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Novatec Infra-Red Die Oven Summary This article shows the superiority of the Infra- Red technology over convection air flow. The comparison is through.

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Presentation on theme: "Novatec Infra-Red Die Oven Summary This article shows the superiority of the Infra- Red technology over convection air flow. The comparison is through."— Presentation transcript:

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2 Novatec Infra-Red Die Oven

3 Summary This article shows the superiority of the Infra- Red technology over convection air flow. The comparison is through theory, heating process and efficiency. Short cycle heating and die management is one of the most significant technology reforms of the extrusion industry in the past 20 years.

4 Three modes of Heat Transfer 1.Conduction 2.Convection 3.Radiation

5 Traditional Air Flow Chest Oven Traditional Air Flow Chest Oven The chest oven, holding multiple extrusion dies, has been the most common design over the years. The tooling is heated by circulating hot air through a common chamber using a blower system. This is the convection air process.The chest oven, holding multiple extrusion dies, has been the most common design over the years. The tooling is heated by circulating hot air through a common chamber using a blower system. This is the convection air process. An extrusion die that does not have accurate temperature throughout or uneven temperature profile on the face will not run properly. In this case more billet is used before accurate profiles can be produced to correct the differences. Short production runs produce off-tolerance material and high die failure.An extrusion die that does not have accurate temperature throughout or uneven temperature profile on the face will not run properly. In this case more billet is used before accurate profiles can be produced to correct the differences. Short production runs produce off-tolerance material and high die failure.

6 A single lid oven exposes the dies to a fresh supply of oxygen and moisture each time the lid is opened. This is another cause of rapid oxidation. A single lid oven exposes the dies to a fresh supply of oxygen and moisture each time the lid is opened. This is another cause of rapid oxidation. Die management is virtually impossible so the solution is to heat lots of dies in case of extrusion issues. This means that dies are left at elevated temperatures for extended periods of time. The die bearing is exposed to rapid oxidation unnecessarily. Die management is virtually impossible so the solution is to heat lots of dies in case of extrusion issues. This means that dies are left at elevated temperatures for extended periods of time. The die bearing is exposed to rapid oxidation unnecessarily.

7 UNEVEN HEATING Why convection air heats dies unevenly Why convection air heats dies unevenly 1. The air being blown in a die box will travel the path of least resistance from inlet to outlet in the convection process. The physical blockage of the air stream causes uneven exposure to the die surface. 2.All the dies in a convection chest oven are under the same lid, Heated air escapes every time the lid is opened. Heated air escapes every time the lid is opened.

8 Inlet Die Direction of Air Outlet Convection Air Flow Oven

9 3. Placing a cold die in the air stream will cool the temperature for the dies further away causing incorrect heat time. It is virtually impossible to avoid this in the die exchange process. Heated dies are then actually cooled without operator knowledge. The biggest cause of unevenly heated dies is when a cold die is placed next to a hot die causing the heated die face to be cooled on one side. This thermal gradient is the cause of die breakage, poor run out and inaccurate non-conformant extrusion dimensions using the first billet.

10 Heating Extrusion Dies Using Infra-Red Technology

11 Most extruders use traditional convection chest ovens for die heating. The air in a common chamber is heated and circulated. The convection process relies on air temperature to transfer energy to the steel through conduction. This procedure is slow and inefficient. Infra-Red energy uses a band of electromagnetic waves to excite the metal molecules in a die through radiation. This molecular excitation is similar to the microwave technology. Infra-Red energy does not use air temperature for thermal transfer. Air is an insulator so the thermal process is accelerated. What is Infra-Red Heating What is Infra-Red Heating

12 Infra-Red is a kind of Radiation which transfer heat from object to another by electromagnetic transmission. The Infra-Red is located between visible light and radio in the electromagnetic spectrum. The wavelength of Infra-Red ranges from 2.0 to 6.0 microns.

13 What is Infra-Red Heating What is Infra-Red Heating When the Infra-Red energy reaches the surface to be heated, the molecules vibrate, converting to heat energy. Heat then travels through the product by conduction.

