CN117979472A - Manufacturing method of area-oriented bare low-voltage high-current heating device - Google Patents
Manufacturing method of area-oriented bare low-voltage high-current heating device Download PDFInfo
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- 238000010438 heat treatment Methods 0.000 title claims abstract description 404
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 23
- 239000000463 material Substances 0.000 claims abstract description 31
- 238000002955 isolation Methods 0.000 claims abstract description 13
- 238000000034 method Methods 0.000 claims description 26
- 238000013461 design Methods 0.000 claims description 22
- 229910045601 alloy Inorganic materials 0.000 claims description 11
- 239000000956 alloy Substances 0.000 claims description 11
- 230000008569 process Effects 0.000 claims description 11
- 238000005520 cutting process Methods 0.000 claims description 10
- 229910052751 metal Inorganic materials 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 7
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 4
- 239000007788 liquid Substances 0.000 claims description 4
- 239000010935 stainless steel Substances 0.000 claims description 4
- 229910001220 stainless steel Inorganic materials 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- 230000008859 change Effects 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 239000012530 fluid Substances 0.000 claims description 2
- 238000003698 laser cutting Methods 0.000 claims description 2
- 229910052759 nickel Inorganic materials 0.000 claims description 2
- 239000007787 solid Substances 0.000 claims description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims 1
- 230000001276 controlling effect Effects 0.000 claims 1
- 230000001105 regulatory effect Effects 0.000 claims 1
- 239000010936 titanium Substances 0.000 claims 1
- 229910052719 titanium Inorganic materials 0.000 claims 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims 1
- 229910052721 tungsten Inorganic materials 0.000 claims 1
- 239000010937 tungsten Substances 0.000 claims 1
- 238000012546 transfer Methods 0.000 abstract description 14
- 230000009286 beneficial effect Effects 0.000 abstract description 2
- 238000005265 energy consumption Methods 0.000 abstract description 2
- 230000009471 action Effects 0.000 description 5
- 230000005674 electromagnetic induction Effects 0.000 description 5
- 230000005611 electricity Effects 0.000 description 4
- 238000002844 melting Methods 0.000 description 4
- 230000008018 melting Effects 0.000 description 4
- 238000012423 maintenance Methods 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 239000010426 asphalt Substances 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 238000005485 electric heating Methods 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 230000033228 biological regulation Effects 0.000 description 1
- 210000003169 central nervous system Anatomy 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005670 electromagnetic radiation Effects 0.000 description 1
- 230000014509 gene expression Effects 0.000 description 1
- 229910000856 hastalloy Inorganic materials 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
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- 238000006467 substitution reaction Methods 0.000 description 1
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Classifications
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/10—Geometric CAD
- G06F30/17—Mechanical parametric or variational design
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/02—Details
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2111/00—Details relating to CAD techniques
- G06F2111/10—Numerical modelling
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/06—Power analysis or power optimisation
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/08—Thermal analysis or thermal optimisation
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Abstract
The application relates to a manufacturing method of an area-oriented bare low-voltage high-current heating device, which is characterized by comprising the following steps: (1) Determining a low voltage (1V-110V) value according to the required heating power and the available heating area, determining parameters such as thickness, length, width and the like of a heating element resistor in the heating device, and customizing an isolation transformer according to the parameters; (2) Designing and drawing a picture of the heating element according to the calculation result; (3) making a heating element from the picture cut sheet material; (4) The heating element is insulated while being fixed on the available heating area of the heat treatment apparatus. Compared with the prior art, the heating device manufactured by the application can reduce thermal resistance, increase heat transfer area, improve heat efficiency, save energy consumption, save the proportion by at least 30 percent, and greatly improve the service life of the heating device. The application is also beneficial to improving the working environment of the heating device and reducing the working temperature of a workshop.
Description
Technical Field
The application relates to the field of heating, in particular to a manufacturing method of a low-voltage high-current labyrinth-shaped heating device.
