Summary
The Continuous Oven with Dual Conveyors for Curing Electric Motors, crafted by INTEK Corporation, stands as a pinnacle of innovation in the domain of industrial heating solutions. This state-of-the-art oven boasts robust specifications, tailored for the precise curing requirements of electric motors. With dual conveyors facilitating seamless throughput, it caters to diverse applications across industries, ensuring uniform curing for enhanced product quality. Manufactured with meticulous attention to detail, it exemplifies excellence in engineering and adheres to stringent quality control standards, ensuring reliability and performance consistency.
- Model: Continuous Oven with Dual Conveyors SN 200006
- Price Range: $90,000 – $120,000 depending on control options
- Internal Dimensions: 144″ Length, 36″ Width, 12″ Height
- External Dimensions: 192″ Length x 52″ Width. 60” Height
- Power Requirement: 240V, 3ph, 60Hz, 45 Amps
- Wattage: 18kW
- Heat Source: Electric Duct Heaters
- Recirculating Blower: 1.5 HP 2500 CFM
- Exhaust: Fractional HP, 300 CFM
- Process Temp: Variable
- Process Time: Variable
The Continuous Oven finds application in various industries, including automotive, aerospace, and electronics, where the curing of electric motors is integral to production processes. It accommodates a wide range of motor sizes and types, making it versatile for different manufacturing requirements. Whether curing winding coils or impregnating insulation materials, this oven ensures consistent results, enhancing product reliability and performance.
- Accommodates multiple electric motors simultaneously.
- Scalable design to handle varying production volumes.
- Configurable conveyor system for efficient material handling.
- Can be integrated into existing production lines for seamless workflow.
Electric Duct Heater
The Electric Duct heating system operates on the principle of electrical resistance heating, where electric current passes through a resistive element, typically made of nichrome wire, enclosed within a duct. As the electric current flows through the resistive element, it encounters resistance, which generates heat. This heat is then transferred to the surrounding air, which is circulated within the oven compartments by powerful fans. The duct design ensures uniform distribution of heat throughout the oven, essential for consistent curing of electric motors. Temperature sensors and control systems regulate the electric current to maintain precise temperature levels, ensuring optimal curing conditions.
Manufacturing Details
The Continuous Oven is meticulously crafted utilizing advanced manufacturing techniques and high-quality materials.
Design and Engineering
Designing and engineering such complex industrial ovens require a combination of specialized tools, software programs, and adherence to scientific principles. Specific tools and programs include:
- CAD (Computer-Aided Design) software for creating detailed 3D models of the oven components and assemblies.
- Thermodynamics principles to calculate heat transfer rates, thermal conductivity of materials, and energy efficiency of the system.
- Material selection expertise to choose appropriate materials based on thermal properties, corrosion resistance, and durability requirements.
- PLC (Programmable Logic Controller) programming for developing control algorithms to regulate temperature, conveyor speed, and other operational parameters.
Material Selection
The selection of materials for manufacturing oven compartments is critical to ensuring durability, thermal efficiency, and compliance with industry standards. Common materials used include:
- Stainless steel: Provides excellent corrosion resistance and mechanical strength, ideal for oven enclosures and conveyor systems.
- Insulation materials (such as ceramic fiber or mineral wool): Essential for minimizing heat loss and maintaining consistent temperature profiles within the oven compartments.
- High-temperature gaskets and seals: Ensure tight seals to prevent heat leakage and maintain temperature uniformity.
- Heat-resistant coatings: Applied to internal surfaces to enhance heat reflectivity and protect against oxidation.
- Galvanized Steel: A cost-effective option with good corrosion resistance for moderate temperatures, but not ideal for high heat.
- Aluminized Steel: Offers superior high-temperature resistance compared to galvanized steel, making it suitable for hotter oven environments.
- Structural Steel: Provides the best strength and rigidity for the oven’s frame, but may require additional corrosion protection if exposed to moisture or humidity.
Assembly
The assembly process of the Continuous Oven typically involves the following stages:
- Fabrication of individual components (such as oven enclosures, conveyors, heating elements, and control panels) according to detailed engineering drawings.
- Integration of heating elements and insulation materials into the oven compartments, ensuring proper placement and alignment.
- Assembly of conveyor systems, including installation of drive motors, gears, and conveyor belts, and alignment to ensure smooth operation.
- Wiring and installation of control systems, including PLCs, temperature sensors, and actuators, following electrical schematics and safety standards.
- Final testing and calibration of the complete system to verify temperature uniformity, conveyor speed accuracy, and overall functionality before shipment to the customer.
Quality Control Steps
INTEK Corporation maintains stringent quality control measures throughout the manufacturing process to deliver products that exceed customer expectations.
Material Inspection
Checking materials like steel, insulation, and electrical components for quality before assembly.
In-Process Inspections
Verifying each assembly step, like frame construction or heating element installation, is done correctly throughout manufacturing.
Component Testing
Ensuring components like heating elements and conveyors function properly before full system assembly.
Complete System Testing
Evaluating the entire oven’s ability to maintain temperatures, operate conveyors, and achieve consistent curing.
Compliance Verification
Guaranteeing the oven meets safety standards and any specific requirements outlined by the client.
This case study serves as a testament to the ingenuity and craftsmanship embodied by INTEK Corporation in delivering cutting-edge solutions for industrial heating applications, ensuring efficiency, reliability, and utmost customer satisfaction.