Multi-wires systems

ATE has developed two induction heating systems for the treatment of parallel conductors, with the names IMW (independent multi-wires) and CMW (common multi-wires).

The main characteristics of the two systems are:

IMW systems allow the heating of multiple wires of different diameters in an independent way (Independent Multi Wires), wire by wire with independent temperature and speed settings for each line.
CMW systems give the possibility to heat wire of the same diameter in a common way (Common Multi Wires), at the same temperature, or wires with a slightly different diameter at practically the same temperature, considering an appropriate speed x diameter ratio.

Compared to other types of heating systems, as resistance, gas, fluid bed furnaces or in a molten lead bath, IMW and CMW multi-wire induction heating systems have the following advantages:

no environmental pollution
more compact dimensions
greater efficiency

The compactness of the heating systems allows them to be easily installed in limited spaces and, above all, in existing lines in which encumbrances are limiting. The frequency converter, heat exchanger and control panel that complete the system can be positioned in the available spaces, even at a certain distance from the heating system.

IMW and CMW systems are completely modular and can heat a variable number of wires. The configuration can be defined according to the customer’s requirements.

CMW and IMW multi-wire induction heating systems can be used in various industrial processes, some of which are listed below:

Annealing

When a metal is plastically deformed at rather low temperatures compared to the melting temperature, it produces:

a variation in grain configuration
work hardening
an increase in the density of dislocations

It is possible to completely or partially recover the state previously to the cold working through a particular annealing treatment called recrystallisation annealing.

This recovery of the original properties of the material is the result of two different processes that occur during the annealing heat treatment, the recovery (reorganisation) of the dislocations and the recrystallisation of the grains.

This type of annealing produces a new structure in the grains without phase changing.

Annealing system of steel cords.

Diameter range: up to 5,5 mm
Temperature: up to 730° C

Tyre reinforcements - Steel cords and Bead wire

Steel cords and bead wire are metal wires used in the reinforcing structures in tyres that are subjected to particular induction heat treatments in some phases of the production processes to deposit a bronze film on the surface and to confer peculiar mechanical properties that are typical of the application.

Heating system of steel cord for brass diffusion.

Diameter range: up to 2,10 mm
Heating temperature: up to 600° C exiting the furnace
Output: up to 78 kg/h

Heating system of steel cord for brass diffusion of bead wires.

Diameter range: up to 2,2 mm
Heating temperature: up to 500 °C exiting the furnace
Output: up to 360 kg/h

High pressure hose reinforcements – Hose wire

HHose wires are metal wires used in the reinforcing structures in high pressure hoses that are subjected to particular induction heat treatments in some phases of the production processes to deposit a brass or bronze film on the surface and to confer peculiar mechanical properties that are typical of the application.

Inline heating of steel cord for brass diffusion.

Diameter range: up to 1,7 mm
Heating temperature: up to 600° C exiting the furnace (generally in the 530-560° C temperature range)

Output:

Output: up to 53 kg/h

Saw wire

Saw wire is used to cut ingots and silicon blocks into very thin sections, from which photovoltaic solar cells and semi-conductors for electronic circuits are obtained. Just like steel cords, these metal wires are subjected to particular induction heat treatments in some phases of the production processes to deposit a brass film on the surface and to confer peculiar mechanical properties that are typical of the application.

Inline heating of steel cord system for brass diffusion.

Diameter range: up to 1,2 mm
Heating temperature: up to 600° C exiting the furnace
Output: up to 29 kg/h

Heating for drying, desiccation, painting, galvanising, surface plastic coating

Liquids, paints, lubricants, polymeric coatings can be heated in a very effective way if they are or come into contact with induction-heated metal materials.

With induction heating, the direct heating by “skin effect” of a surface layer of parallel multi-wires is carried out, making the processes of drying, desiccation of lubricants, painting, galvanising and coating with polymers much quicker, repeatable with a limited use of space and energy compared to hot air or irradiation systems.