Furnace and oven increase output 10-fold
When Thermacore recognised that they needed to decrease their time to market and increase their production speeds they were recommended a batch brazing oven and high temperature sintering furnace.
When Thermacore, a world-class leader in the field of advanced thermal management operating in the Power, Telecom, Computer and Industrial markets, recognised that they needed to decrease their time to market and increase their production speeds they approached Elite Thermal Systems to develop a solution. Commenting on the reason why investment in the new equipment was necessary, Gavin Wood, materials manager of Thermacore Europe, said, ‘We discovered the need for Elite’s services when it became apparent that the production stage of a core product could be optimised. Without the capacity to support the market demand for sintered heat pipes, we knew investment in new equipment had become essential.
Elite Thermal Systems’ engineers developed a very innovative approach to the problem.
Their solution presented us with a design encompassing the implementation of a batch brazing oven and a high temperature sintering furnace.
The sintering furnace now enables us to process ten times the quantity at one time, thus hugely increasing our capacity for this product.’ The brazing process is carried out in a 300 deg C air recirculation batch oven which incorporates a forced cooling system and a custom designed load carrier/ transportation system.
The heating and cooling cycle is controlled very precisely to maintain the integrity and quality of the brazed joints.
On completion of the process cycle the operator is alerted by audible and visual alarms.
During the unloading process the oven is held at a ’stand by’ temperature in readiness for the next load.
The sintering process is carried out in an elevator furnace with a two trolley/hearth system that minimises lost time during the unloading/loading stage.
The heat pipes are loaded into special carrier jigs on the furnace hearth which are then covered by the retort.
The retort is then purged with inert gas prior to being elevated into the pre-heated furnace chamber.
Throughout the process cycle a reducing atmosphere is maintained inside the retort.
The sintering process is fully automated throughout the heating and cooling cycle providing close temperature control within the retort to optimise product quality and yield.
On completion of the process the operator is alerted by audible and visual alarms.
The hot retort is removed from the furnace and placed into a protected cooling area.
The second pre-loaded retort is then elevated into the furnace chamber and the whole cycle is repeated.
Focusing on Elite’s commitment to customer service and support Gus Sumner, maintenance manager at Thermacore commented, ‘Elite Thermal Systems understood our requirement and produced a viable solution to our problem.
From design to implementation, the service received was very good and although we have no maintenance or service agreement with Elite, we feel assured that if a problem were to occur they would be on-site to solve it.’
Control system upgrades materials oven
Custom-designed control system for an oven processing hazardous materials allows on-going safe operation of an otherwise obsolescent piece of equipment.
A new Oven Control System, CROCS, custom-designed and built by Celsum Technologies for an existing oven for hazardous materials had built-in features to allow safe operation of the oven, prolonging the service life of an otherwise obsolescent piece of equipment. The control system is split into three sealed but interlinked compartments. The left-hand compartment houses pneumatic components, keeping them separate from the electrical switchgear so that, for example, a failed air pipe does not cause the electrical components to be sprayed with possibly wet air.
The right-hand compartment houses three Intrinsically Safe Barriers through which the wiring to two temperature sensors and a thermal cut-out fuse are routed.
The doors of the pneumatic and barrier compartments are fitted with interlock switches to ensure that power is disconnected if their doors are opened.
The central section is fitted with a door interlock switch so that the access door cannot be opened if the power is switched on.
The central section contains the main control and switchgear items.
Two TJ34 temperature controllers are fitted, one as a ‘Policeman’ monitor to instantly cut the power to the heating system if the temperature strays over a pre-set limit, and will not allow the heaters to be reconnected until the temperature has cooled and a ‘Reset’ button pressed.
In normal operation, this ‘Policeman’ control is covered by a transparent guard to prevent accidental and unauthorised changing of the trip parameters.
The second TJ34 acts as the oven temperature controller, affording PID control and ease of use to the operator.