Background
At present, electric heating such as industrial plane heating, asphalt melting, metal melting, material melting maintenance, air heating, material drying, constant temperature maintenance and the like still adopts resistance heating pipes and heating plates for heating, the resistance heating pipes and the heating plates heat based on 380V and 220V resistance wires, and the metal pipe body or the metal plate wrapped outside is heated by breaking through very thick insulation and then is heated by a heated object, so that indirect heating is realized, the heat resistance is large, the heating area of the resistance wires is small, the heat transfer efficiency is low, the electricity saving is not facilitated, and the defects of a resistance wire heating mode in the traditional heating device include:
1. The heat loss is large, the heating adopted by the existing asphalt machine, lead melting furnace and the like is made of resistance wires, the inner side and the outer side of a pipe or a plate generate heat, the heat of the inner side (the part which is clung to the heated object) of the pipe or the plate is conducted to the heated object, and the heat of the outer side is mostly dissipated into the air, so that the loss and the waste of electric energy are caused;
2. Ambient temperature rise: because of the large heat loss, the ambient temperature is increased, especially the production environment is greatly affected in summer, the field working temperature exceeds 40 ℃, and some enterprises have to adopt air conditioners to reduce the temperature, which causes secondary energy waste;
3. the electric heating tube is normally used, the service life of the plate is about half a year, and the production is often influenced, so that the maintenance workload is relatively large;
4. The power density is low, and the method cannot be adapted to occasions requiring higher temperature;
5. The thermal inertia is large, and the temperature is greatly floated.
Another improved heating device uses electromagnetic induction heating, and the working principle of the heating device is to work by using the magnetic field induction eddy current heating principle. The electromagnetic induction heating ring body does not generate heat, and in actual use, the insulating material with a certain thickness can be wrapped outside the charging barrel, the surface temperature of the electromagnetic induction heating ring is below 60 ℃, and the heat inside the charging barrel only radiates into the air in a trace amount, so that the heat energy loss can be greatly reduced, the heat efficiency is improved, and the energy-saving effect is remarkable. However, the high-frequency current passes through the coil to generate an alternating magnetic field which changes at high speed, and when the magnetic field strength reaches a certain amount, the alternating magnetic field can be harmful to the central nervous system of a human body. At present, specific regulations are only made on electromagnetic equipment of household and similar electric appliances in China, and related standards of the electromagnetic equipment designed for industrial use are not available. Manufacturers of electromagnetic induction heating devices also only perform EMF tests on the periphery of a single heating device according to European Union standards, but detection is performed under actual working conditions, and the electromagnetic radiation intensity of the electromagnetic heating device is still large, so that uncertain risks exist. In addition, the electromagnetic induction heating device has short service life, generally 2-3 years.
Disclosure of Invention
The application aims to provide a manufacturing method of a low-voltage high-current heating device, which is pursued of the maximum heat transfer area, has high heat efficiency, small heat loss and long service life, so that the heating efficiency is ensured under the condition of improving the energy-saving efficiency.
The application discloses a manufacturing method of an area-oriented bare low-voltage high-current heating device, which comprises the following steps:
(1) Designing the heating device, comprising the following substeps:
1-1, determining heating power and available heating area of a heat treatment device provided with the heating device;
Firstly, determining the power used during heating according to the preset performance of the heat treatment equipment, and then determining the available heating area of a heating cavity, wherein the heating cavity is a space used for heating inside the heat treatment equipment, and the available heating area is the sum of areas of surfaces available for heat exchange on the heating cavity; the specific value of the low voltage actually used is preliminarily determined according to the empirically summarized big data table with power and area, and the range of the low voltage is 1V-110V;
1-2, determining the heating element material and heat exchange area of the heating device;
And then selecting a material for the heating element of the heating device according to the highest temperature or heating characteristic required to be reached when the interior of the heat treatment apparatus is heated, the material comprising: high Wen Hashi alloy plate, nickel-base alloy plate, titanium-base alloy plate, tungsten-base alloy plate, copper-base alloy plate, high temperature resistant stainless steel plate of 2520, 800H, 904L, 310S, 309S, 304, 316L, etc., or aluminum plate, copper plate; the heating element consists of a single-zone heating module which consists of a meandering continuous resistor; then determining the heat exchange area of each available surface on the heating cavity according to the heat conduction property of the material, wherein the heat exchange area is the area of the heating module for carrying out heat exchange with the available surface of the heating cavity in the actual heat exchange process, and the ratio of the sum of the heat exchange areas to the available heating area is more than 40%, preferably more than 60%;
1-3 determining specific parameters of the single zone heating module based on the power and available heating area of the heating chamber and the initially determined (1V-110V) low voltage value
After the power, the available heating area and the low voltage are determined, the optimal specific parameters of the single-zone heating module can be determined according to the power, the available heating area and the low voltage through empirical values and formulas, wherein the specific parameters comprise current, current-carrying capacity, length, thickness, width and interval width of the resistance of the single-zone heating module;
(2) Drawing heating element pictures according to calculation result design
Drawing the shape of the single-zone heating module according to the thickness, the length, the width and the interval width of the single-zone heating module calculated by design, wherein the shape is formed by continuously expanding a zigzag resistor into a shape with a required area, and the shape is similar to a labyrinth shape and is formed by N zigzag straight lines so as to ensure that the available heating area is utilized to the greatest extent;
(3) Manufacturing a heating element according to the picture cutting plate;
Cutting a single-zone heating module with a required area and shape by cutting equipment according to the picture by adopting a metal plate with a required thickness, and cutting screw holes at two ends of a current resistor in and out of the single-zone heating module so as to connect a cable with a transformer, wherein the cutting equipment comprises a laser cutting machine;
(4) Insulating the heating module when the heating module is fixed on the available heating area of the heat treatment equipment;
the fixed part of the heating element, which is contacted with the heat treatment equipment or is contacted with a non-insulated object, is isolated by an insulating layer for insulating treatment, the thickness of the insulating layer is 1-10mm, and the outside of the insulating layer does not need metal wrapping.
