Cartridge Heaters
If it's a heating element that has proven very beneficial for industrial systems, it is the cartridge heater. This heater rod is mainly used to heat solids during various industrial applications. It features a cylindrical tube construction and a metal sheath that contains an adequately insulated resistive electrical circuit.
Cartridge heaters are highly preferred for the uniform heating that they provide. Also, they offer such great versatility, which makes them ideal for use in a wide range of applications. For example, these heater coils can be used in chemical engineering, food production and preparation, and additive manufacturing.
However, there are different types of cartridge heaters sold in the market today. More so, these appliances come in various sizes and designs. So how can you tell which heater will be ideal for your industrial machines and processes?
Consider the following five factors that will help you choose the best and most appropriate cartridge heater rod for your industry:
Cartridge Heater
Location of Installation
Where do you plan to install your cartridge heater? Installing the cartridge heater is the first thing you should consider before selecting the heater rod. Once you have identified where you wish to install it, consider the type of materials that the heater will come into contact with.
This is because not all materials can withstand high amounts of heat. For instance, aluminium and brass respond negatively to heat. And when a cartridge heater is installed in metals made of such materials, it could lead to severe heat damages and leakages.
Another, it is crucial that you check for any contaminants in the installation location. It goes without saying that the best place to install your heater coil would be where there are no contaminants. And as a general rule, the mould's diameter should not exceed 0.1mm over the heater's diameter. This ensures that the cartridge heater fits snugly into its chosen location.
Speed of Response
How fast would you like your cartridge heater to respond? The required speed of response is usually determined by the kind of industrial application or process being undertaken. Some industrial processes, such as plastic manufacturing, require cartridge heaters that respond quickly when activated.
If the industrial application calls for a heater rod with a faster response, you will do well to choose one with a higher wattage. Cartridge heaters with such high wattage ensure that the elements respond faster. More so, high wattage heater rods tend to be more reliable for performance quality. However, if the industrial process does not require speed, you could go for a cartridge heater with less wattage.
Temperature of the Intended Application
What temperatures will your cartridge heater be expected to reach? It would be best to consider the required temperatures of your industrial application. This will help you determine the correct type of sheathing for your heater coil.
The most commonly used material in industries is stainless steel. However, if you are dealing with high-temperature applications, you are recommended to go for an INCOLOY sheathing for your cartridge heater. Not only does such a sheathing help to maximize the lifespan of the element, but it also reduces the need for frequent maintenance.
Furthermore, determining the intended application's temperature helps identify the best type of lead to include in your cartridge heater. For heater rods intended for use under high-temperature applications, fiberglass would be the ideal material for the lead wires. On the other hand, using materials, such as silicone and rubber, in high temperatures would be very ineffective, even leading to poor performance of the industrial processes.
Size and Shape of the Cartridge Heater
What shape and size of a cartridge heater would fit your intended installation location? Usually, all heater rods are designed with standard diameters that are pre-sized. Therefore, when choosing the ideal diameter of the cartridge heater, you might be required to specify its correct fit, as per the location of installation.
However, most companies that sell cartridge heaters usually do all the engineering fit for their clients. Say, for example, you decide to drill and ream a 0.5" hole. Most companies will simply undersize the cartridge heater, such that it slides very quickly into the drilled hole. Actually, these experts and professionals usually make cartridge heaters that are .004" smaller than the requested size. This ensures that the heater coil always fits snugly into the hole so that it works effectively and produces the best results.
Different Type of Cartridge Heaters
Length of the Cartridge Heater
How long do you intend your cartridge heater rod to be? The most appropriate length of your heater coil should be determined by the part you intend to heat. Simply put, the longer the extent of the part you would like to heat, the longer the cartridge heater you will need. Also, if you only intend to heat a small part of the metal, then you would do well to go for a shorter-sized heater coil. Take, for example, a tool or mould that is 5 inches long. To heat this tool, you would typically require a cartridge heater that is also 5 inches long (specifically for the part inserted into the drill hole).
However, the main challenge is where most heater rods are designed with pre-sized standard diameters. In such cases, finding the ideal size for your cartridge heater can prove quite challenging. Therefore, it is recommended that you order customized sizes for your cartridge heater. And if you like, you can consult with our experts; they will advise you on what sizes you should go for if the exact ideal cartridge heater size cannot be created.
Conclusion
There are a wide range of industrial processes that call for the use of cartridge heaters, such as platen heating, mold dyeing and sealing bars. However, cartridge heaters are not all the same; they come in different sizes, shapes, wattage, length and many other varying aspects.
Therefore, before you can choose the most appropriate heater rod for your industrial applications, you would do well first to consider the five key factors discussed in this article. Only by carefully considering these aspects will you choose the ideal cartridge heater. And if you are unsure about which heater coil to go for, you can always reach us to us. Our team of experts will be happy to guide and advise you on which cartridge heater will be most suitable for your industrial needs.
Author’s Bio:
Pragati Malvi is a content writer at Marathonheat. She loves learning new things, researching and curating valuable content to save you time and help you achieve your goals.