Novatec Infra-Red Die Oven

SummarySummary

This article shows the superiority of the Infra-This article shows the superiority of the Infra-Red technology over convection air flow. The Red technology over convection air flow. The comparison is through theory, heating process comparison is through theory, heating process and efficiency.and efficiency.

Short cycle heating and die management is one Short cycle heating and die management is one of the most significant technology reforms of of the most significant technology reforms of the extrusion industry in the past 20 years.the extrusion industry in the past 20 years.

Three modes of Heat Transfer ：

1.Conduction

2.Convection

3.Radiation

Traditional Air Flow Chest OvenTraditional Air Flow Chest Oven ：： •The chest oven, holding multiple extrusion dies, has been the The chest oven, holding multiple extrusion dies, has been the most common design over the years. The tooling is heated by most common design over the years. The tooling is heated by circulating hot air through a common chamber using a blower circulating hot air through a common chamber using a blower system. This is the convection air process.system. This is the convection air process.

•An extrusion die that does not have accurate temperature An extrusion die that does not have accurate temperature throughout or uneven temperature profile on the face will not run throughout or uneven temperature profile on the face will not run properly. In this case more billet is used before accurate profiles properly. In this case more billet is used before accurate profiles can be produced to correct the differences. Short production can be produced to correct the differences. Short production runs produce off-tolerance material and high die failureruns produce off-tolerance material and high die failure..

• A single lid oven exposes the dies to a fresh supply of A single lid oven exposes the dies to a fresh supply of oxygen and moisture each time the lid is opened. This is oxygen and moisture each time the lid is opened. This is another cause of rapid oxidationanother cause of rapid oxidation..

•  Die management is virtually impossible so the solution Die management is virtually impossible so the solution is to heat lots of dies in case of extrusion issues. This is to heat lots of dies in case of extrusion issues. This means that dies are left at elevated temperatures for means that dies are left at elevated temperatures for extended periods of time. The die bearing is exposed to extended periods of time. The die bearing is exposed to rapid oxidation unnecessarilyrapid oxidation unnecessarily..

UNEVEN HEATINGUNEVEN HEATING Why convection air heats dies unevenlyWhy convection air heats dies unevenly ：：

1. The air being blown in a die box will travel the path of least 1. The air being blown in a die box will travel the path of least resistance from inlet to outlet in the convection process. The resistance from inlet to outlet in the convection process. The physical blockage of the air stream causes uneven exposure physical blockage of the air stream causes uneven exposure to the die surface.to the die surface.

2.2. All the dies in a convection chest oven are under the same lid, All the dies in a convection chest oven are under the same lid,

Heated air escapes every time the lid is opened.Heated air escapes every time the lid is opened.

InletInlet

DieDie Direction of AirDirection of Air

OutletOutlet

Convection Air Flow OvenConvection Air Flow Oven

3. Placing a cold die in the air stream will cool the temperature for 3. Placing a cold die in the air stream will cool the temperature for the dies further away causing incorrect heat time. It is virtually the dies further away causing incorrect heat time. It is virtually impossible to avoid this in the die exchange process. Heated dies impossible to avoid this in the die exchange process. Heated dies are then actually cooled without operator knowledge. The biggest are then actually cooled without operator knowledge. The biggest cause of unevenly heated dies is when a cold die is placed next cause of unevenly heated dies is when a cold die is placed next to a hot die causing the heated die face to be cooled on one side. to a hot die causing the heated die face to be cooled on one side. This thermal gradient is the cause of die breakage, poor run out This thermal gradient is the cause of die breakage, poor run out and inaccurate non-conformant extrusion dimensions using the and inaccurate non-conformant extrusion dimensions using the first billet.first billet.

Heating Extrusion DiesHeating Extrusion Dies

UsingUsing

Infra-Red TechnologyInfra-Red Technology

Most extruders use traditional convection chest ovens Most extruders use traditional convection chest ovens for die heating. The air in a common chamber is heated and for die heating. The air in a common chamber is heated and circulated. The convection process relies on air temperature to circulated. The convection process relies on air temperature to transfer energy to the steel through conduction. This procedure transfer energy to the steel through conduction. This procedure is slow and inefficient.is slow and inefficient.