In a preferred embodiment, the substep of step (1) of the design method further comprises steps 1-4, said steps 1-4 being to customize the transformer according to specific values of the determined power, low voltage, high current of the heating means.
In a preferred embodiment, the number of single zone heating modules may be greater than 1 depending on the available heating area.
In a preferred embodiment, when the number of the single-zone heating modules is greater than 1, a plurality of the single-zone heating modules are designed to be connected in parallel or in series.
In a preferred embodiment, the steps 1-3 further comprise: and adjusting the number of the single-zone heating modules, adaptively adjusting the width, length, thickness, interval width and current-carrying capacity of the resistance of the single-zone heating modules, and calculating for a plurality of times to obtain the number of the single-zone heating modules with highest efficiency.
In a preferred embodiment, the steps 1-3 further comprise recording specific parameters obtained by each calculation to update the empirical formula.
In a preferred embodiment, the heating device further includes a temperature control system of a zone control heating device customized according to parameters of the transformers, the number of the zone control temperature control systems is less than or equal to the number of the transformers, and the using method of the heating device includes: plane contact direct heating, external contact indirect heating, internal radiant, convection heating, and indirect heating with a medium that is heated by the heating device to heat a medium such as a liquid or gas and then the heated medium such as a liquid or gas to heat the object to be heated.
In a preferred embodiment, the planar contact directly heated object comprises a solid and a fluid.
In a preferred embodiment, the planar contact direct heating, external contact indirect heating, internal radiant heating, convection heating, and indirect heating with a medium may be used in combination according to actual working requirements.
In a preferred embodiment, two sets of matched cables are used at the current inlet and outlet ends of the low-voltage high-current single-zone heating module resistor, two inlet and outlet terminals of the isolation transformer are connected, and then 220V or 380V of electric matched cables are connected into the isolation transformer. The temperature control system regulates and controls the transformer in real time by detecting the temperature change of the object to be heated so as to ensure the temperature to be accurate.
In a preferred embodiment, the two current inlet and outlet ends of the low-voltage and high-current single-area heating module resistors are connected in parallel or in series by using a plurality of sets of matched cables, then are connected into two inlet and outlet terminals of the isolation transformer in a combined mode, and then the 220V or 380V electric matched cables are connected into the isolation transformer. The temperature control system regulates and controls the transformer in real time by detecting the temperature change of the object to be heated so as to ensure the temperature precision.
Compared with the prior art, the heating device manufactured by the invention has the following advantages:
1) Compared with the existing resistance wire heating device, the heating device manufactured by the invention can enlarge the heat transfer area, reduce the heat resistance, improve the heat efficiency, greatly save the energy consumption, and save the ratio by at least 30 percent, because the invention adopts the area-oriented low-pressure heating, the heat transfer area can be expanded to the maximum extent, the insulating material can be very thin, the heat transfer resistance is small, the heat transfer area is large, the heat transfer efficiency is high, the temperature of the heating section is close to the working temperature, the heat transfer speed is high, the heat productivity and the heat absorbed by an object to be heated basically reach more than 1 to 0.9, and the consumption in the heat transfer process is less. In addition, the isolation transformer with low voltage is adopted, so that the safety is high, and the danger of electric shock can not be generated even if electricity leaks. The low-voltage heating can improve the heat utilization efficiency, save the power supply cost and make the power supply cost more economical and practical.
