Electric machines have significantly improved the electricity efficiency in the injection molding industry over the last twenty years. New methods to save energy and maintain costs down during times of rising energy costs is the necessity of the hour. Melt-stream heating, particularly in the barrel, presents a robust prospect. Typically, 30-70% of your power consumed by heater band is wasted by radiation and convection towards the surrounding environment. Eliminating these losses will reduce specific energy usage and allow machines to be pre-heated faster using the same power delivery infrastructure, thereby reducing downtime to boost 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 rise above those of the barrel before the barrel may be heated, and conversely, a band-heater’s temperature must fall below that relating to the barrel prior to it being 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 the melt stream. The current introduction of lower weight radiant heating elements provides an opportunity for improvement. Another new technology that offers significant advantages is noncontact induction. Barrel heating using helical induction coils has become considered for years, but was poorly applied. Past efforts often used inefficient low-frequency power supplies and also placed the coils in direct connection with the barrel, undermining the compelling great things about induction. Heat generated from the barrel was still capable to escape to ambient along with the coils’ thermal mass wasn’t taken from the equation. Connection with 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 higher quality and much less scrap in contrast to conventional heater bands. The nXheat ™ barrel heating solution (patent-pending) uses an optimized high-frequency power supply and a thermal insulating layer interposed between your barrel and coils to manage the above issues and exploit the entire potential of induction. All of the heat is generated directly throughout the barrel and stays along the way. The coil’s thermal mass can also be 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 significantly improved.
Energy savings for barrel heating as much as 70% in contrast to heater bands
• Additional energy savings – upto 35% more – as a result of reduced air conditioning load
• Additional energy cost reduction from reduced peak power demand
• Fewer heater failures to reduce downtime and maintenance costs
• Immediate cooling and heating reply to improve quality and lower scrap
• Quicker heat-up, typically 2X or even more, to enhance productivity
• More heating capacity- typically 3X higher wattage in to the barrel- eliminates a bottleneck
• Higher barrel temperature capability to mold high-temperature polymers, or metal
• Cool exposed surfaces for increased operator safety
The nXheat™ system relies on a high-frequency power source and helical induction coils to generate heat directly in the barrel wall. A thermal insulating layer is interposed involving the 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™ where induction heating completely replaces conventional heater bands;
2) nXheat-Hybrid™ where 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%. It will be the ideal system for larger machines with over three heating zones as a result of high value of the decrease in power consumption.
On smaller machines with 2 or 3 zones the nXheat-Hybrid™ system can deliver a lot of the savings in the all-zone system because induction can be used in the barrel’s feed zone the location where the greatest amount of heat input is necessary to start the melting process. On such machines, which normally have barrels with inside diameters of 50 mm or less, the hybrid system will typically provide a 30 to 50% decrease in power consumption.
In the hybrid system, downstream zones dexmpky42 use either insulated or uninsulated band heaters. Greater energy savings are achieved by using insulated band heaters. The identical sheet insulation which is used from the induction-heated feed zone enables you to wrap the downstream band heaters. The precision and fast response of induction heating within the feed zone will even substantially reduce temperature overshoot things that may appear with insulated band heaters.
The machine will cover itself with power saving money and other cost and quality benefits. Some examples are reduced scrap stemming from less variation in melt temperature and faster reaction to alterations in target melt temperature. The payback period on investment costs for these particular systems is very reliant on electricity rates, machine size and production schedule (hours of operation per year). This type of system typically costs about 25-50% of your all-zone system.