Opportunity:

A customer involved in international manufacture of heavy vehicle brakes systems needed temperature control for a fill, press and cure application. This application will cure friction material compounds to various die set impressions. This company wished to improve the process by introducing a dual die bed allowing fills of one set, while press and cure was taking place on the other set.

Problem:

The large die sets (four feet square) each has several impressions, which require uniform heating. The platen design incorporated 16 heaters in two bands of eight. Two zones needed to be controlled, which gave a total of 32 heaters being controlled. This design required the two outer heaters of each blank to be at a higher rating to compensate for edge losses. Individual thermocouples would be required for each impression of the die.

The control enclosure must allow for all controllers, fuses, isolators, a PLC data logger and power switching devices. Lastly, the unit must be reliable and operate in a harsh environment of noise, vibration and airborne pollutants.

Solution:

  • 32 heaters
  • thermocouples
  • current transformers
  • Anafaze MLS SERIES controllers
  • DIN-A-MITE®; power controllers were selected.

    The customer was reluctant to utilize DIN-A-MITE controls over Solid State Relays due to the initial cost. However, they linked the DIN-A-MITE package and agreed to try a unit to test Watlow's claims of significant cost savings during installation, ease-of-use, visual status indication and wiring simplicity.

    Following the trial run, the customer was delighted with the product and specified the DIN-A-MITE units for the machine. A standard cabinet enclosure of six feet by four feet was selected to house all the control components. The cabinet was fitted with DIN rails.

    The installation technicians were particularly complimentary of the DIN-A-MITE's installation ease and general serviceability. The project has been expanded to convert six or more machines within a period of ten months. All will be fitted with the DIN-A-MITE controllers, which has been adopted as standard retrofit for all failing SSR's throughout the site.

    Key products were used for this solution: MLS 32-loop controller, DIN-A-MITE, cartridge heater and MI thermocouple