2) The heating device designed and manufactured by the invention can ensure that the current-carrying capacity of the control resistor is not more than 10A/mm 2, thereby greatly prolonging the service life of the heating device.
3) The design method of the invention is an area-oriented design method which can ensure the heat transfer area by adjusting low-voltage and high-current parameters, thereby ensuring the highest heat transfer efficiency.
4) The invention is also beneficial to improving the working environment of the heating device and reducing the working temperature of a workshop. The characteristics of traditional heating determine that can not closely keep warm, and the heat energy that looses makes summer workshop operational environment abominable, and this heating device is because low voltage, heat transfer area are big, heat transfer efficiency is high, and low voltage characteristic determines that can closely keep warm, does not have more loss heat energy, so can not lead to the rapid rise of operational environment temperature.
The numerous technical features described in the description of the present application are distributed in various technical solutions, which can make the description too lengthy if all possible combinations of technical features of the present application (i.e. technical solutions) are to be listed. In order to avoid this problem, the technical features disclosed in the above summary of the application, the technical features disclosed in the embodiments and examples below, and the technical features disclosed in the drawings may be freely combined with each other to constitute various new technical solutions (which are all regarded as being already described in the present specification) unless such a combination of technical features is technically impossible. For example, in one example, feature a+b+c is disclosed, in another example, feature a+b+d+e is disclosed, and features C and D are equivalent technical means that perform the same function, so long as they are used alternatively, it is not possible to use them simultaneously, feature E can be combined with feature C technically, and the solution of a+b+c+d should not be regarded as already described because it is technically infeasible, and the solution of a+b+c+e should be regarded as already described.
Drawings
FIG. 1 is a schematic view of the overall structure of a heating device manufactured by the manufacturing method of the present invention;
Fig. 2 is a schematic structural view of a heating element according to a first embodiment of the present invention.
Fig. 3 is a schematic structural view of a heating element according to a second embodiment of the present invention.
Fig. 4 is a schematic structural view of a heating element according to a third embodiment of the present invention.
Fig. 5 is a schematic structural view of a heating element according to a fourth embodiment of the present invention.
Fig. 6 is a schematic structural view of a heating element according to a fifth embodiment of the present invention.
1-An available heating surface; 2-a heating element; 3-a temperature control device; ; 4-a heat treatment device; 5-isolating transformer;
Detailed Description
The inventor of the present application has conducted intensive studies and extensive screening to develop a method for manufacturing an area-oriented bare low-voltage high-current heating apparatus. Compared with the prior art, the application ensures that the heat exchange area is maximized according to the design of the corresponding low-voltage high-current heating module by using the available heating area of the heat treatment equipment of the heating device, thereby ensuring the improvement of heat exchange efficiency and energy-saving efficiency.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application. It will be understood by those skilled in the art that the claimed application may be practiced without these specific details and with various changes and modifications from the embodiments that follow.
The area-oriented bare low-voltage high-current heating device of the invention is shown in fig. 1, and comprises: the heating element 2, the temperature control device 3, the heat treatment equipment 4 and the isolation transformer 5, wherein the length, the width and the interval of the heating element 2 are designed according to the available heating area and the design voltage of the heat treatment equipment 4 through an empirical formula and are arranged on the heat treatment equipment 4, the connection part is subjected to insulation treatment, the heat treatment equipment 4 is connected with the isolation transformer 5, the isolation transformer 5 is designed according to the specific value of the low voltage used by the heat treatment equipment 4, the isolation transformer 5 is connected with the temperature control device 3, and the temperature control device 3 is used for monitoring the specific heating value of the heating element 2 so as to ensure the safety and the stability of the heating process.
