Heater production process

We understand that the materials needed to process the heater: steel pipes, fillers, heating wires, lead rods, sealing glue, high-temperature wires and other hardware accessories. Let us briefly describe the production process of the heater.

1. What is the production process of heater?

1. Cut the pipe
Select the pipe material and length as required, and there should be no burrs in the cut.

2. Chamfer
There should be no burrs at both ends of the pipe. Use a conical milling cutter to clamp it on the power head and use mechanical methods.

3. Pipe cleaning
The pipes are cleaned using alkali degreasing and acid deembroidery methods. After cleaning, the inner quilt is brushed and wiped.

4. Press-fit solid plug
Press the lead rod into the solid plug.

5. Wire wrapping
Use a wire winding machine to make the resistance wire into a spiral shape according to the production order to ensure uniform winding distance.

6. Welding
Weld the lead rod and resistance wire to ensure close contact and firm welding. The resistance wire will not fall off from the lead rod when shrinking the tube.

7. Fill powder
Use a filling machine to fill magnesium oxide powder, and the filling density reaches 2.3~2.5g/cm3 under vibration.

8. Shrink tube
(1) In order to increase the density of the filling in the tube and increase the electric heating coefficient of the filling without reducing the insulation resistance, the tube is compressed after loading the powder;
(2) Use a shrinking machine to compress and form, tighten the resistance wire and magnesium oxide powder to make it dense, ensuring the insulation of the heating wire from the air, and the center position does not shift and touch the tube wall.

9. Both ends of the car
Ensure that the lead-out rod is symmetrical, and the difference in exposed length at both ends is no more than 2mm.

10. Annealing (according to production order)
Layer the heater evenly into the furnace.

11. Bend pipe
(1) In order to prevent breakage, the bending radius of the pipe shall generally not be less than 2.5 times the pipe diameter;
(2) According to the production single molding, the appearance of the pipe shall not have obvious mechanical scars or local expansion, and there shall be no wrinkles, unevenness, etc. at the bends;
(3) When the bending radius is less than 3 times the pipe diameter and is not annealed, it should be ensured that the pipe weld direction is inward and R is not easy to break.

12. Welding
When parts such as fasteners, flanges or baffles are required according to the production order, the welding is firm and reliable.

13. Sealing
(1) Dry thoroughly before sealing;
(2) Strictly observe the sealing square and stir evenly;
(3) The nozzle area is sealed;
(4) Pay attention to process hygiene when sealing.

14. Surface treatment
Whether there is an anti-scale coating requirement according to the production order.

15. Inspection
Insulation, withstand voltage (electrical strength), cold resistance, leakage current and appearance inspection.

16. Mark.

17. Packaging.