Field of use
The products are designed for industrial processes and are installed on extruder units, in molds, injection molding machines, glue machines. They are needed in packaging areas, pipelines of liquid and gaseous semi-finished products, heating screw blades, bottle production machines, etc.
Consider the most popular destinations.
- Equipment for polymer injection molding processes. Heaters are placed in injection molding machines, molds, their inner diameter corresponds to the injection molding machine ø and are mounted without leaving any gaps.
- Moulding areas of production where final shape is given to future products. Ring heaters are installed on extruders and adapters (located in the area between the molten mass and the head at the outlet of the unit).
- Hot runner systems. The thermostatic control elements are located at the location of the tube injectors. Their number is significantly less than that of the extruders.
- Injection and extrusion blow molding machines. The cylinder is literally hung with collar heating elements.
- Reaction molding machines are also required to maintain the thermal performance of semi-finished products. This type of injection molding is in demand for stamping processes and forging.
Technique for rotational molding. It is used for the production of plastic pontoons, boats, septic tanks.
What are bandage heating elements made of
They are made from five types of raw materials.
- Metal
High conductivity allows rapid heating. The generated power density is 4W/cm².Three-layer construction, which includes resistive wire, micanite insulator and steel lining, does not exceed 0,4 cm in thickness. Operating temperature: +300…+350⁰C. Inner diameter is selected up to 38cm.
- Cast aluminum
Lasts up to 10 years with proper operation. Its performance is close to the above-mentioned heating elements. It is convenient because it manages to make channel passages for starting the cooling medium. It is made with water and air cooling.
- Ceramic
Withstands up to +500⁰C in the working area. Conductive element is protected against overheating by ceramic rectangles. The outer part is made of metal that is resistant to moisture and aggressive media. Thermocouple is located on the outer or inner part of the product. For easy putting on and fixing it is allowed to design through holes. Specific power, diameter and thickness of the product are higher than their metal counterparts.
- Assortment for nozzles
A wide range of diameters, metal housing, rapid temperature increase at optimal current consumption, and the possibility of selecting a dielectric increases the demand for such products.
- Energy-saving type
It has 2 layers of insulation and combines the advantages of ceramic and metal material. It is also possible to order products with double ceramic insulation.
- Variant with forced cooling supply
On request is made with a customer-selected insulator. A bolted fan is mounted to remove excess heat energy.
What is the difference between micanite and ceramics?
Technological processes differ in temperature, duration, technical parameters. Therefore, Intmax manufactures products with different types of insulators.
- Steel heaters with a mica plate insulator are called micanite heaters.
The working element in them is a nichrome wire, which is made spiral to increase the value of the specific power. The heating energy is transmitted by contact action. The slightest discrepancy in the surfaces, holes or scratches on one of the planes are fraught with the emergence of dangerous locations and burn zones.
Micanite heaters have a quick start when heated up, and a long duration of use. To reduce the percentage of heat loss, insulated versions of ring heaters are used.
Insulator tapes consist of 2-4 parts. They are assembled by hand to ensure that the dielectric is uniform. The greater the width of the mica, the shorter the service life. Different types of connections are available, it is allowed to make TENs with holes and openings. They are suitable for large cylindrical vessels and pipes, as well as small nozzles.
In order to facilitate installation and to put the heating element tightly, a heat-resistant paste is used. It is applied on a surface cleaned of dirt stains and dust.
- Ceramic heating elements
Steel products with wire covered with steanite. They withstand a temperature 2 times higher than with mica and a 50% higher power density. Energy transfer occurs through radiation and contact surfaces. Such heating elements are more expensive. If the diameter exceeds 0.5m, then compression springs are installed to adjust the size when heated.
Heaters can be made of two parts if a surface with a significant diameter should be wrapped. They cannot be used in the case of prolonged thermal processes. Another disadvantage is the need to clean the surface frequently. The low heat dissipation and the ability to quickly reach the desired temperature is appreciated in TENs.
Connection accessories: wires, leads, and coatings
It is not enough to have a heater: it is necessary to connect it to the current supply network. And the following elements will help in this case.
- The cable and wire guide.