Example 1
The design of the heating element of the area-oriented bare low-voltage high-current heating device is shown in fig. 2, and the design steps are as follows:
1-1, determining heating power and available heating area of a heat treatment device provided with the heating device;
The specific value of the low voltage and large current actually used is determined by first determining the power used at the time of heating and the available heating area according to the preset performance of the heat treatment apparatus 4, which in this embodiment is 5.6kw, and empirically selecting 20V as the low voltage value used in this embodiment. Determining the available heating area of the heating cavity after determining the low voltage value, wherein the available heating area of the embodiment is about 0.29m 2;
1-2 determining the material and heat exchange area of a heating element 2 of the heating device;
Then, according to the highest temperature or heating characteristic which can be achieved when the heat treatment equipment is internally heated, the material of the heating element of the heating device (hereinafter also referred to as a single-zone heating element 2) is selected, and the highest heating temperature in the embodiment can reach 280 ℃, so that the material selected in the embodiment is a high-temperature hastelloy plate; then determining the heat exchange area of each available surface on the heating cavity according to the heat conduction property of the material, wherein the heat exchange area is the area of the heating element which exchanges heat with the available surface of the heating cavity in the actual heat exchange process, and the ratio value of the sum of the heat exchange areas to the available heating area is more than 40%, preferably more than 60%; the heat exchange area in this example was about 65%
1-3 Determining specific parameters of the single zone heating element 2 based on the power and available heating area of the heating chamber and the initially determined (1V-110V) low voltage value
After determining the available heating area, the optimal specific parameters of the single-zone heating element 2 can be determined according to the power, the available heating area and the low voltage through empirical values and formulas, and in this embodiment, the calculated specific values of the heating element 2 are as follows: the heating element 2 has a thickness of 2.8mm and a meandering continuous resistance width of 10mm. The low voltage and high current heating device manufactured by the manufacturing method of the invention can achieve about 40% of electricity saving rate
Example 2
The design of the heating element 2 of the area-oriented bare low-voltage high-current heating device is shown in fig. 3, and the design steps are as follows:
1-1, determining heating power and available heating area of a heat treatment device provided with the heating device;
Firstly, determining the power used in heating according to the preset performance of the heat treatment equipment 4 to determine the specific value of the low voltage and high current actually used, wherein the preset power of the heat treatment equipment is 25kw in the embodiment, 45V is selected empirically as the low voltage value used in the embodiment, and the available heating area of the heating cavity is determined after the low voltage value is determined, and the available heating area in the embodiment is about 6.64m 2;
1-2, determining the material and heat exchange area of a heating element 2 of the heating device;
Then the material of the heating element of the heating device (hereinafter also referred to as a single-zone heating element 2) is selected according to the highest temperature or heating characteristic that can be achieved when the heat treatment equipment is internally heated, and the highest heating temperature in the embodiment can reach 550 ℃, so that the material selected in the embodiment is 2520 high-temperature resistant 1500 ℃ stainless steel; then determining the heat exchange area of each available surface of the heating cavity according to the heat conducting property of the material, wherein the heat exchange area is the area of the heating element 2 which exchanges heat with the available surface of the heating cavity in the actual heat exchange process, and the ratio of the sum of the heat exchange areas to the available heating area is more than 40%, preferably more than 60%; the heat exchange area in this example was about 70%
1-3 Determining specific parameters of the single zone heating element 2 based on the power and available heating area of the heating chamber and the initially determined (1V-110V) low voltage value
After determining the available heating area, the specific parameters of the optimal single-zone heating element 2 can be determined according to the power, the available heating area and the low voltage through empirical values and formulas, and in this embodiment, since the heat treatment device 4 is in a ring shape, three parallel single-zone heating elements 2 are selected as final designs, and the specific values of the heating elements 2 after parameter substitution are calculated as follows: the heating element 2 has a thickness of 3.9mm and a meandering resistance width of 27mm. The low voltage and high current heating device manufactured by the manufacturing method of the invention can achieve about 50% of electricity saving rate
Example 3
The design of the heating element 2 of the area-oriented bare low-voltage high-current heating device is shown in fig. 4, and the design steps are as follows:
1-1, determining heating power and available heating area of a heat treatment device provided with the heating device;
Firstly, determining the power used during heating according to the preset performance of the heat treatment equipment 4 to determine the specific value of low voltage and high current actually used, wherein the shape of the heat treatment equipment in the embodiment is irregular, so that the middle and two sides are respectively designed, the preset power of the heating single-zone heating element 2 in the middle is 6kw, 40V is empirically selected as the low voltage value used in the embodiment, the preset power of the heating single-zone heating element 2 on the two sides is 17.3kw, 60V is empirically selected as the low voltage value used, the available heating area of the heating cavity is determined after the low voltage value is determined, and the available heating area in the embodiment is about 5.5m 2;
1-2, determining the material and heat exchange area of a heating element 2 of the heating device;
The material of the heating element of the heating device (hereinafter also referred to as single-zone heating element 2) is selected according to the highest temperature or heating characteristic that can be achieved when the interior of the heat treatment apparatus is heated, and since the highest heating temperature in this embodiment can reach 200 ℃, the material selected in this embodiment is 904L; then determining the heat exchange area of each available surface of the heating cavity according to the heat conducting property of the material, wherein the heat exchange area is the area of the heating element which exchanges heat with the available surface of the heating cavity in the actual heat exchange process, and the ratio of the sum of the heat exchange areas to the available heating area is more than 40%, preferably more than 60%; the heat exchange area in this example was about 50%
1-3 Determining specific parameters of the single zone heating element 2 based on the power and available heating area of the heating chamber and the initially determined (1V-110V) low voltage value
After determining the available heating area, the optimal specific parameters of the single-zone heating element 2 can be determined according to the power, the available heating area and the low voltage through empirical values and formulas, and in this embodiment, the specific values calculated by the single-zone heating element 2 are as follows: the thickness of the single-zone heating element 2 in the middle part is 8mm, the bending resistance width is 36mm, the thickness of the single-zone heating elements 2 on the two sides is 10mm, and the bending resistance width is 18.8mm. As calculated, in this embodiment, the power saving rate can be up to about 50% by using the low-voltage and high-current heating device manufactured by the manufacturing method of the present invention.