Infra-Red energy uses a band of electromagnetic waves Infra-Red energy uses a band of electromagnetic waves to “excite” the metal molecules in a die through radiation. This to “excite” the metal molecules in a die through radiation. This molecular excitation is similar to the microwave technology. molecular excitation is similar to the microwave technology. Infra-Red energy does not use air temperature for thermal Infra-Red energy does not use air temperature for thermal transfer. Air is an insulator so the thermal process is transfer. Air is an insulator so the thermal process is accelerated.accelerated.

What is “Infra-Red” HeatingWhat is “Infra-Red” Heating ？？

What is “Infra-Red” HeatingWhat is “Infra-Red” Heating ？？ Infra-Red is a kind of Radiation which transfer heat from object

to another by electromagnetic transmission. The Infra-Red is located between visible light and radio in the electromagnetic spectrum. The wavelength of Infra-Red ranges from 2.0 to 6.0 microns.

What is “Infra-Red HeatingWhat is “Infra-Red Heating ？？

When the Infra-Red energy reaches the surface to be heated, When the Infra-Red energy reaches the surface to be heated, the molecules vibrate, converting to heat energy. Heat then the molecules vibrate, converting to heat energy. Heat then travels through the product by conduction.travels through the product by conduction.

Properties Properties of IR of IR

Material generates Material generates heat after absorptionheat after absorption

Reflection or Reflection or TransmissionTransmission

About NovatecAbout Novatec

Novatec is based in Surrey, British Columbia .The company has Novatec is based in Surrey, British Columbia .The company has been producing Infra-Red equipment for a variety of applications for been producing Infra-Red equipment for a variety of applications for the past 20 years. In 1990, an aluminum extruder asked Novatec to the past 20 years. In 1990, an aluminum extruder asked Novatec to explore the possibility of heating extrusion dies with Infra-Red explore the possibility of heating extrusion dies with Infra-Red technology, and the Novatec Infra-Red Die Oven was technology, and the Novatec Infra-Red Die Oven was developed. Since that time, a number of extruders have installed the developed. Since that time, a number of extruders have installed the ovens and have reported dramatic improvements in speed, flexibility, ovens and have reported dramatic improvements in speed, flexibility, and quality.and quality.

Novatec Infra-Red Die OvenNovatec Infra-Red Die Oven

Past attempts to use Infra-Red waves involved broad Past attempts to use Infra-Red waves involved broad band heating. Generating this spectrum was not energy band heating. Generating this spectrum was not energy efficient.efficient.

Novatec has developed the Infra-Red band technology Novatec has developed the Infra-Red band technology to focus the wave energy to match the absorption in steel. to focus the wave energy to match the absorption in steel. Generating a small band of Infra-Red waves gives a focus Generating a small band of Infra-Red waves gives a focus energy for absorption. This maximizes energy transfer.energy for absorption. This maximizes energy transfer.

Spectrum Absorption

0

20

40

60

80

100

1 2 3 4 5 6 7 8

Infra-Red Wave Length (Micron)

% A

bs

orp

tio

n

Metal

Advantage of using Novatec Infra-Advantage of using Novatec Infra-Red Die Oven:Red Die Oven:

1. Cuts die heat up time by 75%1. Cuts die heat up time by 75%

2. Reduces energy consumption by 50%2. Reduces energy consumption by 50%

7. Advanced PLC control7. Advanced PLC control

3. Reduces die failure by 90%3. Reduces die failure by 90%

4. Increases speed and flexibility4. Increases speed and flexibility

5. Improves extrusion surface finish5. Improves extrusion surface finish

6. Superior safety features6. Superior safety features

1. Cuts die heat up time by 75%1. Cuts die heat up time by 75%

Novatec Infra-Red Die Ovens heat dies much faster Novatec Infra-Red Die Ovens heat dies much faster than convection ovens. As explained above, this is because than convection ovens. As explained above, this is because the dies are being heated by infrared waves, not air. Air the dies are being heated by infrared waves, not air. Air itself is an insulator of thermal energy, and therefore, is a itself is an insulator of thermal energy, and therefore, is a poor medium for thermal transfer. Novatec’s Infra-Red Die poor medium for thermal transfer. Novatec’s Infra-Red Die Ovens single out the wavelength needed to heat die steel Ovens single out the wavelength needed to heat die steel onlyonly…not heat all the air in the oven.…not heat all the air in the oven.

