Electric machines have significantly improved the vitality efficiency of the injection molding industry during the last 20 years. New approaches to save energy and maintain costs down in times of rising energy costs is the need of the hour. Melt-stream heating, particularly of your barrel, presents a solid prospect. Typically, 30-70% in the power consumed by mica band heaters is wasted by radiation and convection on the surrounding environment. Eliminating these losses will reduce specific energy usage and let machines being pre-heated faster using the same power delivery infrastructure, thereby reducing downtime to improve productivity. Inherent characteristics of band-heaters also hamper temperature control response, limiting improvements partly-to-part quality uniformity and efforts to lower change-over times. A band heater’s temperature must first go above those of the barrel ahead of the barrel could be heated, and conversely, a band-heater’s temperature must fall below that relating to the barrel before it can be cooled. The thermal mass of band-heaters as well as the thermal contact resistance between the two as well as the barrel, therefore significantly boost the thermal inertia of your melt stream. The current introduction of lower weight radiant heating elements provides an opportunity for improvement. Another new technology which offers significant advantages is noncontact induction. Barrel heating using helical induction coils has been considered for years, but was poorly applied. Past efforts often used inefficient low-frequency power supplies and also position the coils in direct connection with the barrel, undermining the compelling benefits of induction. Heat generated inside the barrel was still allowed to escape to ambient and the coils’ thermal mass wasn’t taken off the equation. Experience of the recent barrel also increased the coil’s electrical resistance & reduced efficiency gains.
Xaloy nXheat™ induction barrel heating (patent pending) sharply cuts energy costs and improves temperature control for better quality and less scrap in comparison with conventional heater bands. The nXheat ™ barrel heating solution (patent-pending) uses an optimized high-frequency power supply plus a thermal insulating layer interposed between your barrel and coils to handle the aforementioned issues and exploit the entire potential of induction. All the heat is generated directly throughout the barrel and stays at the same time. The coil’s thermal mass is also eliminated, and coil resistive losses are negligible so the exterior surface is cool to touch. Barrel heating efficiency approaches 100 % and temperature control response is quite a bit improved.
Energy savings for barrel heating as high as 70% in comparison with heater bands
• Additional energy savings – upto 35% more – on account of reduced air conditioning load
• Additional energy cost reduction from reduced peak power demand
• Fewer heater failures to slice downtime and maintenance costs
• Immediate cooling and heating reaction to improve quality and lower scrap
• Quicker heat-up, typically 2X or even more, to boost productivity
• More heating capacity- typically 3X higher wattage to the barrel- eliminates a bottleneck
• Higher barrel temperature capacity to mold high-temperature polymers, or metal
• Cool exposed surfaces for increased operator safety
The nXheat™ system works with a high-frequency power source and helical induction coils to create heat directly throughout the barrel wall. A thermal insulating layer is interposed between your coils and barrel to combat heat loss, increase efficiency and improve control response.
The program can be purchased in two forms:
1) all-zone nXheat™ by which induction heating completely replaces conventional heater bands;
2) nXheat-Hybrid™ by which power-saving induction technology heats the barrel’s feed zone while conventional band heaters handle downstream zones.
All-zone nXheat™ delivers maximum savings in power consumption, about 50-70%. This is the ideal system for larger machines with more than three heating zones due to high worth of the lowering of power consumption.
On smaller machines with several zones the nXheat-Hybrid™ system can deliver the majority of the savings of the all-zone system because induction is commonly used in the barrel’s feed zone where the greatest quantity of heat input is needed to start the melting process. On such machines, which usually have barrels with inside diameters of 50 mm or less, the hybrid system will typically give a 30 to 50% decrease in power consumption.
Inside the hybrid system, downstream zones dexmpky42 use either insulated or uninsulated band heaters. Greater energy savings are achieved with the aid of insulated band heaters. A similar sheet insulation that is utilized within the induction-heated feed zone may be used to wrap the downstream band heaters. The precision and fast response of induction heating within the feed zone will likely substantially reduce temperature overshoot conditions that can occur with insulated band heaters.
The program will pay for itself with power cost savings and other cost and quality benefits. Some examples are reduced scrap stemming from less variation in melt temperature and faster reaction to modifications in target melt temperature. The payback period on investment costs for these particular systems is tremendously determined by electricity rates, machine size and production schedule (hours of operation each year). Such a system typically costs about 25-50% of the all-zone system.