Example 4
The design of the heating element of the area-oriented bare low-voltage high-current heating device is shown in fig. 5, and the design steps are as follows:
1-1, determining heating power and available heating area of a heat treatment device provided with the heating device;
firstly, determining the power used during heating according to the preset performance of the heat treatment equipment 4 to determine the specific value of low voltage and high current which are actually used, wherein the shape of the heat treatment equipment is cuboid, the preset power of the whole cuboid is 90KW, one side of each of the three small cuboids is designed as an available heating surface because the shape of an internal heating cavity is also three small cuboids, the power of three single-zone heating elements 2 of the three small cuboids is 30KW, 35V is empirically selected as the low voltage value used in the embodiment, the available heating area of the heating cavity is determined after the low voltage value is determined, and the available heating area in the embodiment is about 9m 2;
1-2, determining the material and heat exchange area of a heating element 2 of the heating device;
Then, the material of the heating element of the heating device (hereinafter also referred to as a single-zone heating element 2) is selected according to the highest temperature or heating characteristic that can be achieved when the interior of the heat treatment equipment is heated, and the highest heating temperature in the embodiment can reach 450 ℃, so that the material selected in the embodiment is nickel-based alloy; then determining the heat exchange area of each available surface of the heating cavity according to the heat conduction property of the material, wherein the heat exchange area is the area of the heating element which exchanges heat with the available surface of the heating cavity in the actual heat exchange process, and the ratio of the sum of the heat exchange areas to the available heating area is more than 40%, preferably more than 60%; the heat exchange area in this example was about 80%
1-3 Determining specific parameters of the single zone heating element 2 based on the power and available heating area of the heating chamber and the initially determined (1V-110V) low voltage value
After determining the available heating area, the optimal specific parameters of the single-zone heating element 2 can be determined according to the power, the available heating area and the low voltage through empirical values and formulas, and in this embodiment, the calculated specific values of the three single-zone heating elements 2 are: the single zone heating element 2 has a thickness of 8mm and a meandering resistance width of 50. In this embodiment, the power saving rate of the large low voltage and large current heating device manufactured by the manufacturing method of the present invention can reach about 40% after calculation.
Example 5
The design of the heating element of the area-oriented bare low-voltage high-current heating device is shown in fig. 6, and the design steps are as follows:
1-1, determining heating power and available heating area of a heat treatment device provided with the heating device;
Firstly, determining the power used during heating according to the preset performance of the heat treatment equipment 4 to determine the specific value of low voltage and high current which are actually used, wherein the shape of the heat treatment equipment is cuboid, the preset power of the whole cuboid is 200KW, the shape of an internal heating cavity is similar to that of the cuboid, so that the bottom of the cuboid is designed as an available heating surface, the bottom heating element 2 of the cuboid consists of a single resistance module, the power of the single resistance heating element 2 is 203KW, 85V is empirically selected as the low voltage value used in the embodiment, the available heating area of the heating cavity is determined after the low voltage value is determined, and the available heating area in the embodiment is about 12.8m 2; 1-2, determining the material and heat exchange area of a heating element 2 of the heating device;
Then, the material of the heating element of the heating device (hereinafter also referred to as a single resistance heating element 2) is selected according to the highest temperature or heating characteristic that can be achieved when the inside of the heat treatment apparatus is heated, and since the highest heating temperature in this embodiment is 80 ℃, the material selected in this embodiment is a 310S stainless steel plate; then determining the heat exchange area of the available heating surface on the heating cavity according to the heat conduction property of the material, wherein the heat exchange area is the area of the heating element which exchanges heat with the available surface of the heating cavity in the actual heat exchange process, and the ratio of the sum of the heat exchange areas to the available heating area is more than 40%, preferably more than 60%; the heat exchange area in this example was about 60%
1-3 Determining specific parameters of the single zone heating element 2 based on the power and available heating area of the heating chamber and the initially determined (1V-110V) low voltage value
After determining the available heating area, the optimal specific parameters of the single-zone heating element 2 can be determined according to the power, the available heating area and the low voltage through empirical values and formulas, and in this embodiment, the calculated specific values of the single resistance heating element 2 are as follows: the thickness of the single resistive heating element 2 is 1mm and the width of the single resistive module is 450mm. In this embodiment, the power saving rate can be up to about 45% by using the low-voltage and high-current heating device manufactured by the manufacturing method of the present invention.
