One: Principle of electromagnetic heater
An electromagnetic heater is a device that converts electrical energy into heat energy using the principle of electromagnetic induction. The electromagnetic heater controller converts 220V, 50/60Hz AC into DC, then into high-frequency high-voltage DC at 20-40kHz, or converts 380V, 50/60Hz three-phase AC into DC, which is then transformed into high-frequency low-voltage high-current DC at 10-30kHz, used for industrial product heating. The electromagnetic heating coil: high-speed changing high-frequency high-voltage current passing through the coil generates a high-speed alternating magnetic field. When an iron-containing container is placed on top, the container surface has cutting alternating magnetic lines, and alternating current (eddy current) is produced in the metal part at the bottom of the container. The eddy current causes the charged particles at the bottom of the container to move rapidly and randomly, colliding and frictioning with each other to produce heat energy. This achieves the effect of heating items. It is a heating method that converts electrical energy into magnetic energy, causing the heated steel surface to generate induced eddy currents. This method fundamentally solves the problem of low heat efficiency in resistance heating, such as electric heat plates and electric heating 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 insulating cotton. The wrapped insulating cotton reduces heat loss, enhancing thermal efficiency and speeding up heating while being more energy-efficient. The thickness of the insulating 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: For longer heating cylinders, group winding is used, where several turns are placed close together, then spaced a few centimeters, and multiple groups of coils are evenly wound. For shorter cylinders, a single-layer winding method is employed. (Spring winding is typically used for small heating elements with high power density, and is often used with thermal oil.)
Step 2: After wrapping with thermal insulation, secure it externally with high-temperature straps. Using high-temperature straps to secure the insulation ensures it stays in place, facilitating wrapping around the electromagnetic heating coil.
Step 3: Wrap around the electromagnetic heating coil. The length of the wire wrap varies with power levels. Ensure the specific wire lengths are combined in multiple sets, with consistent winding directions for each set. The spacing between each coil should be greater than 10 centimeters to avoid interference between multiple machines.
Step 4: Connect the two terminals of the electromagnetic heating coil wrapped around the material cylinder to the L1, L2 output of the electromagnetic heater, or to OUT1, OUT2 marked. Connect to U, V, W or R, S, T marked. Connect to a 380V three-phase power supply, N to the neutral wire; do not connect if not specified. Do not interconnect the soft switch line, power line, and electromagnetic coil line, or connect them to the housing.
Step 5: Power-On Adjustment. Measure the incoming line current (A) corresponding to the power working current. The operating frequency is typically between 9-13KHz. Higher frequency results in higher current; increase the coil turns, and vice versa. Inductance is just one of the applied parameters. Specifically, measure the working frequency and current, and adjust the coil turns to match the power. For higher heating temperature requirements, decrease the inductance. Maintain a frequency of not less than 11KHz when heating to the desired high temperature (as the workpiece temperature increases, the equivalent series resistance R rises, and the resonant frequency of RLC decreases. Similarly, an increase in R with a constant bus voltage results in a normal decrease in current).
Four: Advantages of Electromagnetic Heating Mainboard
Industrial-grade DSP Digital Processor: Fast processing speed, real-time monitoring cycle by cycle, and quick 30-protection response.
2: Mobile Remote Flashing Program/Configuration Parameters: Smart Cloud Technology, Zero Distance between Supply and Demand
3: Central Control Technology: Supports parallel connection of multiple cores at the same level, adjacent coils are close without interference, and there is no low-frequency noise. Solves interference issues in winding coils of various equipment.
4: Automatic Load Scanning: Capable of statically or dynamically scanning the coil load status, it avoids mismatched coil sensitivity, improves load adaptability, and reduces on-site debugging difficulty.
5: Digital Load Match Rate: Can directly display the load match rate when the low-power start and no start, convenient for customers to monitor and adjust the system's working status, increase product lifespan, and solve the problem of insufficient power in factory testing.
6: Long-distance heating: Insulation thickness can exceed 5 centimeters, with high thermal efficiency in high-temperature applications and a 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 capacitance operation, not damaged under extreme conditions.
9: AI Smart 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 Fitoelectromagnetic Heater
Five: Applications of Electromagnetic Heater
1. Plastic and rubber industry, including: blowing film machines for plastic, drawing machines, injection molding machines, granulators, extruders for rubber, vulcanizing machines, and cable production extruders, etc.
2. Building materials industry, including: pipeline production lines, plastic pipe production lines, PE rigid flat meshes, geotextile machines, automatic hollow molding machines, PE honeycomb board production lines, single/double wall corrugated pipe extrusion lines, composite air cushion film machines, PVC rigid pipes, foam core tube production lines, PP extruded transparent sheet production lines, extruded polystyrene foam pipes, PE缠绕膜机组.
3. Energy and food industry applications, such as: heating for crude oil pipelines; food machinery, such as: ultra-charge machines and other electrically heated equipment.
4. High-power commercial induction 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 good ventilation within the instrument.
2. If the environment is corrosive gas, it is necessary to apply insulating varnish. Alternatively, use other insulating anti-corrosion materials.
3. Do not attempt to repair or pour water on the device while it is still powered on. Use a fire extinguisher in case of fire! 3. The air temperature must not exceed 50℃.
Seven: Main Application Fields of Electromagnetic Heater Products:
Industrial heating equipment such as plastic machinery injection molding machines, granulators, blow film machines, drawing machines, thermal oil, diffusion pumps, boilers, etc., in the electromagnetic heating energy-saving transformation; residential heating products like electromagnetic water heaters, electromagnetic water bottles, electric cooktops, electric wall heaters, and other electromagnetic heating appliances.
