One: Principle of electromagnetic heater
An electromagnetic heater is a device that converts electrical energy into thermal energy using the principle of electromagnetic induction. The electromagnetic heater controller converts 220V, 50/60Hz AC into DC, then transforms the DC into high-frequency, high-voltage electricity at 20-40KHz, or converts 380V, 50/60Hz three-phase AC into DC, which is then transformed into high-frequency, low-voltage, high-current electricity at 10~30KHz. This is used for heating industrial products. The electromagnetic heating coil: high-speed alternating 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 surface of the container cuts through the alternating magnetic field lines, and alternating currents (eddy currents) are produced in the metallic bottom part of the container. The eddy currents cause the charged carriers at the bottom of the container to move rapidly and randomly, colliding and rubbing against each other to produce heat energy. This results in the heating effect on the item. It is a heating method that, by converting electrical energy into magnetic energy, generates induced eddy currents on the surface of the heated steel body. This method fundamentally solves the issue of low thermal efficiency in resistance heating methods such as electric heating 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 insulated cotton can reduce heat loss, enhancing heat efficiency and speeding up heating while being more energy-saving. The thickness of the insulating cotton is specified; for low-power, 1.5cm is ideal, and for high-power, 2-2.5cm is preferable (after wrapping; 10KW and above are considered high-power). Coiling method: Generally, for longer heating tubes, use a grouped coiling method, where several turns are placed close together, spaced a few centimeters apart, and evenly wrap multiple groups of coils. For shorter, narrow tubes, use a concentric coiling method. (Spring coiling is typically used for small heating elements with high power density, and is often employed with thermal oil.)
Step 2: After wrapping with thermal insulation, secure the exterior 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 varies depending on the power, with different wire lengths required. The specific winding length and multiple combinations must have a unified winding direction. The spacing between each coil should be greater than about 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 output terminals of the electromagnetic heater, which are marked as L1, L2, or OUT1, OUT2. Connect to U, V, W, or R, S, T labels. Connect to a three-phase 380V power supply, with N connected to the neutral wire; no connection is required. Do not interconnect the soft switch line, power line, and electromagnetic coil line, nor connect them to the housing.
Step 5: Power-on Debugging. Measure the input current (A) with a clamp meter to correspond to the working current for the power rating. The operating frequency should be within the range, typically between 9-13 KHz. Higher frequency corresponds to higher current; increase the coil turns, vice versa. Inductance is just one of the applied parameters; the specific values need to be measured for the working frequency and current. Adjust the coil turns to match the power rating. For high heating temperature requirements, reduce the inductance. Maintain an operating frequency of 11-28 KHz, ensuring the frequency is not below 11 KHz when heating to the required high temperature (as the workpiece temperature increases, the equivalent series resistance R increases, resulting in a lower resonance frequency for RLC. Similarly, an increase in R with a constant bus voltage will result in a decrease in current, which is normal).
Four: Advantages of the Electromagnetic Heating Mainboard
1: Industrial-grade DSP Digital Processor: Fast processing speed, real-time monitoring and 30 protective responses with quick response.
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 is no low-frequency noise. Resolves 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 complexity.
5: Digital Load Match Rate: Clearly displays the load match rate at low power startup and shutdown, facilitating customer monitoring and system adjustment for improved product lifespan and addressing insufficient power during factory testing.
6: Long-distance heating: Insulation thickness can exceed 5 cm, high-temperature application systems have high thermal efficiency, and coil lifespan is long.
7: 304 Long-distance Heating: Unique control technology, no heating in the coil, excellent equipment operating parameters.
8: Resonant Capacitance Monitoring: Capacitance status monitoring software, real-time monitoring of the working condition of resonant capacitors, not damaged 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 Fitoelectromagnetic Heater
Five: Application Range of Electromagnetic Heaters
1. The plastic and rubber industry, including plastic blowing film machines, drawing machines, injection molding machines, granulators, rubber extruders, vulcanizing machines, 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 molding 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 industries, such as: heating for crude oil pipelines; food machinery, such as: overfilling machines and other electrically heated equipment.
4. High-power commercial electromagnetic stove core.
5. Drying and heating in printing equipment.
Six: Maintenance of Electromagnetic Heaters
The main unit should be dusted regularly, typically every two 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 environment is corrosive gas, apply insulating varnish. Alternatively, use other insulating and anticorrosive materials.
3. Do not attempt to repair or submerge in water while the device is still plugged in. Use a fire extinguisher in case of fire. 3. The 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, drawing machines, thermal oil, diffusion pumps, boilers, etc., in electromagnetic heating energy-saving transformation; residential heating products like electromagnetic water heaters, electromagnetic water bottles, electric stoves, wall-mounted water heaters, and other electromagnetic heating appliances.