Power to the heaters, which is controlled by the TJ34 via a 3-phase solid-state relay, may not be engaged until the system is secure, and until the pneumatic motor driving the oven circulating fan is working, or if an alarm condition prevails, or until a manual ‘Heat’ button is pressed.
High intensity, long life, low power LED indicators show when the power is connected to the system, when air pressure is acceptable or too low, when the heaters are operational, and whether the ‘Policeman’ circuit is in ‘Safe’ or ‘Trip’ mode.
Celsum Technologies’ managing director, Dr Roy Carter, said, ‘The CROCS system was purpose-designed to meet the customer’s needs, and was installed using existing hardware and external cabling for speed and to keep costs and down-time low.
Drying system improves safety air bag manufacture
A carbon infra-red drying system, from Heraeus Noblelight, is helping Airbags International to improve the manufacture of side impact airbags.
A carbon infra-red drying system, from Heraeus Noblelight, is helping Airbags International to improve the manufacture of side impact airbags. The system has also significantly reduced scrap levels on a coating line at the company’s Congleton factory. Airbags International is a company within the Autoliv organisation, an automotive safety products provider, both in seat belts and airbags, whose list of innovations includes the side-impact airbag for chest protection, the inflatable curtain for head protection in side impacts and the anti-whiplash seat.
At its Congleton factory, Airbags International manufactures both frontal airbags and inflatable curtains.
Both of these products feature a cushion which is folded in a specific way to make it unfold fast and safely in the event of a vehicle collision.
The cushions, for both frontal airbags and inflatable cushions are produced from Nylon 66, which is woven on-site at Congleton.
An important stage in the finishing process is the silicon coating of the nylon web, after it has been washed and dried and then fixed in a Stenter.
The smooth coating ensures that the cushion will unfold without sticking when deployed, at inflation times as fast as 50 thousandths of a second.
Its smoothness also prevents any possible damage to facial skin.
However, in common with all textile factories, the environmental humidity is quite high and, as the Nylon 66 fabric is very hydroscopic, its moisture content can be as much as three per cent to five per cent when the relative humidity rises above 38 per cent.
That was causing a problem at the coating stage for the heavier cloth used for inflatable curtains.
Consequently, Airbags International decided to investigate ways to reduce the cloth’s moisture content down to two per cent to ensure the correct adhesion, drying and surface finish of the silicon coating and to reduce scrap levels.
After rejecting overall humidity control in the coating area because of the inordinate cost, on-site trials were carried out using carbon infra-red emitters from Heraeus Noblelight.
Using the data obtained in tests to establish the correlation between the relative humidity, the moisture content of the cloth and the temperature of the cloth, the infra-red heaters were operated to determine the heating profiles necessary to achieve the required moisture reductions for the various cloth recipes.
As a result, a 120kW carbon, medium wave infra-red system was installed and it proved so successful that it achieved pay-back in just 10 rolls of fabric said Heraeus.
In operation, the infra-red system is controlled by an optical pyrometer, which measures the surface temperature of the fabric and then transmits a signal to regulate the power of the 64, 2kW emitters within the infra-red module, which is mounted above the fabric web.
The cloth is coated with silicone on both sides but the critical heating operation takes place just before the coating is applied to the bottom side.
It is essential that the moisture is removed before this bottom coating is applied, otherwise it will be sealed in, potentially causing damage to the final surface finish.
The new system has been designed to heat fabric from ambient temperature to around 120 degrees C, at line speeds of up to 30 metres per minute, to suit web widths of two metres and 2.4 metres.
It has proved ideal for this application, as Mark Smith, project engineer at Airbags explained: ‘The infra-red module has been retrofitted very easily in to the coating line, with very little space requirement.
Operationally, because medium wave infra-red targets the water rather than the fabric, there has been no burning or scorching, as there could have been with alternative drying systems.
And the fast response of the carbon emitters also means that there is no damage to the coated fabric in the event of unexpected line stoppage.’