At the site of current flow can cause breakdowns of the outer layer, sparks, fire, melting. To prevent this from happening, nickel, copper wires and thermosilicone are used. Calculate the cross-section based on the applied load. Each wire and cable have a sufficient thickness of insulation, do not change size during operation, maintain the integrity and tightness of the outer layer. They function at high temperature and humidity and do not get rusty. - Coatings for wires
To keep cables intact, fiberglass siliconized tubing and metal braids have been invented for them. Protection is made against getting wet, solar heat, buildup, and accidental damage. Metal grounded braids are suitable for cables up to 10 cm in diameter. They are crimped or connected by welding. Fiberglass refers to dielectrics and is able to keep wires in case of fire in sections. - Connectors
Thermally stable connectors in straight and 90⁰ configuration are designed for high-temperature processes with a limit value of +500⁰C, current supply up to 35A and voltage up to 600V. - Beads made of ceramic material
Do not affect the flexibility of the cables used, but increase the chance. Considered a good way to enhance the protective characteristics of wires. Chemically inert, thermally stable, wear-resistant, they become a barrier to the occurrence of unexpected events that will lead to the failure of heating elements and production downtime.
- Terminal pads
Made of steatite, they can be completely or partially transparent. The wire placed inside the box is tightened with a screw. At this time, the clamping plate stabilizes the position of the wire and creates a channel of current flow through the brass conductor. The box has several individual contacts, allowing the assembly of the same type of solutions and wires of different metals. - Ceramic box in a metal enclosure
A flexible, heat-resistant wire in a braid is placed in the front channel, it can enter evenly, axially or tangentially. - Leading through the cable
The cable is placed in a braided case. It is attached to the heater through a sleeve at the outer edge. In each individual case one of 3 types of spatial arrangement is chosen. This depends on the location of the cylindrical object to be heated and the space available around it. - Bolted fixation.
Two M5 fasteners are suitable, as well as studs.
Replacement or repair
All products are inspected before being shipped to the customer. If after installation you can not organize the process heating with clamp heating elements, it means that the installation was carried out incorrectly or something went out of order during carelessness of work.
Breakdowns of the conclusions eliminate only specialists! Soldering or organizing another way of current leads can help. When the coil has overheated considerably and a rupture has occurred, a new heating element is ordered.
What you need to know before ordering a ring heater?
Intmax company accepts orders for clamp thermowells according to the conditions of their further operation. If you have ordered from us, please duplicate your order and specify the required number of products.
In the case when we cooperate for the first time, tell us what kind of production you need the products, where they will be installed and what parameters they should withstand. Our specialists will calculate the necessary dimensions of the ring heaters, their number, which will fully comply with the factory operating conditions.
Temperature, voltage, duration and frequency of heating, type of connection, the integrity of the product or the collection of 2 halves – these data we collect before designing. In order for the heater to withstand high thermal ratings, sufficient power supplied per unit area must be determined. A power reserve must be provided so that the product does not operate at its extremes.
Heating leads to increased tensile stress on the fixing elements. Here, too, care must be taken to ensure that the material properly absorbs the forces applied to it (no cracking, no bursting).
The TENs are pressed tightly against the cylindrical shape of the extruder, the element of the channel system, another part of the production system. There must be no defects on the heater metal to get a quality fit. You do not have to rely too much on thermal paste, because it is applied in a thin layer. Ceramic heaters are set, so here it is important to have a tight arrangement of plates.
To prevent the consequences of a short circuit helps grounding. A special cable is connected to a common terminal to prevent the flow of current through a suddenly opened output.
Where is the right place to order a band heater?
When there is a need for heaters, the customer has two options: to make a purchase in a company with a large production or buy the heater in a small private firm.
- Development of heaters for specific needs can only afford a company with considerable experience in this area. In the first case, the customer will be confident that they will make the necessary products according to all the rules, so they will last a long time. Without failure will stand the calculated temperature values, voltage, power. A mold, extruder will not cool down during the production cycle. The contractor provides a warranty for a specified period of operation of the ring heating elements. Replacement elements can always be ordered additionally.
- Cooperation with a little-known company is not profitable for the following reasons. Most likely, you will not be offered an individual design of the heater, but something close to the working parameters. Do you need parts with holes or cutouts? It is possible that they will not be able to make them. The cost will definitely be higher than that offered by a large manufacturer. If the price is slightly lower, we can assume that the components for making the heating elements are made in China. Then the issue of quality falls under doubt. Another potential nuisance ̶ delaying the production time.
Intmax: We are known, valued and repeat orders.