It should be noted that in the present patent application, relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element. In the present patent application, if it is mentioned that an action is performed according to an element, it means that the action is performed at least according to the element, and two cases are included: the act is performed solely on the basis of the element and is performed on the basis of the element and other elements. Multiple, etc. expressions include 2, 2 times, 2, and 2 or more, 2 or more times, 2 or more.
All references mentioned in this application are considered to be included in the disclosure content of this application in its entirety so that they may be subject to modification if necessary. Further, it is understood that various changes or modifications of the present application may be made by those skilled in the art after reading the above disclosure, and such equivalents are intended to fall within the scope of the application as claimed.
Claims (10)
1. A method of manufacturing an area-oriented bare low voltage high current heating apparatus, the method comprising the steps of:
(1) Designing the heating device, comprising the following substeps:
1-1, determining heating power and available heating area of a heat treatment device provided with the heating device;
Firstly, determining the power used during heating according to the preset performance of the heat treatment equipment, and then determining the available heating area of a heating cavity, wherein the heating cavity is a space used for heating inside the heat treatment equipment, and the available heating area is the sum of areas of surfaces available for heat exchange on the heating cavity; the specific value of the low voltage actually used is preliminarily determined according to the empirically summarized big data table with power and area, and the range of the low voltage is 1V-110V;
1-2, determining the heating element material and heat exchange area of the heating device;
The material of the heating element of the heating device is then selected according to the highest temperature or heating characteristics that are required to be reached when heating the interior of the heat treatment apparatus, said material comprising: high Wen Hashi alloy plate, nickel base alloy plate, titanium base alloy plate, tungsten base alloy plate, copper base alloy plate, 2520, 800H, 904L, 310S, 309S, 304, 316L, etc. stainless steel plate or aluminum plate, copper plate; the heating element consists of a single-zone heating module, wherein the single-zone heating module can be a module with a single resistance unfolding area or a module with a zigzag continuous resistance unfolding area; then determining the heat exchange area of each available surface on the heating cavity according to the heat conduction property of the material, wherein the heat exchange area is the area of the heating module for carrying out heat exchange with the available surface of the heating cavity in the actual heat exchange process, and the ratio of the sum of the heat exchange areas to the available heating area is more than 40%, preferably more than 60%;
1-3 determining specific parameters of the single zone heating module based on the power and available heating area of the heating chamber and the initially determined (1V-110V) low voltage value
After the power, the available heating area and the low voltage are determined, the optimal specific parameters of the single-zone heating module can be determined according to the power, the available heating area and the low voltage through empirical values and formulas, wherein the specific parameters comprise current, current-carrying capacity, length, thickness, width and interval width of the resistance of the single-zone heating module;
(2) Drawing a heating element picture according to the calculation result design;
Drawing the shape of the single-zone heating module according to the thickness, the length, the width and the interval width of the single-zone heating module calculated by design, wherein the shape is formed by continuously expanding a zigzag resistor into a required area so as to ensure that the available heating area is utilized to the greatest extent;
(3) Manufacturing a heating element according to the picture cutting plate;
Cutting a single-zone heating module with a required area and shape by cutting equipment according to the picture by adopting a metal plate with a required thickness, and cutting screw holes at two ends of the single-zone heating module for current to enter and exit so as to connect a cable with a transformer, wherein the cutting equipment comprises a laser cutting machine;
(4) Insulating the heating module when the heating module is fixed on the available heating area of the heat treatment equipment;
The part of the heating element, which is contacted with the heat treatment equipment or is contacted with a non-insulated object and is fixed, is isolated by an insulating layer for insulating treatment, the thickness of the insulating layer is 1-10mm, and the outside of the insulating layer does not need metal wrapping.
