Custom Rubber Company was having issues with uneven heating in their dog toy production machines, causing some toys to split or be undercured. An analysis found temperature differences of over 100°F across some machine surfaces. Insulation boards were added to machine edges, reducing temperature differences by around 10-15%. Additional improvements may include installing a roof and calibrating thermocouples, as different types (K vs J) can report over 5°F difference in the same conditions. These changes aim to enhance product quality by achieving more even heating.
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Fire resistant junction boxes and special Ex-rated enclosures for use in hazardous locations and potentially explosive environments. Fully ATEX compliant and with multiple international approvals.
Fire Rated and Special Application Enclosures for Hazardous AreasAbtech Ltd
Fire resistant junction boxes and special Ex-rated enclosures for use in hazardous locations and potentially explosive environments. Fully ATEX compliant and with multiple international approvals.
Computerized bench-top muffle furnace is a CE certified & computerized benchtop high temperature muffle furnace with laptop and pre-installed control software.
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Increasing Inductor Lifetime by Predicting Coil Copper Temperatures PresentationFluxtrol Inc.
In recent years, there has been a significant increase in the customer demands for improved induction coil lifetime. This has led to several publications in recent years by induction tooling manufacturers [1-4]. The main conclusion in these papers is that besides mechanical crashes the cause of most induction coil failures is localized overheating of the coil copper due to insufficient cooling.
What is lacking from these publications is any way to determine what is sufficient cooling. In this paper, a scientific method for determining local copper temperatures will be presented. This will include evaluations of heat transfer coefficients for different sections of a multi-component inductor, dependence of heat transfer coefficient on water pressure and water passage cross-section, non-uniform power density distributions in various 2-D cross-sections and the resulting temperature distribution in the copper winding. The effects of duty cycle on optimal design will also be considered.
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Perfect metal melting furnace for jewellers, refiners, and manufacturers also discover finest casting with gold casting machine and casting jewellery machine.
Computerized bench-top muffle furnace is a CE certified & computerized benchtop high temperature muffle furnace with laptop and pre-installed control software.
This presentation is about my academic project on generating electricity using thermoelectric generator (TEG), to harvest the thermal energy dissipated by combustion gases. The current project discusses the optimal design of the thermoelectric generator (TEG) and the design is conducted analytically based on the idea of air cooled TEG system using fins and an experimental system is fabricated and tested by attaching to exhaust pipe of a two wheeler IC engine for the heat source to verify the validity of the proposed system.
Increasing Inductor Lifetime by Predicting Coil Copper Temperatures PresentationFluxtrol Inc.
In recent years, there has been a significant increase in the customer demands for improved induction coil lifetime. This has led to several publications in recent years by induction tooling manufacturers [1-4]. The main conclusion in these papers is that besides mechanical crashes the cause of most induction coil failures is localized overheating of the coil copper due to insufficient cooling.
What is lacking from these publications is any way to determine what is sufficient cooling. In this paper, a scientific method for determining local copper temperatures will be presented. This will include evaluations of heat transfer coefficients for different sections of a multi-component inductor, dependence of heat transfer coefficient on water pressure and water passage cross-section, non-uniform power density distributions in various 2-D cross-sections and the resulting temperature distribution in the copper winding. The effects of duty cycle on optimal design will also be considered.
Weiber is one of Bench top Muffle Furnace manufacturers in India and Asia, providing muffle furnace ideal for laboratories, research centres, and medical sector, pharmaceutical and other industries.
Delmer Melting Casting equipment machinwDelmer Group
Perfect metal melting furnace for jewellers, refiners, and manufacturers also discover finest casting with gold casting machine and casting jewellery machine.
2. Project Background
Custom Rubber Company is
producing dog toy with machines
that do not have a previse
temperature control.
The temperature in some area of
the heat chamber is always
exceeding the desired range (350±
10 °F) for about 10 °F. Some areas
might have lower temp.
High temperature causes splits on
the edge of toys. Low temp causes
under cure.
3. Project Description
Solve the heat distribution problem; enhance the
product passing rate.
