Heatecx Limited
Our cartridge heater filling machine has been specifically designed to address the complex structure of single-ended heating elements. Its primary function is the precise and compacted introduction of magnesium oxide (MgO) powder into metal tubes, ensuring electrical insulation and thermal transfer. Unlike universal filling machines, this equipment guarantees optimal centering of the heating coil through an electronically controlled vibration system. It is the ideal solution for manufacturers seeking to elevate the quality of their industrial cartridge heaters, ensuring uniform powder density from the welded bottom to the tube mouth.
This cartridge heater filling machine has been specifically designed to address the complex structure of single-ended heating elements. Its primary function is the precise and compacted introduction of magnesium oxide (MgO) powder into metal tubes, ensuring electrical insulation and thermal transfer. Unlike universal filling machines, this equipment guarantees optimal centering of the heating coil through an electronically controlled vibration system. It is the ideal solution for manufacturers seeking to elevate the quality of their industrial cartridge heaters, ensuring uniform powder density from the welded bottom to the tube mouth.
The equipment is presented as a PLC-controlled MgO filling station, capable of operating in manual or automatic mode according to the needs of the production line. Its versatility is remarkable, allowing it to work with a wide range of diameters (6-40mm) and lengths up to 1500mm, making it a flexible tool for different production batches. Thanks to its electronic frequency vibration regulation, the operator can adjust the compaction intensity for different wire gauges and powder types, optimizing filling time and reducing material waste in the manufacturing of high-efficiency cartridge heaters.
The machine's architecture is designed for ergonomics and durability in industrial environments:
• Clamping and Guiding Mechanism: It features a system of clamps or nozzles designed to hold the tube vertically. Since the cartridge has a pre-welded bottom, the machine holds it firmly to transmit vibration without damaging the outer tube.
• Electromechanical Vibration System: The base of the equipment integrates a vibration generator connected to the electronic governor. This structure not only vibrates but does so with a specific frequency that fluidizes the MgO powder so that it penetrates every turn of the wire, and then compacts it as it settles.
• Hopper and Dosing: The MgO powder reservoir is located at the top. The dosing system is synchronized with the PLC to release the material flow only when the tube and wire are in position, preventing spills and dirt in the work area.
• Operator Interface: An accessible control panel allows the user to select the mode (manual/auto), adjust the cycle time, and monitor the machine's status in real-time.
|
Parameter |
Value / Description |
|
Main Application |
MgO Filling for Cartridge Heaters |
|
Tube Diameter Range |
6 mm - 40 mm |
|
Supported Tube Length |
50 mm - 1500 mm |
|
Control System |
PLC (Programmable Logic Controller) |
|
Vibration Control |
Electronic frequency regulation (adjustable) |
|
Operation Modes |
Manual / Automatic |
|
Filling Material |
Magnesium Oxide (MgO) Powder |
|
Key Functions |
Coil centering, high-density compaction, filling timer |
The machine stands out in the market for combining mechanical robustness with electronic precision:
• Guaranteed Coil Centering: The main challenge in cartridge heaters is that the coil does not touch the walls (short circuit). This machine uses a guiding system and vertical vibration that keeps the spiral perfectly centered while the MgO powder flows around it, ensuring superior dielectric insulation.
• Density Control by Frequency: It incorporates an electronic governor that manages the vibration frequency. This allows for maximum powder compaction, which is vital for the heater's lifespan: higher density leads to better heat dissipation and a lower risk of wire burnout.
• Smart Management via PLC: The programmable logic control system allows for process standardization. The exact filling time can be pre-configured to avoid bottlenecks and ensure that each cartridge receives the same amount of insulation.
• Production Flexibility: Its design allows for quick tooling changes to switch from a thin 6mm tube to a robust 40mm one, adapting to custom orders without long downtimes.
Yes. High-density cartridge heaters require the magnesium oxide (MgO) powder to be extremely compacted to rapidly transfer heat from the wire to the metal sheath without overheating the core. Our machine achieves this thanks to two key features:
1 Electronic Frequency Control: It doesn't just "shake" the tube; it allows adjusting the vibration frequency to achieve the maximum possible packing density of the MgO grain.
2 Adjustable Times: Through the PLC, the vibration time can be extended to ensure no air pockets remain, allowing the creation of heaters capable of withstanding higher than normal watt loads (up to 20-30 W/cm² in subsequent swaging processes).