14 Properties of IR Material generates heat after absorption Reflection or Transmission

15 About Novatec Novatec is based in Surrey, British Columbia.The company has been producing Infra-Red equipment for a variety of applications for the past 20 years. In 1990, an aluminum extruder asked Novatec to explore the possibility of heating extrusion dies with Infra-Red technology, and the Novatec Infra-Red Die Oven was developed. Since that time, a number of extruders have installed the ovens and have reported dramatic improvements in speed, flexibility, and quality. Novatec Infra-Red Die Oven

16 Past attempts to use Infra-Red waves involved broad band heating. Generating this spectrum was not energy efficient. Novatec has developed the Infra-Red band technology to focus the wave energy to match the absorption in steel. Generating a small band of Infra-Red waves gives a focus energy for absorption. This maximizes energy transfer.

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18 Advantage of using Novatec Infra-Red Die Oven: 1. Cuts die heat up time by 75% 2. Reduces energy consumption by 50% 7. Advanced PLC control 3. Reduces die failure by 90% 4. Increases speed and flexibility 5. Improves extrusion surface finish 6. Superior safety features

19 1. Cuts die heat up time by 75% Novatec Infra-Red Die Ovens heat dies much faster than convection ovens. As explained above, this is because the dies are being heated by infrared waves, not air. Air itself is an insulator of thermal energy, and therefore, is a poor medium for thermal transfer. Novatecs Infra-Red Die Ovens single out the wavelength needed to heat die steel only…not heat all the air in the oven. Novatec Infra-Red Die Ovens heat dies much faster than convection ovens. As explained above, this is because the dies are being heated by infrared waves, not air. Air itself is an insulator of thermal energy, and therefore, is a poor medium for thermal transfer. Novatecs Infra-Red Die Ovens single out the wavelength needed to heat die steel only…not heat all the air in the oven.

20 Heater Efficiency Comparison

21 Press (T) Die Size (Dia. X thickness) (mm) Die Temp ( ) Heat Time Infra-RedConvection x Hrs 30mins4~5Hrs x hrs 00mins4~5Hrs x Hrs 15mins5~6Hrs x Hrs 35mins5~6Hrs Heat Time Comparison Heat Time Comparison

22 2. Reduce energy consumption by 50% Because of the wavelength heating process explained above, the efficiency of the die heating process is greatly improved. Not only does the level of heating time reduce overall, but also the power draw to maintain oven temperature once heated is less than 500 watts. (By contrast, a typical hair dryer operates on 1200 to 1400 watts.) The savings on power usage alone is a significant benefit when using Novatecs Infra-Red Die Oven. Because of the wavelength heating process explained above, the efficiency of the die heating process is greatly improved. Not only does the level of heating time reduce overall, but also the power draw to maintain oven temperature once heated is less than 500 watts. (By contrast, a typical hair dryer operates on 1200 to 1400 watts.) The savings on power usage alone is a significant benefit when using Novatecs Infra-Red Die Oven.

23 Extrusion Die Oven - Electricity Usage Comparison Convection Air Flow OvenNOVATEC Infra-Red Oven Each Cavity 10 Dies 24 kW 480V Each Cavity 2 Dies 22 kW 480V Die Heat Up Cycle 8Hours X 20.4 kW/hr = % Power Draw Die Heat Up Cycle 1Hour X 18.7k W/hr = % Power Draw Total Cycle 8 Hours kW X $0.07 kWh = $11.42 Total Cycle 1 Hour 18.7 kW X $0.07 kWh = $1.31 Total Cost to Heat Each Die $11.42 ÷ 10 = $1.14 Total Cost to Heat Each Die $1.31 ÷ 2 = $0.65 Die Temperature Holding Cycle 20.4 kWh÷10 Dies X $0.07/kWh = $0.14 Per Die Per Hour Die Temperature Holding Cycle 0.5 kWh÷2 Dies X $0.07/kWh = $ Per Die Per Hour The Infra-Red Oven is 52% more cost effective than a Convection Oven.

