Heater bands and Mica heater bands are heating devices with a ring shape and are clump around tube-shaped elements to help in the molding process. However, they may develop premature failures during operations due to environmental challenges that may create shorts, forced the bands to overheat beyond the required temperatures, or even cause the development of hot spots, which may paralyze their operations. Therefore, they may need replacements. Here are some pieces of advice from a specialist on how you can extend their lives when they encounter certain problems.
Contamination is a serious problem that frequently affects Heater bands and Mica heater bands, leading to their failure when working. The main contaminants that affect them are plastic, moisture, and hydraulic oil. Typically, these contaminants will damage the lead wires that are inside the band. You can prevent problems by replacing the Heater bands and Mica heater bands frequently. Additionally, ensure that the heaters are installed on a machine barrel that has no grit and scale because these scales usually cause a hot spot on the heater surface and, as a result, change the path of heat conduction.
Poor conduct problem
Heater bands and Mica heater bands are conductive heaters, so it is critical to keep them tightly fit. Supposing you fail to keep them tight enough, they will develop some localized hot spots, which may cause some failures due to wire resistance. It is worth noting that the higher the working temperature you use, the more tightly you need to keep the heater. Address these problems by ensuring that you check the machine barrels and order heaters that fall within the same measurement. You also need to read instructions to the letter before you carry out installation and tightening procedures.
Watt density challenges
Normally, heaters are sized up to bring the press up so that heating can be done as quickly as possible. However, the Heater bands and Mica heater bands’ wattage is usually higher than the normal operational level. This high wattage drives up the temperatures inside the heater during the molding process and can shorten the heaters’ lifespan. Address these problems by choosing a watt density close to the load requirement levels and a safety measure in consideration. Further, you can seek help from the supplier to help you size the wattage properly after purchase.
When the sensors of your heaters encounter problems, and they become loose, or they disconnect to the extent that they cannot make contact with the surface that has been measured, then runaway temperature commands will take place. Another problem may also be caused by temperature overshooting. You can address these problems by checking the sensor contact to ensure they are well in place and when you will be carrying out design work of the system, ensure that the total wattage that you apply to the actual wattage that is required is matched to reduce cycling frequency and the temperatures from overshooting.
Finally, if you follow the above control measures on how to take care of your heater bands and bands, you will enjoy using them and prolong their lifespan.