Website focuses on heater products
HEAT-LINK website focuses on providing a cross section of the most popular cartridge, band, flexible silicone rubber heaters, thermocouples, RTD sensors and temperature control design configurations.
Watlow, an innovative UK manufacturer of industrial heaters, temperature sensors and controllers, has announced the launch of a new e-commerce site, HEAT-LINK. HEAT-LINK focuses on providing a cross section of the most popular cartridge, band, flexible silicone rubber heaters, thermocouples, RTD sensors and temperature control design configurations. All products are manufactured and stocked at the UK headquarters in Nottingham.
‘Our goal is to be the thermal system e-commerce leader for product quality, customer satisfaction and on-time delivery,’ said Keith Wells, Operations Director.
Watlow are planning to expand the site to include many other popular thermal product lines in 2006 and provide customers an exclusive user facility to directly access their own product combinations.
Infra-red heating system warms tyres
An infra-red heating system using emitters from Heraeus Noblelight, is helping to ensure that some tyres in the A1 Grand Prix are at their optimum operating temperature at the start of every race.
An infra-red heating system, developed by Tyre Technology, of Holmfirth, and using infra-red emitters from Heraeus Noblelight, is helping to ensure that the tyres of some of the cars taking part in the new A1 Grand Prix are at their optimum operating temperature at the start of every race. The system has already been used successfully by various race car and tyre manufacturers throughout Europe. The correct tyre temperature is an important parameter in the operating performance of a modern race car, as it is the tyres which transmit the power to the track and the tyres which provide the frictional force to keep the car on the track.
The high specification tyres, specially developed for racing, are designed to perform at their best when they reach an optimum temperature.
Conventionally, they are heated to this temperature by means of tyre blankets while in the pits garage.
However, conventional tyre blankets feature considerable heat-up times and need to be switched on well in advance of their expected use.
They are also extremely energy-intensive and can take up to 2 hours to heat up a typical racing tyre.
In contrast, the new heating system can heat a tyre to 85 deg C from cold in less than ten minutes and heated tyres can be held, energy-efficiently at this temperature for up to 2 hours.
Essentially, the new Franc 11 system consists of an easily assembled and dismantled aluminium framework which contains ten, 2.5kW carbon infra-red emitters.
Up to four wheels at a time can be placed within the framework and the operator simply sets the required temperature, presses the start button and draws an insulating blanket into position.
The new system offers significant advantages over conventional heating blankets.
It provides deeper heat, so that heat is retained for longer and it delivers even heat so that there are no hot spots.
Warm-up times have been drastically reduced and the system is particularly energy-efficient.
Moreover, it saves valuable garage space, as one Franc 11 system can replace up to 16 sets of conventional tyre blankets.
Carbon emitters are medium wave emitters with a carbon heating element and are part of the comprehensive product portfolio offered by Heraeus Noblelight, part of the multi-national Heraeus Group.
Heraeus specialises in the production and application of high quality energy sources covering the entire electromagnetic spectrum, from ultra-violet to infra-red.
It has over 40 years experience in infra-red technology and offers the expertise, products and systems to provide efficient and effective solutions to drying, heating and curing problems throughout industry.
Three furnaces upgrade instrument making
Installation of three custom-built furnaces has upgraded and expanded production facilities for a specialist manufacturer of radio-frequency, microwave and sensing components.
Installation of three custom-built furnaces from Carbolite has upgraded and expanded production facilities for e2v technologies, a specialist manufacturer of radio-frequency, microwave and sensing components. The company produces a wide variety of components and sub-assemblies, including vacuum tubes, magnetrons, amplifiers, diodes, image sensors and thermal imaging cameras that are used for applications ranging from space exploration to radio therapy. Many of the products require dissimilar materials such as ceramics and copper to be joined, generally using silver/copper eutectic alloys.
This process is performed in a Carbolite multi-hearth ‘top hat’ furnace with a maximum operating temperature of 1200 deg C and temperature uniformity of +/-5 deg C.
