Cartridge heaters are a type of electric heating element that are commonly used in industrial settings to provide localized heating in machinery and equipment. Here are the basic steps involved in manufacturing cartridge heaters:
Core wire selection: The core wire is the heating element of the cartridge heater and is usually made of nickel-chromium or iron-chromium alloys. The wire is selected based on the required wattage and operating temperature of the cartridge heater.
Coil winding: The core wire is wound around a ceramic or metallic core to create the heating element. The number of turns and the diameter of the wire are determined based on the desired electrical resistance and watt density of the heater.
Core assembly: The heating element is inserted into a metal sheath, which is usually made of stainless steel or Incoloy. The ends of the core wire are welded or crimped to lead wires that will provide power to the heater.
Sealing and insulation: The ends of the metal sheath are sealed with ceramic or epoxy material to prevent moisture and contaminants from entering the heater. The entire assembly is then insulated with magnesium oxide powder to improve heat transfer and electrical insulation.
Finishing: The cartridge heater is cut to the required length and the lead wires are attached to terminal blocks or connectors. The heater may be coated with a protective layer to resist corrosion or abrasion.
Testing: The finished cartridge heater is tested to ensure that it meets the required specifications for electrical resistance, wattage, and insulation resistance.
Manufacturing cartridge heaters requires specialized equipment and expertise in electrical engineering and metalworking. It is important to follow safety procedures and quality control measures to ensure that the heaters are reliable and safe for use in industrial applications.
| Resistance heating wire |
NiCr 80/20 wire |
| Wattage Tolerance |
+5%, -10% |
| Resistance tolerance |
+10%, -5% |
| Length tolerance |
±1 mm |
| Diameter tolerance |
-0.02mm |
| Standard Cold Zone |
5-10mm |
| Insulation resistance (cold) |
≥ 500 MΩ |
| Maximum leakage current (cold) |
≤ 0.5 mA |
| Thermocouple Location |
type J / K / Ground wire |
Advantages
internal wiring: high temperature resistance, uniform heating, high thermal conductivity and difficult cable fracture.
external wiring: high temperature resistance, uniform heating and high thermal conductivity.
Function:
1. Operating conditions: ambient temperature-20ºC ~ + 60ºC, relative temperature <80%;
2. Electrical strength: cold withstand voltage AC work 1500V 50Hz lasts for 1 min without breakdown phenomenon;
3. Thermal insulation performance: AC 1000V 50Hz lasts for 1 min without breakdown phenomenon;
4. Leakage current <0.5MA; Insulation resistance> 30MΩ;
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