstract to identify the essential problems. In this step, requirements are analyzed with reference
to the required functions and constraints.
Establish function structures and break overall function into sub-functions. In this step, overall
function will be broken down into sub-functions until each sub-function can be realized with a
certain components or working principle. The flow of material, energy and signal were used to
connect function blocks.
Search for working principles that fulfill the sub-functions and combine these principles into
working structure.
Advanced Materials Research Vol. 813 (2013) pp 188-191Online available since 2013/Sep/10 at www.scientific.net© (2013) Trans Tech Publications, Switzerlanddoi:10.4028/www.scientific.net/AMR.813.188
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Evaluate solutions and make decision.
Conceptual design framework
The FBS framework can be used as ontology for the understanding of engineering design [7],
which has been widely acknowledged in design society [7-10]. In this study, the extended FBS
framework was used to guide the conceptual design of a multifunctional hot-dip galvanizing
simulator. The tasks in conceptual design phase can be represented with the FBS framework, which is
demonstrated briefly in Fig.1.
R
F
C B
S D
1 Abstraction 2'Formulation
5 Evaluation
3'Synthesis
4 Analysis
6 DocumentaionE
7 Reformulation
3 Synthesis
R=Requirement; F=Function; E=Effect; S=Structure; C=Constraints; B=Behavior D=Design description
9 Reform
ulation
RFCESB
FBS
Refine
8 Refo
rmulat
ion
2 Search
1 Abstraction
Fig.1 The extended FBS framework
According to ref [5, 7-10], the concepts in the extended FBS framework can be described briefly as
below.
Requirement. Requirements are the specifications that come from customer need and
environment issues. The later includes the constraints from a social aspect, a nature aspect,
product lifecycle operations and environmental entity.
Function. With reference to existing function-related literature, function can be defined as the
general input-output relationship of a system whose purpose is to perform a task.
Effect. According to Pahl and Beitz, effect refers to the working principle that meets functional
requirements.
Structure. Structure is a description of the essential facts of a product independent of the inputs,
which refers to the parts or components of a product, their features, their attributes, and their
topological relations.
Constraint. In our framework, constraints include the value of the function property,
environment-related constraints and users’ non-technical functions.
Behavior. Behavior refers to a state change caused by a given input flow via the designated
working principle of a system.
Conceptual Design of a Simulator
Function and constraint clarification
Using benchmarking approach to existed galvanizing simulator and acquiring the knowledge about
customer need. It can be determined that the overall function of this simulator is to simulate
CAL/CGL process, which consists of the following subfunctions: surface oxidation-reduction
reactions of iron and steel samples, continuous thermal treatment, hot galvanizing, coating thickness
control by air knife and galvanizing diffusion. The samples can be used for the tissue analysis and
analyses of mechanical properties, corrosion resistance, adhesiveness, surface inspection and welding
performance.
The constraints are extracted from cost, environment and working scenario aspects. For example,
the simulator should be 50% cheaper than international advanced products, with maintenance cost
equivalent to 30% of the international products of the same kind and more than 75% of the spare parts
costing about one half of the price of those of the international products of the same kind; The area of
site of the simulator is 80m2; the equipment height should lower than 4.8m; the smaple dimension and
coated weight are also determined. The overshooting temperature for the cooling process should be
precisely controlled, e.g., the temperature is 5% lower than the target temperature
Advanced Materials Research Vol. 813 189
Working process of the simulator
According to the functional requirement and customer need, the simulator is used for the
investigation of the controlling condition and process parameters for the steel plate hot dip
galvanizing with laboratory condition. With reference to the hot-dip galvanizing process [1], the
process of achieving the total function can be shown in Fig. 2. Detailed information about the process
can be found in [3].
End
Start
Put zinc pot
to galvanizing
room
Strat protective
atmosphere system
Is the temprature of
Liquid zinc ok?Keep heating
Install sample and
fix thermocouple
Control the atmosphere in the cooling room,
infrared heating room and alloying room
Control the infrared heating
system to heat the sample
Is there a cooling
process?
Back to the cooling
room, and cooling the
sample
Complete heat
treatment
Is heat treatment
completed ?
Turn on the knife style gate
value and push sample to zinc
pot
Using air knife to control the coating thickness and control the the location of the
sample
Is sample need alloyed?Alloying the
sample
Cooling the sample
Take the sample down, and Inspect the
systems
No
NoNo
No
YesYes
Yes
Yes
Fig. 2 A possible working process of the simulator
Structure
Due to its functional requirements, and the working process, the structure of the galvanizing
simulator can be primarily determined. The simulator consists of a total of 22 components: 1) infrared
heating system; 2) cooling room; 3) cooling system; 4) drive system; 5) alloying system; 6)
galvanizing room; 7) air knife; 8) zinc pot; 9) protective atmosphere system; 10) pneumatic system;
11) vacuum system; 12) exhaust system; 13) control system; 14) civil engineering system; 15)
monitoring system, etc. The major components and the illustrative solution of a simulator are shown
in Fig. 3. Eight component of our conceptual prototype is presented in Fig. 3.
Fig. 3 The structure of the simulator.
1)infrared heating system ;2)electromagnetic induction system; 3)zinc pot; 4)main supporting
system; 5)cooling system; 6)driven system; 7)quartz tube; 8)vacuum gate value
190 Metallurgy Technology and Materials II
Behavior
In the conceptual design phase, we use Solidworks as a modeling and simulation tool to build 3D
model of the simulator and perform some kinemics and dynamic analysis. By acquiring this kind of
behavior knowledge, designers are able to make basic decisions and evaluate whether some of the
constraints and functions can be meet with this design. Other behavior of this simulator can be
obtained by operation a true prototype of this simulator, which is out of the scope of this study.
Summary
This paper aims at applying design methodology to perform the conceptual design process of a
multifunction galvanizing simulator. The function-behavior-structure framework is extended and
applied to guide the conceptual design process of a multifunctional galvanizing simulator. A possible
working process of the simulator and a major structure of the simulator are presented in this paper.
Behavior knowledge can be acquired and used to make basic decisions on the designed simulator. In
our future work, the framework will be improved and applied further to the development of a novel
galvanizing simulator.
References
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Advanced Materials Research Vol. 813 191
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