2. The method of manufacturing according to claim 1, wherein the substep of step (1) of the design method further comprises steps 1-4, said steps 1-4 being to customize the transformer according to specific values of the determined power, low voltage, high current of the heating means.
3. The method of manufacturing according to claim 1, wherein the number of single zone heating modules may be greater than 1 depending on the available heating area.
4. A method of manufacturing according to claim 3, characterized in that when the number of single zone heating modules is greater than 1, a plurality of the single zone heating modules are designed to be connected in parallel or in series.
5. A method of manufacturing according to claim 3, wherein the steps 1-3 further comprise: and adjusting the number of the single-zone heating modules, adaptively adjusting the width, length, thickness, interval width and current-carrying capacity of the resistance of the single-zone heating modules, and calculating for a plurality of times to obtain the number of the single-zone heating modules with highest efficiency.
6. The method of manufacturing according to claim 5, wherein steps 1-3 further comprise recording specific parameters obtained by each calculation to update the empirical formula.
7. A heating device made by the method of any one of claims 1 to 6, further comprising a temperature control system of a zone control heating device customized according to parameters of a transformer, the number of zone control temperature control systems being equal to or less than the number of transformers, the heating device using method comprising: plane contact direct heating, external contact indirect heating, internal radiant, convection heating, and indirect heating with a medium that is heated by the heating device to heat a medium such as a liquid or gas and then the heated medium such as a liquid or gas to heat the object to be heated.
8. The heating device of claim 7, wherein the planar contact directly heated object comprises a solid and a fluid.
9. The heating apparatus of claim 7, wherein the planar contact direct heating, the external contact indirect heating, the internal radiant heating, the convection heating, and the indirect heating using a medium can be combined according to actual working requirements.
10. A method of installing a heating apparatus manufactured by the method of any one of claims 1 to 6, wherein according to the design, two sets of matched cables are used at two ends of a low-voltage high-current single-zone heating module, or two inlet and outlet ends of an isolation transformer are connected separately, or two ends of a plurality of single-zone heating modules are connected in parallel or in series through a plurality of sets of matched cables, then the two inlet and outlet ends of the isolation transformer are connected in a combined manner, and finally 220V or 380V of electric matched cables are connected into the isolation transformer; and finally, detecting the temperature change in the heat treatment equipment through a temperature control system, and regulating and controlling the transformer in real time so as to ensure the temperature to be accurate.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211305146.8A CN117979472A (en) | 2022-10-24 | 2022-10-24 | Manufacturing method of area-oriented bare low-voltage high-current heating device |
| PCT/CN2023/126290 WO2024088270A1 (en) | 2022-10-24 | 2023-10-24 | Method for manufacturing area-oriented exposed low-voltage large-current heating apparatus |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211305146.8A CN117979472A (en) | 2022-10-24 | 2022-10-24 | Manufacturing method of area-oriented bare low-voltage high-current heating device |
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| CN117979472A true CN117979472A (en) | 2024-05-03 |
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| CN202211305146.8A Pending CN117979472A (en) | 2022-10-24 | 2022-10-24 | Manufacturing method of area-oriented bare low-voltage high-current heating device |
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| CN (1) | CN117979472A (en) |
| WO (1) | WO2024088270A1 (en) |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB900515A (en) * | 1957-07-08 | 1962-07-04 | Eisler Paul | Electric surface heating devices |
| CN104869676A (en) * | 2015-04-24 | 2015-08-26 | 冯冠平 | Low-voltage transparent electrothermal film and preparation process thereof |
| CN106060983A (en) * | 2016-06-03 | 2016-10-26 | 苏州捷迪纳米科技有限公司 | Low-voltage driven high-temperature electrothermal film, electric heating module and preparation method of low-voltage driven high-temperature electrothermal film |
| CN111156824A (en) * | 2020-01-21 | 2020-05-15 | 西安博莱炉业科技股份有限公司 | Electric heating element structure for high-temperature resistance hearth and arrangement method thereof |
| CN111491401A (en) * | 2020-04-21 | 2020-08-04 | 苏州好特斯模具有限公司 | Manufacturing process of metal surface thick film heater |
| CN114840971B (en) * | 2022-03-16 | 2024-07-05 | 辽宁顺达机械制造(集团)有限公司 | Method for determining heating steam consumption and heating coil area of marine cabin |
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