Which is used to heat metal parts of cars without causing harm to adjacent parts.
Induction heater produces heat without the use of physical contact or fire. Does not require complete dismantling of parts adjacent to the heated part that are not resistant to heat
The new induction heater is 50% more powerful than the previous version CH33
Using the induction heater CH 37, various types of work can be performed:
heating rusted bolts and nuts
heating rusted door hinges
heating of steel and aluminum surfaces during repairs
heating rusted bolts with exhaust pipe flanges in hard-to-reach places
heating of rusted bolts and nuts of suspension and steering
easy removal of anti-corrosion coating and PVC putty.
Induction heater designed to heat all magnetic (thermal conductive) materials by concentrating the magnetic field at the end of the heater. But, the heater also works well with aluminum. The magnetic field oscillates at a frequency of approximately 55 kHz. The magnetic field creates an eddy current in the material, and electrical resistance leads to heating of the metal.
CH 37 has an internal cooling system, water acts as a coolant. The circulating water cools the power electronics, cables, induction heater handle, and the heater itself. Once the heater turns on, the water pump begins pumping cooling water into the heater.
Specifications:
- Supply voltage 208-240 V, 16 A, 1 phase
- Frequency: 50-60Hz
- Protection class: IP21
- Working cable length: 3m
- Cooling: water (20 l)
- Device weight: 34 kg
Induction heater for a wide range of applications
In April 2008, the famous Swedish company CAR-O-LINER officially introduced a new induction heater with increased power CH37. The new product is more powerful than the previous version CH33 by as much as 50%!
The CH37 uses the latest technology - compare: when using a gas burner for local heating, you are limited when working in close proximity to plastic and other heat-sensitive materials. The CH37 heater is also used to heat parts, but without an open flame (!!!) - surfaces are heated by high-frequency currents, which makes it possible to heat parts and surfaces even in the most inaccessible places.
This type of heater is designed to heat all magnetic (thermal conductive) materials by concentrating a magnetic field at the end of the heater. However, the heater also works well with aluminum. The magnetic field oscillates at a frequency of approximately 55 kHz. The magnetic field creates an eddy current in the material, and electrical resistance leads to heating of the metal.
CH 37 has an internal cooling system, water acts as a coolant. Circulating water cools the power electronics, cables, heater handle and the device itself. As soon as the induction heater turns on, the water pump starts pumping cooling water into it.
Induction heating
At the beginning of 2010, Gas Injection WorldWide, a partner of Japanese Injection Molding Machines in gas/water/steam injection technologies, carried out the world's first commercial launch of a new technology - external induction heating as part of the general RTC (Rapid Temperature Cycling) technology.
In issue 10-2009 of the Plastics magazine, our company allows us to achieve high gloss by heating the mold before injection and during filling of the product cavity. This technology is excellent for volumetric or large flat products, giving them not only shine without coloring, but also eliminating internal stresses and numerous defects that are inevitable during conventional casting.
RTC IHC technology - external induction heating - is used for another group of products - small products with maximum dimensions of 30 x 30 x 3.0 cm (about the size of a 15-inch monitor), which are small in height, and are conventionally called “two-dimensional”. The main advantages of external induction heating technology:
- The technology can be used with existing molds
- The heating rate of the mold surface is approximately 4 times faster than using steam casting
External induction heating technology works in the following way:
- The mold opens;
- A robot enters the mold cavity from above to remove the previous product from the movable side of the mold, and at the same time a heating device enters the mold cavity from below, which is adjacent to the stationary side of the mold (as a rule, the front surface is located on the stationary side) at a distance of 3.0-5.0 mm from the surface of the mold;
- The heating device with a copper induction coil heats the mold cavity to a predetermined temperature, usually within 3 to 6 seconds, after which the mechanical device is lowered down;
- The mold closes and the normal injection molding cycle occurs.
In induction heating, high-frequency alternating current is passed through a copper induction coil. Using a well-known electromagnetic phenomenon, the current in the induction coil induces an eddy current (Eddy Current) in the first 200 microns of steel on the mold surface. The resistance to eddy current flow in the steel creates very rapid heating of the mold surface. The shallow heating depth (200 microns) compared to the steam injection molding method (8.0 mm) allows heating to be carried out with significantly lower energy costs.
If you insert your hand between the mold and the heating device, you will not feel any heat or change in temperature, but if you put your wedding ring on, it will become very hot very quickly. Therefore, the advantage of induction heating technology is the absence of energy dissipation.
To implement this technology you need:
- Controller RTC IHC
- Copper induction coil
- Feeding mechanical heating device
Panel made of glass-filled polycarbonate
Induction heating technology can easily eliminate melt flow lines and weld lines, especially on products such as a TV remote control or mobile phone housing with buttons, camera or monitor housing, various view panels in a car, when the melt diverges and converges repeatedly. As with the use of steam casting technology, induction heating has, in addition to the shine of the product (which is achieved without painting), all the advantages of the RTC SWC technology:
- Eliminates visible cold junction lines and material flow
- High quality surface with very good gloss without staining even on standard material
- Excellent shedding of surface structure, especially difficult areas (for example, acoustic grilles on a TV case)
- Smooth surface even when using glass-filled materials
- Elimination of “silvering” on the front surface
- Improved surface optical properties - less distortion / more uniform refractive index
- It is possible to reduce the wall thickness (reduce the weight of the product and reduce the cycle time) and increase the length of the melt flow path, it is possible to reduce the holding and cooling time
- Reduced cycle time and significantly lower power consumption compared to other RTC methods
At the same time, induction heating works well on small products, and, most importantly, their shape should be “two-dimensional”, that is, the product does not have a large thickness (no more than 30mm), and induction heating is used for the front surface. The technology not only improves the appearance of the product and allows you to achieve excellent shine without expensive coloring, but also significantly reduces the number of defects.
