Electromagnetic Heater Principle
An electromagnetic heater is a device that converts electrical energy into heat energy using the principle of electromagnetic induction. The electromagnetic heating 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, for industrial product heating. 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 above it, the container surface has cutting alternating magnetic lines, and alternating current (eddy current) is produced in the metallic bottom part of the container. The eddy current causes the charge carriers at the bottom of the container to move rapidly and randomly, colliding and frictioning with each other to produce heat energy. This effectively heats the items. It is a heating method that converts electrical energy into magnetic energy, causing induced eddy currents on the surface of the heated steel, fundamentally solving the issue of low thermal efficiency in resistance heating methods such as electric heating plates and coils, which heat through conduction.
Two: Structure of electromagnetic heater
Step 3: Installation Instructions for the Electromagnetic Heater
Step 1: Wrap the extruder barrel with insulation cotton. The wrapped insulation cotton reduces 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, and for high-power (10KW and above), 2-2.5cm is recommended (after wrapping). Winding method: For long heating cylinders, use grouping winding, where several turns are grouped together, spaced a few centimeters apart, and evenly wrapped in multiple groups. For short, thin cylinders, use the overlapping winding method. (Spring winding is typically used for small heating elements with high power density, where thermal oil is commonly used.)
Step 2: After wrapping with thermal insulation, secure it externally with high-temperature straps. The use of high-temperature straps is to firmly hold the insulation in place, facilitating wrapping around the electromagnetic heating coil.
Step 3: Wind around the electromagnetic heating coil. The length of the winding varies with the power, with different winding lengths required. The specific winding lengths should be in multiple sets, with a uniform winding direction for each set. The spacing between each coil should be greater than 10 centimeters to avoid mutual 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, with N connected to the neutral wire; no connection is needed for the remaining wire. Do not intermix the soft switch wire, power supply wire, and electromagnetic coil wire, nor should they be connected to the housing.
Step 5: Power-on Debugging. Measure the incoming current (A) to match the corresponding working current for power operation; the working frequency is typically between 9-13KHz. Higher frequency results in higher current, and increasing the coil turns has the opposite effect. Inductance is just one of the applied parameters; specifically, measure the working frequency and current, then adjust the coil turns to match the power. For higher heating temperature requirements, decrease the inductance slightly. The working frequency should remain above 11KHz when maintaining the desired high temperature (as the workpiece temperature rises, the equivalent series resistance R increases, the resonance frequency of RLC decreases; similarly, an increase in R, with the bus voltage unchanged, leads to a decrease in current, which is normal).
Four: Advantages of Electromagnetic Heating Mainboard
1: Industrial-grade DSP Digital Processor: Fast processing speed, real-time monitoring cycle by cycle, and quick 30-item protection response.
2: Mobile Remote Flashing Program/Configuration Parameters: Smart Cloud Technology, Zero Distance in Supply and Demand Relationship
3: 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 various issues related to coil winding interference in equipment.
4: Automatic Load Scanning: Capable of statically or dynamically scanning coil load status, avoiding mismatched coil sensitivity, enhancing load adaptability, and reducing on-site debugging complexity.
5: Digital Load Match Rate: Directly displays the load match rate when starting with low power or not starting, facilitating customer monitoring and system status adjustment, enhancing product lifespan, and addressing insufficient power in factory testing.
6: Long-distance heating: Insulation thickness can exceed 5 centimeters, with high thermal efficiency in high-temperature applications and long coil lifespan.
7: 304 Long-distance Heating: Unique control technology, no coil heating, excellent equipment operating parameters.
8: Resonant Capacitor Monitoring: Capacitor status monitoring software, real-time monitoring of the resonant capacitor's working condition, non-destructive under extreme circumstances.
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 Fitoo Electromagnetic Heater
Five: Application Range of Electromagnetic Heater
1. Plastic and rubber industry, including blow molding machines for plastic, drawing machines, injection molding machines, granulating machines, extruders for rubber, vulcanizing machines, and cable production extruders, etc.
2. Construction materials industry, including: gas pipeline production lines, plastic pipe production lines, PE rigid flat mesh, geotextile machine units, automatic hollow molding machines, PE honeycomb board production lines, single and double-wall corrugated pipe extrusion production lines, composite air cushion film machine units, PVC rigid pipes, core foam tube 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 of crude oil pipelines; food machinery, such as: overloading 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, apply insulating varnish. Alternatively, use other insulating anti-corrosion materials.
3. Do not attempt to repair or submerge in water while the product is powered on. Use a fire extinguisher in case of fire! 3. 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, blowing film machines, wire 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, electromagnetic stoves, electromagnetic wall-mounted boilers, and other electromagnetic heating appliances.
