Showing posts from 2019

How Electric Heater Are Manufactured?: Basic

Before Reading this post, I would recommend you to see my post on Electric Heater Working Principle for sake of clarity. In the manufacturing of electric heater, a resistance material, often in the form of wire or strip, is used as resistance wire. This Wire is formed into suitable form, Usually coiled, according to end requirement. This coil wire or resistance material is made to surround by insulating material so that only heat can be passed thru it while insulating it from live current carrying conductor. But here is the trick, we have studied in our high school that a bad conductor of heat is also bad conductor of electricity. So how can the insulation material will hold back the current while allow to heat to pass through it?. Actually a compromise is made so that the material will allow some heat to travel through it, while also allowing some electric current in the form of leakage current to get to the sheath material. But the compromise is made in such a way that it favors hea

How an Induction Heater Works?

    A n induction heater, as the name suggest works on the principle of induction. Here by the term Induction means to induce, induce an electric current. This induce electric current is also called eddy currents. In these type of heater, the principle of heating is same, the resistance heat produce due to resistance of the material to the flow of electric current. But in this system, we are not providing an external Voltage potential source, which, in conventional electric heating provide the required potential for the electrons to flow, Instead we are making the electrons to flow in to fro direction because of rapidly changing polarity. The change in Polarity is made by electromagnetic radiation that impinges to the surface of the material to be heated by a suitable formed emitter, usually formed  as a coil. Based on the frequency, the polarity changes form +ve to -ve and again form -ve  to again +ve a number of times in a given time. Because of this changing potential, a changing

How Thermocouples Works?

Thermocouples are temperature-measuring devices that generate a voltage or electrical potential difference when two different metals are joined together and exposed to heat. This voltage is proportional to the temperature difference between the two junctions and can be measured and converted into a temperature reading. The working principle of thermocouples is based on the Seebeck effect, discovered in 1821 by Thomas Johann Seebeck. The Seebeck effect is the phenomenon where a voltage or electrical potential difference is generated when two different conductors or metals are joined together and exposed to a temperature gradient. The voltage generated is proportional to the temperature difference between the two junctions and is known as the Seebeck voltage. When a thermocouple is exposed to heat, the heat causes electrons to move from one metal to another at the junction, creating a voltage. The voltage generated is then measured and converted into a temperature reading using a s

How to prolong Your Electric Heater Life.

    E lectric Heater works under high temperature. Normally an Electric Heater would fail, when its heating wire melt down. So to get your heater deliver its intended job done for an appreciated long time, some precautions should be taken. The very important thing to be taken into consideration is the heater sheath watt density. A sheath watt density can be defined as the total rated power divided by its exposed surface area from which heat is to dissipated. It Should be noted that for a given size Heater (for instance a Tubular Electric Heating Element ), the watt density depends upon the medium to be heated and its surrounding environment. For Example a heater designed to heat water can not be used in open air, if, when used, will burn sooner it reach its failure temperature. Other Precaution Required to be taken is to check with the connection. Since an electric heater works in a high temperature environment, the heater terminal are usually equipped with post terminals (screws and

Electric Heater Or Heat Pumps What to use?

Electric Heater and Heat Pumps both Supply Heat. But there should be judicious decision in selecting them. To Compare, An electric Heater is 100% efficient whereas a heat pump is more than 100% efficient. The Efficiency depends upon the environment. While Heat pumps mostly have more than 100% efficiency (cop>1), they have limited application and find use in such as room heater or as water heater. They can not provide heat at more than few hundred degree Celsius. Although, heat pump technology is evolving and is made to provide heat at high temperature, its installation and maintenance cost is still making big on pockets. Heat pump have lots of parts and accessories which make them costly. On the other hand, electric heater, depending upon the made, can work even in around thousand degree Celsius range. Also, Electric Heater are simple in made and easy to control. Hence they are cheap as compared to Heat Pumps. Working of a heat pump is similar to a domestic Refrigerator. In domes

Why we use Casting Heaters?

Introduction     Casting Heaters have Tubular Heating Elements inside, which is cast in suitable form in aluminum or brass, With Aluminum with the most used case.  The Reason for choosing Aluminum, is that Aluminum is a good conductor of Heat. Because of its heat Conducting property, a uniform temperature can be expected through out the heater material and hence results in a quality good product. Also, Thermal Inertia of Aluminum is very high as compared to other metals. Hence during power cuts, the molten metal inside the barrel remains in its molten form and will not choke the line, which is frequent when used with other heaters. Product Life Cycle Casting Heater Life Cycle starts with initialization of requirement for such Heaters. The Ideal situation, where these heater would be employed, would be in a process where uniform temperature is required at all section. Other Situation would be, where High Thermal Inertial would be required, so that startup time would be minimiz