24 3. Reduces Die Failure up to 90% Extruders who use the Novatec Infra-Red Die Ovens have reported a dramatic decrease in die failure and breakage. Not only do convection ovens take longer to heat a die, they heat dies unevenly. Studies show that even after four hours of soak time in a convection oven, a 14 inch die can have as much as a 100 degree difference between one side of the die to the other. This will cause uneven runout in multi-hole dies, and consequently, uneven stresses on the die. All of this results in premature die failure and breakage and higher scrap rates. Novatecs Infra-Red technology heats dies to within single digit temperature variation throughout the die, reducing die failure. Extruders who use the Novatec Infra-Red Die Ovens have reported a dramatic decrease in die failure and breakage. Not only do convection ovens take longer to heat a die, they heat dies unevenly. Studies show that even after four hours of soak time in a convection oven, a 14 inch die can have as much as a 100 degree difference between one side of the die to the other. This will cause uneven runout in multi-hole dies, and consequently, uneven stresses on the die. All of this results in premature die failure and breakage and higher scrap rates. Novatecs Infra-Red technology heats dies to within single digit temperature variation throughout the die, reducing die failure.

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26 4. Increases Speed and Flexibility As mentioned above, a 14-inch die would be heated in less than 60 minutes with a Novatec Infra-Red Die Oven, as opposed to 4 hours in a convection oven. This will provide increased flexibility of die changeovers on the extrusion press, and reduce throughput time. As mentioned above, a 14-inch die would be heated in less than 60 minutes with a Novatec Infra-Red Die Oven, as opposed to 4 hours in a convection oven. This will provide increased flexibility of die changeovers on the extrusion press, and reduce throughput time.

27 5. Improves surface finish of extrusions Because the dies do not have to stay in the oven for 4+ hours, the die bearings are not subject to excessive oxidation prior to extrusion. This provides a higher extrusion finish. Also, airflow systems, such as those used in a convection oven, tend to deposit particles on dies and bearings. Novatec Infra-Red Die Ovens do not require an airflow system, and therefore, keep the dies free of contaminants. Because the dies do not have to stay in the oven for 4+ hours, the die bearings are not subject to excessive oxidation prior to extrusion. This provides a higher extrusion finish. Also, airflow systems, such as those used in a convection oven, tend to deposit particles on dies and bearings. Novatec Infra-Red Die Ovens do not require an airflow system, and therefore, keep the dies free of contaminants.

28 6. Superior Safety Features Watchdog thermocouple system and backup Mechanical Contactor prevents thermal run awayWatchdog thermocouple system and backup Mechanical Contactor prevents thermal run away Static lid stops that will activate under any non- normal condition, i.e. power outage, power spikeStatic lid stops that will activate under any non- normal condition, i.e. power outage, power spike Emergency Stop Push ButtonEmergency Stop Push Button Annealing LightAnnealing Light

29 Unique PLC System Automation Control 7. Advanced PLC Control

30 ORION Series Little, Tiny, SCADA ! Interface up to 20 loops of control. Include profiling, single set-point recipes, trending, alarm monitoring\history and graphic objects for each loop, then add data acquisition with historical viewing, and you have ORION. Real Time and Historical Trends Profile open, edit, save and download! Temperature

31 2 Cavity Oven 3 Cavity Oven

32 Drawer Oven 6 Cavity Oven

33 Be on the leading edge of extrusion technology! Were all looking for ways to stay ahead of the competition, and this is especially true in the extrusion business. Novatecs Infra-Red technology is truly on the cutting edge for this industry. It can be the key that gives your plant the edge you need over your competitors. Dont wait until they have one, too! Call today and explore the possibilities of Novatecs Infra-Red Die Oven for your plant. Were all looking for ways to stay ahead of the competition, and this is especially true in the extrusion business. Novatecs Infra-Red technology is truly on the cutting edge for this industry. It can be the key that gives your plant the edge you need over your competitors. Dont wait until they have one, too! Call today and explore the possibilities of Novatecs Infra-Red Die Oven for your plant.

34 Contact Us Head Office Ph Fax


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