0.55

0.95

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

Emission Ratio

Metal Sheath Heater

Novatec Black BodyInfra-Red Heater

Heater Efficiency ComparisonHeater Efficiency Comparison

Press(T)

Die Size(Dia. X thickness)

(mm)

DieTemp( )℃

Heat Time

Infra-Red Convection

2800 430 x 330 475 2Hrs 30mins 4~5Hrs

2800 430 x 190 475 2hrs 00mins 4~5Hrs

3680 520 x 245 475 2Hrs 15mins 5~6Hrs

3680 520 x 340 480 2Hrs 35mins 5~6Hrs

Heat Time ComparisonHeat Time Comparison ：：

2. Reduce energy consumption by 50% 2. Reduce energy consumption by 50%

Because of the wavelength heating process explained Because of the wavelength heating process explained

above, the efficiency of the die heating process is greatly above, the efficiency of the die heating process is greatly

improved. Not only does the level of heating time reduce overall, improved. Not only does the level of heating time reduce overall,

but also the power draw to maintain oven temperature once but also the power draw to maintain oven temperature once

heated is less than 500 watts. (By contrast, a typical hair dryer heated is less than 500 watts. (By contrast, a typical hair dryer

operates on 1200 to 1400 watts.) The savings on power usage operates on 1200 to 1400 watts.) The savings on power usage

alone is a significant benefit when using Novatec’s Infra-Red Die alone is a significant benefit when using Novatec’s Infra-Red Die

Oven.Oven.

Extrusion Die Oven - Electricity Usage ComparisonExtrusion Die Oven - Electricity Usage Comparison

Convection Air Flow Oven NOVATEC Infra-Red Oven

Each Cavity ：10 Dies 24 kW 480V

Each Cavity ：2 Dies 22 kW 480V

Die Heat Up Cycle ：8Hours X 20.4 kW/hr =163.2 kWh@ 85% Power Draw

Die Heat Up Cycle ：1Hour X 18.7k W/hr = 18.7 kWh@ 85% Power Draw

Total Cycle ：8 Hours163.2 kW X $0.07 kWh = $11.42

Total Cycle ：1 Hour18.7 kW X $0.07 kWh = $1.31

Total Cost to Heat Each Die ：$11.42 ÷ 10 = $1.14

Total Cost to Heat Each Die ：$1.31 ÷ 2 = $0.65

Die Temperature Holding Cycle ：20.4 kWh÷10 Dies X $0.07/kWh= $0.14 Per Die Per Hour

Die Temperature Holding Cycle ：0.5 kWh÷2 Dies X $0.07/kWh= $0.0175 Per Die Per Hour

The Infra-Red Oven is 52% more cost effective than a Convection Oven.

3. Reduces Die Failure up to 90%3. Reduces Die Failure up to 90%

Extruders who use the Novatec Infra-Red Die Ovens have Extruders who use the Novatec Infra-Red Die Ovens have reported a dramatic decrease in die failure and breakage. Not only reported a dramatic decrease in die failure and breakage. Not only do convection ovens take longer to heat a die, they heat dies do convection ovens take longer to heat a die, they heat dies unevenly. Studies show that even after four hours of soak time in unevenly. Studies show that even after four hours of soak time in a convection oven, a 14 inch die can have as much as a 100 a convection oven, a 14 inch die can have as much as a 100 degree difference between one side of the die to the other. This degree difference between one side of the die to the other. This will cause uneven runout in multi-hole dies, and consequently, will cause uneven runout in multi-hole dies, and consequently, uneven stresses on the die. All of this results in premature die uneven stresses on the die. All of this results in premature die failure and breakage and higher scrap rates. Novatec’s Infra-Red failure and breakage and higher scrap rates. Novatec’s Infra-Red technology heats dies to within single digit temperature variation technology heats dies to within single digit temperature variation throughout the die, reducing die failure.throughout the die, reducing die failure.