The limitation is due to the fact that after the start of the cycle, heating stops and the temperature of the mold drops. The second time it rises when material is injected, and then falls again.
Another method of induction heating is internal induction heating, where heating elements are built into the mold. This avoids the temperature drop to a certain point, but there is a conflict between the heating zone and the cooling zone inside the mold, reducing efficiency and increasing energy consumption. In addition, unlike external induction heating, the mold must be modified, and the cost of license fees and patents is quite high.
A third method of induction heating uses the insertion of heating cartridges into a mold, similar to hot runners, but this technology has the disadvantages of the previous method and is also less effective - visible weld lines remain despite the shine of the product, and hot runners tend to burn out after a few weeks.
Similar to external induction heating is the external infrared heating method. The same device rises from below into the mold cavity once a cycle and produces heating, but with the help of infrared elements. Despite the similarity of technologies in practical results, there is a huge difference between them:
- Unlike the induction method, infrared heating radiates heat into the air. This leads to heat dissipation and energy loss;
- The big disadvantage of infrared heating method is that the energy is reflected from the polished surface of the mold, so the heating speed is very slow and the electricity consumption is high;
In general, to summarize, the infrared method uses radiant heat, while the induction method uses electromagnetic effect. Therefore, the induction method provides heating much faster, while using significantly less electricity.
The world's first customer of an external induction heating system produces a part for the automotive industry made from ABS/PC, which is then vacuum metallized. Since the negative effect of visible weld lines and melt flow paths has been reduced several times, the amount of defects compared to traditional injection molding after the metallization process has decreased several times. Using induction heating from Gas Injection WorldWide, the scrap rate after plating has been reduced to less than 2%. It is worth noting that the part is used by one of the main German car manufacturers, but its name cannot be published.
In the office of our company you can watch a video of the production of this product with the process of external induction heating.
| Photo | Name, scope of application | Brief technical characteristics |
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The vulcanization press is intended for the production of rubber products by molding in compression molds. |
1. Nominal force: 8.0 (800) mN (tf) |
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The press is designed for molding and vulcanizing rubber and asbestos products. The technological parameters of the presses allow them to be used not only for the production of rubber products, but also products from various plastics and other moldable materials. |
1. Nominal force: 2.5 (250) mN (tf) |
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The press is designed for molding and vulcanizing rubber and asbestos products. The technological parameters of the presses allow them to be used not only for the production of rubber products, but also products from various plastics and other moldable materials. |
1. Nominal force: 2.5 (250) mN (tf) |
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Heating plates of presses are rectangular plates. They are made from solid steel plates, ground and milled on all sides. The set consists of two plates. The number of heaters in a mold is determined by its mass (or heat transfer surface area), operating temperature and heater power. Heating plates can be PETN, ohmic or induction.
The Orenburg Press Machine Plant produces heating plates for hydraulic press brands DG, DE, P, PB.
The heating plates of the presses are rectangular steel plates 70 mm thick. They are made from solid steel plates, ground and milled on all sides.
The heating plate consists of two parts fastened together, in one of which grooves are milled for laying heating elements (heating elements). The power of one heating element is from 0.8 to 1.0 kW, voltage 110 V. The plates have grooves for placing heating elements with a diameter of 13 mm. Two heating elements connected in series are installed per phase.
The quality of plastic products is greatly influenced by the temperature at which they are manufactured. The temperature regime of the mold depends on the structure of the processed material and the features of the technological process chosen to produce this product.
The set consists of two plates. The number of heaters in a mold is determined by its mass (or heat transfer surface area), operating temperature and heater power. Depending on the required heating power, 6 or 12 heating elements are installed on each stove. The contact clamps are covered with covers.
To heat molds, electric heaters are mainly used, based on the use of resistance elements of various designs. The space around the spiral is reliably insulated, which increases its service life. The electric heater is located in the thickness of the mold at a distance of 30-50 mm from the forming surface, because with a closer location, local overheating is possible, which will lead to defective products.
Control of the heating temperature of the plates is ensured by the use of THC thermocouples. Heat-resistant wire placed in a metal sleeve safely connects the plates to the cabinet.
| Heating plates for hydraulic press P, PB | |||
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Used for heating removable molds heating plates, in which channels are drilled to accommodate tubular electric heaters. The heating plates are attached to the press platens through insulating pads to reduce heat transfer to the press. For stationary molds, heating plates are attached to the bottom of the die and to the top of the punch.
Recently, induction heating of molds with electric current of industrial frequency has become widespread. With induction heating, electricity consumption is reduced, the heating time of the mold is reduced, and the service life of electric heaters is increased.
For purchasing questions heating plates for presses please contact us via the feedback form or by phone numbers listed in the contacts.
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Form of payment, delivery procedure, warranty of heating plates:
- Sales are carried out on the terms of 50% prepayment when ordering slabs for production and 100% prepayment if they are in stock.
- Delivery is carried out by transport companies of the Supplier or Buyer by agreement, as well as by railway transport.
- Transport costs for delivery of goods are paid by the Buyer.
- The warranty for all new products is 12 months, for products after major overhaul - 6 months.
Please note that the information on the site is not a public offer.