Electromagnetic Heater Principle

Electromagnetic heaters are devices that convert electrical energy into heat energy by utilizing the principle of electromagnetic induction. The electromagnetic heating controller converts 220V, 50/60Hz AC into DC, then into a high-frequency, high-voltage DC power of 20-40KHz, or 380V, 50/60Hz three-phase AC into DC, which is then converted into a high-frequency, low-voltage, high-current DC power of 10-30KHz. This is used for industrial product heating. Electromagnetic heating coils: High-speed alternating high-frequency current passing through the coil generates a high-speed alternating magnetic field. When an iron-containing container is placed above it, the container surface exhibits cutting alternating magnetic lines, producing alternating current (eddy currents) in the metallic bottom part of the container. The eddy currents cause the charge carriers in the container bottom to move rapidly and irregularly, colliding and frictioning against each other to generate heat energy. This achieves the effect of heating the item by converting electrical energy into magnetic energy, creating induced eddy currents on the surface of the heated steel body. This method fundamentally solves the issue of low heating efficiency in resistive heating elements like electric heating plates and coils, which heat through thermal conduction.

Two: Structure of the electromagnetic heater

Three: Installation Steps for Electromagnetic Heater

Step 1: Wrap the extruder barrel with thermal insulation cotton. The insulated cotton helps reduce heat loss, enhancing thermal efficiency and speeding up heating while being more energy-efficient. The thickness of the insulation cotton is specified: for low-power, 1.5cm is ideal, while for high-power (10KW and above), 2-2.5cm is recommended (this is the thickness after wrapping). Winding method: Typically, for longer heating cylinders, use the grouping winding method, where several turns are placed close together, then spaced a few centimeters apart, and evenly wind multiple groups. For shorter cylinders, use the overlapping winding method. (Spring winding is usually used for smaller heating elements with high power density, and is often employed with thermal oil.)

Step 2: After wrapping with thermal insulation, secure it externally with high-temperature straps. The high-temperature straps are used to secure the insulation, making it easier to wrap around the electromagnetic heating coil.

Step 3: Wind around the electromagnetic heating coil. The length of the wire varies depending on the power, with different winding lengths required. The specific winding lengths and combinations must be uniform, with a spacing between each coil of approximately more than 10 centimeters to avoid interference between multiple machines.

Step Four: Connect the two terminals of the electromagnetic heating coil wrapped around the material cylinder to the output terminals L1, L2, or marked as OUT1, OUT2 of the electromagnetic heater. Connect to U, V, W, or marked as R, S, T. Connect to a three-phase 380V power supply; N connects to the neutral wire; no connection if not required. Do not interconnect the soft switching line, power line, and electromagnetic coil line, or connect them to the housing.

Step 5: Power-On Adjustment. Measure the incoming current (A) corresponding to the power working current using a clamp meter. The operating frequency is typically between 9-13KHZ, as there is no specific range. Higher frequency corresponds to higher current; increase the number of turns in the coil, and vice versa. Inductance is just one of the applied parameters. Specifically, measure the operating frequency and current, and adjust the power by adding or subtracting the coil turns. For higher heating temperature requirements, reduce the inductance. Maintain a frequency of no less than 11KHz when heating to the desired high temperature (as the workpiece temperature rises, the equivalent series resistance R increases, and the resonant frequency of RLC decreases; similarly, as R increases, the current decreases with the bus voltage remaining constant, which is normal).

Four: Advantages of Electromagnetic Heating Mainboard

1: Industrial-grade DSP Digital Processor: Fast processing speed, real-time monitoring in each cycle and quick response to 30 protection features.

2: Mobile Remote Flashing Program/Configuration Parameters: Smart Cloud Technology, Zero Distance in Supply and Demand Relationship

3: Central Control Technology: Supports parallel connection of multiple cores at the same level; adjacent coils are close without interference and there's no low-frequency noise. Solves interference issues in winding coils for various equipment.

4: Automatic Load Scanning: Capable of statically or dynamically scanning the coil load status, preventing mismatched coil sensitivity, enhancing load adaptability, and reducing on-site debugging difficulties.

5: Digital Load Match Rate: Visibly displays the load match rate when the low-power start and no start are activated, facilitating customer monitoring and system adjustment for improved product lifespan and addressing insufficient power in factory testing.

6: Long-distance heating: Insulation thickness can exceed 5 cm, high-temperature application systems have high thermal efficiency and long coil lifespan.

7: 304 Long-Distance Heating: Unique control technology, coils do not heat up, excellent equipment operating parameters.

8: Resonant Capacitance Monitoring: Capacitance status monitoring software, real-time monitoring of resonant capacitor operating status, undamaged under extreme conditions.

9: AI Intelligent Algorithm: Automatically scans and detects the installation direction of current sensors, and only one output current sensor is required to calculate power. Advantages of the Fit Electromagnetic Heater

Five: Application Range of Electromagnetic Heaters

1. The plastic and rubber industry, including blowing film machines, filament extruders, injection molding machines, granulators, rubber extruders, vulcanizers, and cable production extruders, etc.

2. Construction materials industry, including: gas pipe production lines, plastic pipe production lines, PE rigid flat meshes, geotextile machine groups, automatic hollow forming machines, PE honeycomb board production lines, single and double-wall corrugated pipe extrusion lines, composite air cushion film machine groups, PVC rigid pipes, core foam pipe production lines, PP extruded transparent sheet production lines, extruded polystyrene foam pipe materials, PE缠绕膜机组.

3. Energy and food industry applications, such as: heating of crude oil pipelines; food machinery, such as: super loader machines, and other equipment requiring electrical heating.

4. High-power commercial electromagnetic cooktop core.

5. Drying and heating in printing equipment.

Six: Maintenance of Electromagnetic Heaters

1. The main unit should be dusted regularly, typically every 2 months. Use a soft-bristled brush or a high-pressure air gun for dusting to ensure a good ventilation environment inside the instrument.

2. If the operating environment is a place with corrosive gases, it is necessary to apply insulating varnish. Alternatively, use other insulating anticorrosive materials.

3. Do not attempt to repair or immerse in water while the product is still powered on. Use a fire extinguisher in case of fire! 3. Air temperature must not exceed 50°C.

Seven: Main Application Fields of Electromagnetic Heater Products:

Industrial heating equipment such as plastic machinery injection molding machines, granulators, blowing film machines, wire drawing machines, thermal oil, diffusion pumps, boilers, etc., in the electromagnetic heating energy-saving transformation; and domestic heating products such as electromagnetic water heaters, electric water bottles, electric cooktops, electric wall heaters, and other electromagnetic heating appliances.