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Installation Tips 2 and Preventive Maintenance-Cartridge Heaters
Evaluating 2 Your cartridge Heater Problems
Heat Calculations Watt Density Catridge Heaters-2
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Evaluating Your Cartridge Heater Problems:
Improvement of your cartridge heater can be the single most cost effectiveprocess improvementyou can make impacting the performance of your machine, system, or process. OEMs worldwide have relied upon National plastic Heater's ability to diagnose root causes of heater failure or improve upon the heating profile of an application.
Q. How can cartridge heater performance be optimized?
To optimize performance one must carefully consider:
Cartridge Heater location
Fit to mating surfaces and location
Temperature sensing method
Material being heated
Type of control method
Q. How can NPH assist with engineering services and provide solutions with insertion heater application problems?
NPH Cartridge Heater Engineering Services include:
Production and product development assistance
Thermal engineering consulting
Design optimization for performance and energy consumption
FEA and Lab Simulation
The more complex the design, and the more critical heat is to design performance, the greater the impact NPH Engineering services will have on your process. Your application, performance goals and future plans create a unique opportunity to explore the power of NPH Engineering services for all heat solutions with cartridge heaters.
Q.What Cartridge Heater Solutions can NPH Provide?
NPH Cartridge Heater Solutions, your smart heat management choice...
While many companies can build a general use cartridge heater, NPH and its partners are committed to manufacturing and supplying the best cartridge heater specifically for your application. When you see the design elements beyond the obvious similarities to commodity heaters, critical engineering decisions can be made to dramatically improve durability, product quality, responsiveness and cycle time.
Every application carries with it performance requirements that must be carefully considered. Factors such as movement, moisture, dimensional tolerances, operating temperature, material being heated, and environmental conditions will impact the design of the cartridge heater.
NPH manufactures cartridge heaters with better components, materials and precision…….
High watt density cartridge heaters are built with 8” long ceramic cores, 33% longer than our competitors, resulting in fewer electrical connections on longer heaters.
Standard stainless steel sheath is SS321 for improved corrosion resistance (incoloy is also available).
New, compact right angle exit with flat sides to aide removal. (When cartridge heaters last as long as NPH’s do, this is important)
Anti-seize coating applied in house for faster delivery.
Centerless grinding option to a tolerance of +/- .0008” for a better fit.
Computer controlled winding ensures the right wattage distribution profile on every heater, every build.
Technical support to understand your application and design a cartridge heater with your specific use in mind.
Attaining and maintaining ISO 9001 since 2000.
High watt density vs. medium watt density construction
All cartridge heaters NPH manufactures are swaged (highly compacted) heaters. Customers who require precise, durable heat should accept nothing less. The compaction created during the swaging process enables the cartridge heaters to more responsively deliver heat, and provides the resistance wire with dense thermal mass improving performance and heater life greatly over loose fill cartridge heaters. Both high watt and medium watt construction can be built as an energy saving eheat cartridge heater.
Q. What are Eheat Cartridge Heaters?
NPH eheat cartridge heaters are constructed with a special high thermal transfer sheath materialthat creates a fast responding, longer lasting, more energy efficient heater.At the same rated wattage, NPHl is a leading supplier of cartridge heaters that have measured up to 25% improved energy efficiency over traditional build cartridge heaters.
Our eheat cartridge heaters are the fast responding, energy efficient and direct replacements for your existing cartridge heaters. Extend the capabilities of your existing system with eheat cartridge heaters manufactured by NPH, or develop around its strengths to bring smart heat management capabilities to your market.
The high thermal transfer sheath results in a cartridge heater that can perform the same work with fewer watts - saving energy and reducing total system amperage.
For higher watt density applications such as a hot glue system, the eheat delivers heat to the application faster, resulting in more heat delivered with a lower heater core temperature. This extends cartridge heater life.
NPH eheat cartridge heaters reach set point faster, and can reduce cycle times of demanding applications.
High watt density cartridge heaters
The machine winding of the high watt density cartridge heater delivers the most precise distributed wattage profile. High watt density heaters supplied by NPH can be built to your specifications from 1” long to over 100”. Warranted to 160 watts per square inch.