First Hypothesis
the temperature is not distributed evenly in the
heating chamber due to heat loss around the edge of
the heat chamber
4. Heat Analysis on Original Machine
Top View Side View
Max Temp: 161.39 °C
Min Temp: 57.72 °C
Max Temp: 151.11°C
Min Temp: 87.72°C
Set Temp: 160°C, 165.56 °C
5. About the Insulation Material
Type: Pyropel MD-18
Form: Semi-rigid Fiberboard
Thickness: 1/4 in
Thermal Conductivity at 200 ºF : 0.31
Thermal Conductivity at 400 ºF : 0.36
Continuous Use Temperature: 550 ºF
7. Heat Analysis – 1st
Cycle
Max Temp: 172.22 °C
Min Temp: 80.33 °C
Max Temp: 153.94 °C
Min Temp: 88.67 °C
Top View Side View
Set Temp: 171°C, 171 °C
Back
8. Results
Before
Temp Diff of top side:
103.67°C ,
64.24%
Temp Diff of side:
63.39°C
41.95%
After
Temp Diff of top side:
91.67°C
53.23%
Temp Diff of side:
65.27°C
42.40%
9. Heat Analysis – 2nd
Cycle
Set
TC3-Ext.Fixed Platen: 350 ºF,
TC4-Int. Fixed Platen: 350 ºF
TC1-Ext. Movable Platen: 360 ºF
TC1-Ext. Movable Platen: 360 ºF
Took 1 picture every 1min 10sec
8 samples/cycle
10mins per cycle
Randomly chose 3 cycles
We currently lack series
temperature data for the original
machine
10. Results
Without Insulation Board
Setting(°C) Means std dev % of difference
160
161.11
NA
0.0063
160
161.11
NA
0.0063
165.56
165.56
NA
0
165.56
165.56
NA
0
With Insulation Board
Setting(°C) Means std dev % of difference
176.67
176.53 0.86 -0.00071
176.67
176.32 0.85 -0.0018
182.22
182.29 0.42 0.00035
182.22
182.25 0.12 0.00012
11. Results
Bad parts number due to machine issue (Split &
under cure) decreased
Before: 37.5 splits & 1.25 under cure /shift
Now: 3.55 splits & 0.33 under cure /shit
12. Top of the Machine
The major heat loss is through
the top edges of the heat
chamber
Hard to add insulation board
on the top – air tubes
Solution
Install a roof
reduce the direct contact
between the heat chamber
and the surrounding cold air
13. Second Cause -Thermocouples
Custom Rubber Co. are using different types of
thermocouples on different machines
Mostly used K type and J type thermocouples
Question:
Do different types of thermocouples give standard
temperature feedbacks?
Are all feedbacks from thermocouples are reliable?
15. Boiling Water Calibration
Calibrated both types of thermocouples in boiling
water to see if both of them gives feedback
around 100°C
Type K: 98.79°C
Type J: 104.07°C
5.28°C (41.5 F)temperature difference
Temp setting for one machine with K type
thermocouples may not suitable for those with J
type thermos couples
All new purchased thermocouples need to be
calibrated before using
16. On-site Experiment
Replaced my K type
thermocouples with the
original ones installed in the
machine
One gave feedback of
134.43°C; the other gave
130.04°C
Old thermocouples might
have errors on testing –
Calibrate them periodically
Magnetic influence –
provide a layer of insulators
on the thermocouples
17. Conclusion
Possible solutions to solve the heat
distribution problem
Providing insulation boards to the
edges of the machine
Installing a roof on the top of the
machine
Calibrating all the thermocouples
periodically
18. Acknowledgements
Dr. Clare Rimnac – for her advice, help and
support
Dr. Alexis Abramson – for her technical advice,
thermometer and thermal couples.
John Bellett – for giving me relevant documents,
information and suggestions.
Charlie Braun – for giving me a chance to have
this project in Custom Rubber Co.
Maintenances – for adding insulation boards and
helping me to do the thermocouple experiment