This Chart shows the heat up time for a 16"x 6" die at 4 different thermocouple points in the die. Note the evenness of the heating throughout the die. It reached target temperature in 91 minutes.

0

50

100

150

200

250

300

350

400

450500

550

600

650

700

750

800

850

900

950

1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96 101 106 111 116 121 126 131 136

Time (min.)

Tem

p (

deg

. F

) Middle : 3" Dep

Oven Set Point

Surface Temperature

Front : 1" Deep

Back : 1" deep

4. Increases Speed and Flexibility4. Increases Speed and Flexibility

As mentioned above, a 14-inch die would be heated in As mentioned above, a 14-inch die would be heated in

less than 60 minutes with a Novatec Infra-Red Die Oven, as less than 60 minutes with a Novatec Infra-Red Die Oven, as

opposed to 4 hours in a convection oven. This will provide opposed to 4 hours in a convection oven. This will provide

increased flexibility of die changeovers on the extrusion press, increased flexibility of die changeovers on the extrusion press,

and reduce throughput time.and reduce throughput time.

5. Improves surface finish of extrusions5. Improves surface finish of extrusions

Because the dies do not have to stay in the oven for 4+ Because the dies do not have to stay in the oven for 4+

hours, the die bearings are not subject to excessive oxidation hours, the die bearings are not subject to excessive oxidation

prior to extrusion. This provides a higher extrusion finish. Also, prior to extrusion. This provides a higher extrusion finish. Also,

airflow systems, such as those used in a convection oven, tend airflow systems, such as those used in a convection oven, tend

to deposit particles on dies and bearings. Novatec Infra-Red to deposit particles on dies and bearings. Novatec Infra-Red

Die Ovens do not require an airflow system, and therefore, Die Ovens do not require an airflow system, and therefore,

keep the dies free of contaminants.keep the dies free of contaminants.

6. Superior Safety Features6. Superior Safety Features

• Watchdog thermocouple system and backup Watchdog thermocouple system and backup Mechanical Contactor prevents thermal run awayMechanical Contactor prevents thermal run away

• Static lid stops that will activate under any non-Static lid stops that will activate under any non-normal condition, i.e. power outage, power spike normal condition, i.e. power outage, power spike

• Emergency Stop Push ButtonEmergency Stop Push Button

• Annealing LightAnnealing Light

Unique PLC System Unique PLC System Automation ControlAutomation Control

7. Advanced PLC Control7. Advanced PLC Control

ORION SeriesORION Series

Little, Tiny, SCADA !Little, Tiny, SCADA !

Interface up to 20 loops of control. Include Interface up to 20 loops of control. Include profiling, single set-point recipes, trending, profiling, single set-point recipes, trending, alarm monitoring\history and graphic alarm monitoring\history and graphic objects for each loop, then add data objects for each loop, then add data acquisition with historical viewing, and you acquisition with historical viewing, and you have ORION.have ORION.

Real Time and Historical TrendsReal Time and Historical Trends Profile open, edit, save and download!Profile open, edit, save and download!

Temperature

2 Cavity Oven2 Cavity Oven

3 Cavity Oven3 Cavity Oven

DrawerDrawer OvenOven

6 Cavity Oven6 Cavity Oven

Be on the leading edge of extrusion technology!Be on the leading edge of extrusion technology!

We’re all looking for ways to stay ahead of the We’re all looking for ways to stay ahead of the

competition, and this is especially true in the extrusion business. competition, and this is especially true in the extrusion business.

Novatec’s Infra-Red technology is truly on the cutting edge for Novatec’s Infra-Red technology is truly on the cutting edge for

this industry. It can be the key that gives your plant the edge this industry. It can be the key that gives your plant the edge

you need over your competitors. Don’t wait until they have one, you need over your competitors. Don’t wait until they have one,

too! Call today and explore the possibilities of Novatec’s Infra-too! Call today and explore the possibilities of Novatec’s Infra-

Red Die Oven for your plant.Red Die Oven for your plant.

Contact Us

Head Office

Ph. 604-888-3328 Fax. 604-888-4538Email: Sales@Novatecpro.com