Induction Heating Roller
What is an Induction Heating Roller?
It is a kind of cylindrical roller used in continuous processing of industrial materials, which can generate heat by itself.
The basic principle of heating is to use the coil inside the roller body to generate electromagnetic field, through the magnetic line of cutting the metal surface to generate Joule heat to achieve the effect of heating the roller body itself, the roller surface and the processed material for heat exchange, and through the closed-loop temperature control system to maintain the working temperature of the roller body set.
Induction Heating Roller material selection
Electromagnetic heating high temperature roller material selection 42GrMo4, 38GrMoAl, 40Cr, 34CrNiMo6, 60CrNi, 9Cr3Mo, such as forging alloy steel, high-quality steel, heat treatment process of quenching, stress relief, quenching. The inner wall of the heating roller has uniform wall thickness, and the hardness of the outer surface can reach HRC50～58 after deep quenching.
Manufacturing precision of electromagnetic heating rollers: uniform temperature on the surface of the roller body, temperature difference ≦±1℃, thermal deformation ≦0.01mm under 20℃, straightness, runout, coaxiality maximum ≦0.002mm.
Roller body surface treatment: imported formula plating hard chrome treatment, chrome layer is meticulous, strong bonding force; can also be customized according to customer requirements into a fluorine coating, mirror treatment; high surface hardness can be nano thermal spraying on the surface of the electromagnetic heating rollers, so that the surface hardness HRC ≥ 68.
Mostly used in high temperature compounding of aviation materials, chemical fiber materials, polymer materials, special rubber and other industries; new high temperature FCCL flexible copper-platinum material compounding, PTFE glass fiber filter media membrane compounding, polyimide (PI) synthesis, carbon fiber polymer material synthesis, metal foil compounding, thermoplastic carbon fiber dip CoPEEK, PPSU, PA, PES and so on.
Induction Heating Roller structure
Electromagnetic induction heating roller internal structure is more complex. In accordance with the needs of different production processes, electromagnetic heating rollers are divided into single-axis shape and double-axis shape two structural forms.
That is, the roll body is supported by a single end or double-end support. Single-axis general application of chemical fiber spinning process is more common, followed by the application of special plastic film drying, drawing and so on. Biaxial roller body is more widely used, such as material calendering, pressing, drying, composite, molding, heat-setting, heat transfer, etc..
The structure of double-axis type electromagnetic heating roller consists of left end cover, right end cover, inner axis heating coil, temperature measuring device and so on.
The internal structure of the induction heating roller consists of a metal roller body, a support shaft, an induction coil, a temperature sensor and so on.
Parameters of Electromagnetic Induction Heating Roll
Roller Dimensions | external diameter | Φ100mm-Φ1500mm |
Length of roll surface | 300mm-3000mm | |
Temperature ranges | Temperature setting range 50-500°C | |
Temperature distribution accuracy ±1 | ||
Linear pressure 10-260kg/cm | ||
Surface treatment | Hard chrome plated, mirror/super mirror | |
Mechanical specifications | Linear speed max5000m/min | |
Full runout ±0.01mm (on request) | ||
Comparison of the Performance
| Comparative factors | Thermal oil roller | Electrically heated roller | Steam heated roller | Electromagnetic roller |
| Mediums for heating | thermal oil | electric heating wire | thermal steam | electromagnetic fields |
| Thermal energy utilization（η） | 60% | 80% | 75% | 95% |
| Maximum temperature of roll surface ℃ | 280 | 350 | 180 | 420 |
| Temperature uniformity of the roll surface ℃ | ±4 | ±20 | ±10 | ±1 |
| Temperature control accuracy ℃ | ±3 | ±10 | ±5 | ±0.05 |
| heating speed | slowly | slowly | slowly | quickly |
| working environment | oil contaminated | cleaner | cleaner | Clean, non-polluting |
| Production Hazards | Thermal oil leakage, flammable | Dangerous and easy to leak | Need to install a boiler, prone to leaks | No leakage, no direct contact with electricity, safe |
| Post Maintenance | Complicated disassembly | Easier maintenance | Complicated disassembly | No leakage, no direct contact with electricity, safe |
| operational performance | Oil line easily clogged, coking | Operation is harder to control | Prone to air leaks and scaling | Human-machine interface, visualization |
| Useful life (years) | 3-5 years | 3-4 years | 4-6 years | More than 10 years |
| Equipment cost | inexpensive | inexpensive | inexpensive | Higher cost |
