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 heating controller converts 220V, 50/60Hz AC power into DC power, which is then transformed into high-frequency, high-voltage DC power at 20-40kHz, or converts 380V, 50/60Hz three-phase AC power into DC power and then into high-frequency, low-voltage, high-current DC power at 10-30kHz, for industrial product heating. The electromagnetic heating coil: High-speed alternating high-frequency high-voltage currents passing through the coil generate 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 currents (eddy currents) are induced in the metallic bottom part of the container. The eddy currents cause 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 heat generation effect is achieved by converting electrical energy into magnetic energy, causing induced eddy currents on the surface of the heated steel, which is a method of heating. This method fundamentally solves the issue of low heating efficiency in resistive heating elements like electric heaters and heating coils, which rely on heat conduction.

2: Structure of electromagnetic heaters

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 accelerating heating speed while being more energy-efficient. The thickness of the insulation cotton is specified: for low-power models, 1.5cm is ideal, while for high-power models, 2-2.5cm is recommended (after wrapping; 10KW and above are considered high-power). Winding method: For longer barrel lengths, group winding is used, where several turns are grouped together, spaced a few centimeters apart, and evenly wound in multiple groups. For shorter barrel lengths, a single-layer winding method is employed. (Spring winding is typically used for smaller heating elements with high power density, and is often used with thermal oil.)

Step Two: After wrapping with thermal insulation, secure the exterior with high-temperature straps. The use of high-temperature straps to secure the insulation is to ensure 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. The specific wire lengths and multiple combinations of wrap directions must be uniform. The spacing between each coil group 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 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 for neutral wire, no connection if not applicable. Do not interconnect the soft switch wire, power supply wire, and electromagnetic coil wire, or connect them to the housing.

Step 5: Power-on Debugging. Measure the input current (A) corresponding to the rated power working current. The operating frequency is typically between 9-13KHZ. Higher frequency corresponds to higher current, and more turns in the coil; vice versa. Inductance is just one of the applied parameters. Specifically, measure the operating frequency and current, and adjust the coil turns to match the power. For higher heating temperature requirements, reduce the inductance. The operating frequency should be within 11-28KHz, maintaining a frequency of at least 11KHz when heating to the required high temperature (as the workpiece temperature increases, the equivalent series resistance R increases, and the resonant frequency of RLC decreases; similarly, as R increases, the current will decrease under constant bus voltage, which is normal).

Four: Advantages of the Electromagnetic Heating Mainboard

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

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 without low-frequency noise. Resolves interference issues in coil winding of various equipment.

4: Automatic Load Scanning: Capable of statically or dynamically scanning the coil load status, to prevent mismatched coil sensitivity, enhance load adaptability, and reduce on-site debugging difficulties.

5: Digital Load Match Rate: Visually displays the load match rate when the equipment is on low power start or not running, facilitating customer monitoring and system adjustment for improved product longevity and addressing power shortage issues in factory testing.

6: Long-distance heating: Insulation thickness can exceed 5 centimeters, with high thermal efficiency in high-temperature applications and a long service life for coils.

7: 304 Long-Distance Heating: Unique control technology, no heating of the coil, excellent equipment operating parameters.

8: Resonant Capacitor Monitoring: Capacitor status monitoring software that continuously monitors the operational state of resonant capacitors, ensuring no damage in 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 Electric Heating Element

Five: Application Range of Electromagnetic Heaters

1. Plastic and rubber industry, including: blowing film machines for plastic, extruders, injection molding machines, granulators, rubber extruders, vulcanizers, and cable production extruders, etc.

2. Construction materials industry, including: gas pipeline production lines, plastic pipe production lines, PE rigid flat mesh, geotextile mesh units, automatic honeycomb molding machines, PE honeycomb board production lines, single and double wall corrugated pipe extrusion lines, composite air cushion film 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 industry applications, such as: heating of crude oil pipelines; food machinery, such as: super loaders and other electrically heated equipment.

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 good ventilation within the instrument.

2. If the operating environment contains corrosive gases, it is necessary to apply insulating varnish. Alternatively, use other insulating and corrosion-resistant 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 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.