Conceptual Design of a Multi-functional Hot-Dip Galvanizing Simulator

Xiaodong Hao, Qifu Zhang

China Iron & Steel Research Institute Group, Beijing 100081, China hxd_sunday@126.com

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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