Specify a high watt density cartridge heater if:
* High watt density cartridge heaters are commonly built below 65 watts per square inch and in lengths up to 100” long for specific applications.
Medium watt density cartridge heaters
The medium watt density cartridge heater has a continuous resistance spiral throughout the heater delivering unparalleled reliability. For longer cartridge heaters there are fewer internal electrical connections. Medium watt density heaters start at 8”long and can be built to over 100”. Each medium watt density cartridge heater supplied by NPH is warranted to 65 watts per square inch.
Specify a medium watt density cartridge heater if:
*In the past only high watt density cartridge heaters could support an internal type J or K TC. NPH can now manufacture medium watt density cartridge heaters with an internal Thermocouple.
Consists of the following cartridge/insertion heater categories:Standard imperial and metric round cartridge heaters
Medium watt density cartridge heaters
High watt density cartridge heaters
Split sheath cartridge heaters
Square cartridge heaters
Small diameter/miniature pencil heaters
Bolt cartridge heaters
Custom cartridge/insertion heaters
Applications for the above include:Cartridge Heaters for-Extrusion Dies, Liquid Immersion
Metric Heaters for-Plastic Molds and Injection Molding
Insertion Heaters for-Plastics Extrusion
Custom Cartridge Heaters for-Packaging Machinery, Labeling and Sealing
Square and Round Cartridge Heaters for-Hot Plates and Platens, Hot Stamping
Cartridge Heaters for-Hot Runner Molds, Various Types of Dies
Insertion Heaters for- Medical Equipment and Other Industrial Applications
The square cartridge heater configuration simplifies wiring and installation while optimizing performance in a wide range of solid, liquid, and gas heating applications. Tooling applications are particularly well served by the square cartridge heater approach. Typical square cartridge heating applications include platens, molds, sealing bars, sealing plates and dies. Versatile slot style mounting simplifies installation in small tooling components such as bushings and nozzles and is particularly useful when leads must exit at a specific location on the component surface.
Some applications demand much longer heater life, that is where miniature small diameter pencil/cartridge heaters have immense application value. Life expectancies of five, seven or even ten years are not unreasonable for some mission-critical applications:
Blood warmers used in medical theaters must never fail
Battery conditioners for EVA spacesuits on the International Space Station must last ten years before replacement, due to payload costs
Here on earth, high throughput semiconductor chip testers must operate without significant downtime for the 5 year life of the equipment. For these applications, a service life of 50,000 to 90,000 hours is a requirement that is both reasonable and attainable.
Some common issues with most standard cartridge heaters are as follows:
Heater removal: a cartridge heater will oxidize after many hours of operation and maybe difficult to remove. Consider drilling a through hole so the heater can be hammered out or choose a split sheath cartridge heater.
Lubricants: like graphite or silicone facilitate the insertion of the cartridge heater but can carbonize at higher temperature and then the heater will be really stuck.
The NPH split sheath cartridge heateris designed especially for platen, die or mold industrial heating applications where the holes are poorly drilled or worn through age. Independent expansion of each section of the split sheath cartridge heater when energized, creates intimate contact with the wall of the hole.
Through the patented split-sheath design and highly specialized manufacturing techniques, NPH split sheath insertion heaters reduce your total cost of process heating by an average of 40% over other heaters.
NPHs split sheath cartridge heaters use a unique, patented split-sheath design that expand when energized to maximize heat transfer through greater contact with the wall of the bore. Better heat transfermeans less power is consumed to maintain the set point temperature, reducing operating costs.
Bolt cartridge heaters are used to tighten large bolts that secure heavy machinery and equipment. The shaft of the heater is inserted into the hollow bolt and energized to expand it, which allows further tightening of the nut. Manufactured with a high watt density, they heat up in just a few minutes, resulting in cost savings on reduced man hours removing nuts from bolts and studs. Large bolts can be heated to full expansion in just a few minutes. This heater design is manufactured with specific diameter sheaths to fit industry standard hollow bolts. High watt densities with special heated lengths distribute heat evenly to surrounding bolt.
Telephone: 905-859-8225 Facsimile: 905-859-4691
Toll Free: 1-877-674-9744
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