The design allows three retorts to be in operation at a time and includes a parking bay for the top hat heating chamber when it is not in use.
An integral hoist moves the furnace to the required position.
The inconel retorts measure 210mm diameter x 550mm high internally and have provision for forming gas, consisting of nitrogen with a small percentage of hydrogen, to be introduced in order to create a clean atmosphere.
Each retort base has a work-piece support stand, a metal seal to maintain the atmosphere within the retort and an electric fan that cools it to 60 deg C, in order to speed up production cycles.
A limit switch automatically indicates the presence of a retort and also changes the temperature control thermocouple between the furnace and the retort, as appropriate.
A programming controller with 20 programmes and 500 segments linked to a data acquisition device controls the heating cycles, and over-temperature protection for the furnace and the work-pieces is also provided.
The forming gas atmosphere is supplied to each retort through a dedicated solenoid valve and adjustable flow meter.
A Carbolite GTF12/728 tube furnace capable of operating at up to 1200 deg C with a hydrogen atmosphere is used for processing parts before assembly.
This furnace has vacuum-formed heating elements with single zone control and accepts a work tube 1200mm long x 110mm internal diameter.
A third Carbolite furnace, which has a maximum temperature of 1800 deg C, a hydrogen gas system and a water cooling system, is used for annealing tungsten.
The design of the unit allows work-tubes, which measure 80mm ID x 1200mm long, to be changed quickly and easily if they are damaged by the high temperatures.
Both the tube furnaces are controlled by high-precision PID units with multiple programmable segments.
Over 400 ovens, furnaces catalogued
Over 400 standard ovens and furnaces, with temperatures to 2700 deg F - and customised heat processing systems for laboratory or production usage - are described in an updated catalogue.
Over 400 standard ovens and furnaces, with temperatures to 2700 deg F, are described in this updated catalog from Grieve. Custom-designed heat processing systems, too. Grieve offers laboratory, bench, cabinet, truck, walk-in and conveyor ovens; clean room and pharmaceutical ovens; laboratory and industrial furnaces; environmental test chambers, incubators and more.
For all heat processing and heat treating applications.
Catalog includes full specifications and schematics for all standard ovens and furnaces.
Grieve has representatives worldwide to serve every application.
Visit our web site to locate yours.
Thermal rig puts brake systems to the test
AP Braking has expanded and upgraded its R and D facilities with the installation of a specially modified Carbolite thermal chamber suitable for long-term test programmes involving flammable liquids.
AP Braking, a division of AP Hydraulics , has expanded and upgraded its R and D facilities with the installation of a specially modified Carbolite thermal chamber suitable for long-term test programmes involving flammable liquids. The new equipment is an upgraded version of an existing chamber used by the company for several years and is designed to accept rigs for thermal stroking tests on components such as brake cylinders and calipers. These components can incorporate a number of different metals and plastics, as well as various fluids and greases.
Thermal stroking tests are carried out by attaching components to jigs fixed inside the chambers, with hydraulic pipework passing through the oven walls to external actuators.
Up to four components can be tested at a time.
A typical SAE (Society of Automotive Engineers) test requires brake cylinders to be subjected to 1000 strokes per hour for 70 hours at a temperature of 120C to simulate conditions in an engine compartment.
The chamber has a maximum temperature of 200 deg C and can be programmed to provide temperature cycling if required.
It is integrated with the test rigs, so it automatically switches off if a fault develops, and an explosion relief panel is also fitted.
In case a component fails, surfaces that could come into contact with flammable liquids are below their auto-ignition temperature, and elements are positioned away from flammable vapours.
The chambers are also sealed to prevent liquid escaping.
Furnaces accurately heat-treat turbine blades
Two specially designed electric furnaces meet a growing need for accurately controlled diffusion and solution heat treatment of industrial gas turbine blades and nozzle guide vanes.
