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, for industrial product heating. The electromagnetic heating coil: high-speed changing high-frequency high-voltage current passing through the coil generates a high-speed changing alternating magnetic field. When an iron-containing container is placed on top, the container surface possesses cutting alternating magnetic lines, and alternating currents (eddy currents) are produced in the metallic bottom part of the container. The eddy currents cause the charged particles at the bottom of the container to move rapidly and randomly, colliding and frictionally generating heat energy. This, in turn, achieves the effect of heating 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 like electric heat plates and heating coils, which heat through conduction.
Two: Structure of the electromagnetic heater
Step 3: Installation Instructions for the Electromagnetic Heater
Step 1: Wrap the extruder cylinder with insulating cotton. The wrapped insulating cotton reduces heat loss, enhancing thermal efficiency and accelerating heating speed while being more energy-saving. There is a requirement for the thickness of the insulating cotton; for low-power, 1.5cm is ideal, while for high-power, 2-2.5cm is preferable (after wrapping, 10KW and above are considered high-power). Winding method: Generally, 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 of coils. For shorter, smaller cylinders, use the single-layer winding method. (The spring winding method is usually used for smaller heating elements with high power density, and heat transfer oil is often used in this manner.)
Step 2: After wrapping with thermal insulation, secure it externally with high-temperature straps. Using high-temperature straps to secure the insulation is to keep it 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. The specific wire lengths for multiple combinations must be uniform, with a spacing between each coil of about 10 centimeters or more 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 of the electromagnetic heater, which are marked as L1, L2, or OUT1, OUT2. Connect to U, V, W, or R, S, T. Connect to a three-phase 380V power supply, and connect N to the neutral wire; do not connect if not applicable. Do not cross-thread the soft switch wire, power supply wire, and electromagnetic coil wire, and ensure they are not connected to the housing.
Step 5: Power-on Adjustment. Measure the input current (A) to match the power operating current. The operating frequency should be within the range, typically between 9-13 KHz. Higher frequency corresponds to higher current, and vice versa. Inductance is just one of the applied parameters. Specifically, measure the operating frequency and current, and adjust the number of coil turns to match the power. For higher heating temperature requirements, decrease the inductance. The operating frequency should be between 11-28 KHz, maintaining a frequency of at least 11 KHz when heating to the desired high temperature (As the workpiece temperature increases, the equivalent series resistance R increases, causing the resonance frequency of the RLC to decrease. Similarly, with R increasing and bus voltage unchanged, a slight decrease in current is normal).
Four: Advantages of the Electromagnetic Heating Mainboard
1: Industrial-grade DSP Digital Processor: Fast computing speed, real-time monitoring cycle by cycle, and quick response to 30 protection functions.
2: Mobile Remote Flashing Program/Configuration Parameters: Smart Cloud Technology, Zero Distance between Supply and Demand
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 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: Clearly displays the load match rate when starting at low power or not starting, facilitating customer monitoring and adjustment of system operation status, extending product life, and solving power shortage issues in factory testing.
6: Long-distance heating: Insulation thickness can exceed 5 cm, 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 that real-time monitors the working condition of resonant capacitors, ensuring no damage in extreme situations.
9: AI Intelligent Algorithm: Automatically scans and detects the installation direction of current sensors, and only one output current sensor needs to be installed to calculate power. Advantages of the Fit Electromagnetic Heater
Five: Applications of Electromagnetic Heaters
1. The plastics and rubber industry, including blowing machines, extruders, injection molding machines for plastics, granulating machines, as well as extruders, vulcanizing machines, and cable production extruders for rubber.
2. Construction materials industry, including: gas pipeline production lines, plastic pipe production lines, PE rigid flat mesh, geotextile machine groups, automatic honeycomb molding machines, PE honeycomb board production lines, single and double wall corrugated pipe extrusion production lines, composite air cushion film machine groups, PVC rigid pipes, core foam tube production lines, PP extruded transparent sheet production lines, extruded polystyrene foam pipe materials, and 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 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 operating environment is in 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 device is powered on. Use a fire extinguisher in case of fire. 3. The air temperature must not exceed 50°C.
Seven: Main Application Fields of Electromagnetic Heaters
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; as well as domestic heating products like electromagnetic water heaters, electric water bottles, electric cooktops, electric wall-mounted boilers, and other electromagnetic heating appliances.
