Heatecx Limited
Unlock unparalleled efficiency and elevate the quality of your heating elements with the HTR-5000 Roll Reducing Machine. Engineered for the demands of modern manufacturing, the HTR-5000 is more than just a machine; it’s a strategic investment in the future of your production line.
At the core of every high-performance heating element lies perfectly densified Magnesium Oxide (MgO). The HTR-5000 employs advanced rotary swaging technology to transform low-density MgO powder into a compact, thermally efficient mass, ensuring:
Superior Insulation: Eliminate air pockets and porosity, dramatically boosting the dielectric strength of your insulators for safer, higher-voltage operation with minimal leakage risk.
Optimized Heat Transfer: Achieve maximum thermal conductivity, channeling heat efficiently from the resistive wire to the metal sheath. This translates into significant energy savings and extended product lifespan for your customers.
Unwavering Reliability: Maintain precise wire centering within the tube, preventing short circuits and ensuring consistent performance across every single heating element.
The HTR-5000 Rolling Mill operates under the principle of rotary swaging, a cold plastic deformation process that reduces the outer diameter of the tube while increasing its length. This process is fundamental for the densification of the internal insulating material.
The heart of the HTR-5000 is its Double Cardan Shaft transmission system. Unlike simple transmission systems, the double cardan ensures a completely synchronized and vibration-free power transfer to each roller station.
• Superior Stability: The elimination of backlash and minimization of radial vibration ensure that the compression force is applied perfectly concentrically, which is vital for keeping the resistive wire centered and preventing short-circuit failures.
• Reduction Geometry: The process is carried out in multiple stages (8, 12, 16, or 18 segments), where each pair of rollers applies a progressive reduction. This gradual reduction is key to preventing tube cracking and ensuring that the MgO is compacted homogeneously.
MgO Density and Conductivity Improvement
The main objective of swaging is to transform low-density MgO powder into a compact mass with a bulk density greater than 3.2 g/cm³.
• Improved Insulation: Compaction eliminates air pockets and porosity, drastically increasing the dielectric strength of the insulator. This allows the resistance to operate at higher voltages with minimal risk of electrical leakage.
• Thermal Conductivity Optimization: Densified MgO is an excellent heat conductor. The HTR-5000 ensures maximum heat transfer from the resistive wire to the metal sheath, resulting in greater energy efficiency and extended heater element life.
The HTR-5000 tubular heater reducing machine is a versatile solution for the production of a wide range of high-density heating elements, capable of processing tubes from 5 mm to 25 mm in diameter and lengths up to 5000 mm.
|
Heating Element Type |
Diameter Range (mm) |
Key Industries and Specific Use |
|
Tubular Heaters |
5.0 - 25.0 |
HVAC/R and Petrochemical: Production of elements for immersion heaters, forced air heaters, and defrosting systems. |
|
Cartridge Heaters |
High Density |
Injection Molding: Manufacturing of high wattage cartridges for dies and nozzles, where rapid heat transfer is critical. |
|
Hot Runner Heaters |
Millimetric Precision |
Plastics and Packaging Industry: Heating elements with extremely tight tolerance requirements. |
|
Finned Heaters |
Post-Swaging |
Industrial Drying: Preparation of tubes for fin addition, used in industrial ovens and dryers. |
The HTR-5000 is fundamental in sectors that demand reliability and precision, such as the pharmaceutical industry, where sterilization requires exact thermal control, and the food industry, for heating processing equipment.
The HTR-5000 is distinguished by its design focused on automation and long-term stability.
Stability and Durability
• Double Cardan Transmission: Ensures extended life of transmission components and uniform reduction without the risk of a "spiral effect" in the tube.
• Robust Construction: The machine's chassis, weighing 2200 KG, is designed to absorb the vibrations inherent in the swaging process, ensuring stability even at high production speeds.
• Roller Materials: Use of mold steel and high-hardness alloys, with an option for tungsten carbide, for superior wear resistance and lower replacement frequency.
Operational Efficiency and Automation
• Variable Speed Control: Allows adjustment of the swaging speed (constant or uneven speed) to optimize the process according to the tube material (stainless steel, Incoloy, copper) and the reduction rate.
• Optional PLC Integration: Designed for full integration into automated production lines, facilitating communication with powder filling and cutting equipment.
• Quick Maintenance: The modular design of the roller segments allows for format changeover in minimal time, maximizing machine uptime.
Below are the technical parameters that define the operational capacity of the HTR-5000 Roll Reducing Machine:
|
Technical Parameter |
Specification |
Engineering Notes |
|
Model |
HTR-5000 (Roll Reducing Machine) |
Based on the improved FH-B1 platform |
|
Transmission Structure |
Double Cardan Shaft |
Maximum stability and synchronization |
|
Reduced Tube Diameter |
5.0 mm to 25.0 mm |
Industry standard range |
|
Reduced Tube Length |
120 mm to 5000 mm |
Capacity for long elements |
|
Swaging Speed |
Constant / Uneven (Adjustable) |
Optimization of reduction rate |
|
Mold Material |
High Hardness Alloy / Mold Steel |
Tungsten Carbide option |
|
Number of Stations (Segments) |
8, 12, 16, 18 (Configurable) |
Total power = 0.75 KW * No. Segments |
|
Power per Segment |
0.75 KW |
High-efficiency motors |
|
Power Requirements |
Three-phase 380V / Three-phase 220V / Single-phase 220V |
Global adaptability |
|
Dimensions (LengthWidthHeight) |
1750 mm * 1600 mm * 1300 mm |
Compact footprint for its capacity |
|
Operational Weight |
2200 KG |
High mass structure for stability |
• Optional Marking (Post-Swaging): Integration of a laser or inkjet marking system at the end of the reduction line. This option allows critical information such as lot number, manufacturing date, or product code to be engraved directly onto the tube sheath, facilitating traceability and quality control.
• Annealing Line Integration: Ability to integrate the HTR-5000 with an annealing line immediately after the rolling process. Annealing is crucial for relieving internal stresses generated by swaging in the tube, improving the malleability and fatigue resistance of the tubular heater before the bending phase.
• Automated Transport System (Filling to Reduction): Option to integrate an automated tube conveyor that connects the MgO filling stage with the HTR-5000 input. This system minimizes manual handling, reduces the risk of tube contamination, and ensures a continuous and efficient workflow, optimizing the automation of the production line.
• Logistics and Installation Services: The HTR-5000 is generally shipped pre-assembled and factory-tested, drastically reducing commissioning time. We offer installation, calibration, and training manuals and videos. Delivery times are coordinated according to configuration and location, with a commitment to transparency and logistical efficiency.
• Roller Options and Monitoring: We maintain tungsten carbide roller options and remote diagnostic systems (Industry 4.0), along with advanced safety covers, for a complete and cutting-edge solution.
Mold (roller) changeover time on the HTR-5000 is a crucial factor for operational efficiency. Thanks to its modular design and the double cardan shaft transmission system, which ensures stable alignment, the process is minimized. For a standard 12-station configuration, the estimated total changeover time ranges from 45 to 90 minutes. Fine adjustment is the most critical stage, as it guarantees uniform MgO densification. Practices such as pre-assembly of rollers, the use of pneumatic tools, and continuous operator training are recommended to optimize this time and maximize Overall Equipment Effectiveness (OEE).