The Rolls Wood Group, one of the world’s leading companies specialising in the servicing of gas turbines for industrial applications, has increased its heat-treatment capabilities with the addition of two specially designed electric furnaces from Carbolite. The company employs about 400 people in Scotland, Canada and the USA and specialises in the repair and overhaul of aero-derived engines such as the RB211, Avon, Olympus and 501 used in the oil, gas and power-generation industries. The furnaces were ordered to meet a growing need for accurately controlled diffusion and solution heat treatment of turbine blades and nozzle guide vanes at the Aberdeen headquarters.
Both the Carbolite furnaces are top-loading units with inconel alloy retorts, 600mm diameter x 1000mm high internally, which allow the use of gas atmospheres.
One unit has a maximum nominal temperature of 1200 deg C and is designed for use with argon, while the other heats to 1250 deg C and can be used with argon and hydrogen if a surface cleaning effect is required.
Temperature uniformity on both furnaces meets RPS953 inside the retorts at 50 deg C below maximum.
Components to be processed are placed in a ‘cake stand’ type of jig before being loaded into the retort from above.
After fitting a gas-tight water-cooled sealing flange, the retort is lifted from its cradle by a crane and lowered into the furnace chamber.
The operator can then start one of a number of pre-set programmes held in the digital control system or set a new programme to suit the material to be processed.
Both furnaces are rated to heat a 50kg load to 50 deg C below their maximum temperatures in three hours.
At the end of a heating cycle, the retorts are lifted on to a separate frame to cool.
Temperature accuracy and uniformity throughout the heating chamber is achieved by the use of a cascade control system with a master multi-segment programmer linked to two end-zone controllers that inter-communicate with each other.
Over-temperature instruments are also fitted, and an eight-channel chart recorder provides a hard-copy record of each cycle.
A sophisticated gas control system is included on the furnace with argon and hydrogen gas facilities, to ensure that hydrogen can only enter the retort when the temperature is above 800 deg C.
The retort is also automatically purged with argon before and after hydrogen is admitted.
Flood lamp cures UV materials rapidly
High intensity UV flood lamp for rapid curing of UV materials is compact, light weight and has an integral cooling system to ensure low casing temperature and optimal UV bulb operating conditions.
UV Light Technology, the Birmingham based UV light equipment manufacture, has just launched its brand new high intensity UV flood lamp for rapid curing of UV materials. Representing the very latest technology this product is undoubtedly a leader in its field. The unit is compact and light weight.
Constructed in aluminium to provide robustness and durability it is designed to meet the most demanding industrial requirements.
It incorporates an integral cooling system to ensure low casing temperature and optimal UV bulb operating conditions.
The UV 400W flood lamp can be fitted with various types of UV bulb and filter glass depending upon the particular application.
This provides for an extremely versatile UV light equipment solution and enables the UV light emission spectrum to be precisely matched to the chemistry of the UV material.
Typical applications include: * Curing UV structural adhesives for bonding glass, plastics, metals and ceramics.
* Curing UV adhesives, potting compounds, encapsulants and sealants for electronic and opto electrical applications.
* Curing UV hardening polyester resin/glass fibre composite materials.
The UV flood lamp produces high UV light intensity, uniformly distributed over a large illumination area.
The high performance is due to the combination of efficient 400W metal halide UV bulbs, computer optimised spectral grade aluminium reflector and special filter glass materials.
UV Light Technology is raising the standard for the safe use of UV light equipment in the workplace.
The UV 400W Flood Lamp is supplied with the most comprehensive operating, service and repair manual.
This includes maximum permissible exposure times as defined by the ICNIRP guidelines, within the beam angle at various distances.
This is essential for assessing the level of risk for potential adverse health effects arising, or likely to arise from exposure to the UV light emissions.
This product is just one of UV Light Technology’s impressive range of ultra violet light equipment for an increasingly wide spectrum of applications Worldwide.
A readily accessible introduction of the use of UV light across a wide variety of applications is provided by UV Light Technology’s Web site.
It also acts as a product selector enabling engineers to make the initial choice of the appropriate UV light equipment best suited to a particular application.