BCE Cartridge Heaters

 

BCE manufactures a wide range of cartridge heaters for a variety of industrial applications, and can provide you with heaters manufactured to your exact specifications. Cartridge heater size, sheath, leads, terminals, wattage and voltage can all be adapted to meet your exact needs.

Low to Medium Watt Density Cartridge Heaters

BCE precision cartridge heaters provided localized heat to restricted work areas requiring close thermal control. Dies, platens, and a variety of other types of processing equipment are efficiently heated and can be closely controlled. Part work temperatures of up to 1250ºF are obtained by a combination of heater location and proper wattage output. Basic heater designs are readily adaptable to a wide variety of special requirements, sizes, or ratings. Heating element wires are constructed just beneath outside surface for optimum heat transfer and minimum core temperature, resulting in faster part heating.

The maximum power densities for low to medium watt density cartridge heaters is computed at 60 watts per square inch of heated surface. With proper fit in a heat sink, long life can be expected. Consult BCE for higher watt density applications. Lower watt density will result in longer life. Standard voltages are either 120V or 240V. Other voltages are available.

High Watt Density Cartridge Heaters

The useful life of a Cartridge heating element is determined by how quickly the heat generated in the internal resistance wire can be dissipated to the outside sheath. BCE high watt density cartridge heaters are design and constructed in a way that accelerates the transfer of heat from the resistance wire to the sheath. This is accomplished by relocating the wire so that it is closer to the sheath; and swaging the outside diameter of the heater, thereby compressing the magnesium oxide filler so that it becomes an improved conductor of heat from the wire while maintaining its dielectric properties. By improving the heat transfer rate, it is possible to manufacture elements of higher densities because the differential between the wire temperature and the sheath temperature has been minimized.

Common applications for high watt density cartridge heaters are dies, heat sealing machines, hot melt adhesive equipment, plastic molding machines, platens, and shoe machinery.

Optimizing Performance and Operating Life of High Watt Density Cartridge Heaters

Cartridge Heater Fit

High watt density heaters require careful fit to insure optimum performance and long life.  BCE recommends that installation holes not be drilled and reamed over .002” or larger than the nominal hole size required. 

Cartridge Heater Cycling

Rapid cycling of heaters from very low to very high temperatures shortens their life considerably. It is recommended therefore, that care be taken to compute the correct wattage for any given installation. Optimum wattage should result in a 50/50 off/on cycle.

Location of temperature Sensor and Cartridge Heater

When thermostats are used, the sensing element ought not to be placed further than 1⁄2" away from the heater wherever possible.

For more information about cartridge heaters, call BCE at 510-274-1990 or visit their website at https://bcemfg.com.

OEM Equipment Manufacturers: Look Toward the Experienced Sales Engineer for Project Success

Original Equipment Manufacturers (OEMs) who work closely with vendor sales engineers in the design of assembly components (such as electric heating elements and vacuum feedthroughs) gain a valuable competitive advantage. By understanding what these professionals have to offer, and taking advantage of their skills, OEM designers end up with better project outcomes.

Sales engineers are a readily available resource of application knowledge. Unlike information pulled from the Internet, sales engineers possess real-time product information. They are also exposed to many different product applications and are a wealth of tacit knowledge. All readily available for sharing with their customers.

OEM design engineers often find themselves sailing in uncharted waters. In the application of electric heaters or feedthroughs for instance, designers don't always have a full grasp of heater or feedthrough design constraints. When these situations occur, the heater sales person provides a real benefit in teaching and advising the designer what is possible.  Additionally, many sales engineers have access to unpublished product and application information, which can be hugely important when attempting to build a leading edge product.

Of course any solutions proposed are likely to be based upon the products sold by the representative, but the best sales people will share the virtues of their products openly and honestly. The best sales engineers will even admit when they lack the product or experience to solve the problem, but even in this situation, you can be sure their perspective will still be of value. The goal is to build a long-term, trusting relationship - one of value to both parties. Sales engineers are in the business of dealing with people and making the important connections between customers and manufacturers. They make it their business to know what’s going on with products, companies and industries.

As an engineer or purchasing professional responsible for the design and manufacture of OEM equipment, know that working closely with a vendor sales engineer will save you precious time and greatly improve the likelihood of successful project outcomes. Their success, and your success, go hand-in-hand.

BCE ISO 9001: 2015 Update

BCE is very pleased to announce the company has been awarded ISO 9001: 2015 approval.

July 23, 2018 - BCE, Inc., a California based designer and manufacturer of electric thermal systems and vacuum feedthrough devices, announced today that it has been recognized for its commitment to quality and excellence by being certified in accordance with ISO 9001:2015.

For more information, contact BCE by calling 510-274-1990 or visiting https://bcemfg.com.

FAQ: Custom Heater Assemblies

Custom heater assembly that includes a sealed cartridge
heater, thermowell, and thermocouples (multiple).

What is a custom heater assembly?

In general terms, a custom heater assembly is a device that transforms electrical current to heat energy, is designed in a way that accommodates the needs of a unique heating requirement, and is used for the heating of gases, liquids, plastics, or metals.

What is a thermowell?

A thermowell is machined metallic tube used to house and protect sensors or heating elements. Thermowells not only protect heaters and sensors from erosive or corrosive media, they also allow for easy removal and replacement without exposing the process media.

What is a cartridge heater?

A cartridge heater is a cylindrically shaped electric heating element intended to be inserted in holes in metal platens or immersed in flowing media. The design incorporates a ceramic bobbin wound with nichrome resistance wire, carefully centered inside a metallic tube, and then backfilled with magnesium oxide (MgO), which provides electrical insulation. Cartridge heaters can be either swaged (compacted MgO) or un-swaged (loosely filled MgO). Swaging allows for maximum heat transfer to outside surfaces while keeping internal heater temperatures as low as possible, and preserving dielectric qualities.

What is a sealed cartridge heater?

A sealed cartridge heater incorporates all of the characteristics of a standard cartridge heater but is additionally sealed with BCE’s proprietary epoxy seal making it vacuum compatible. The seal additionally elongates heater life, especially in high humidity and moisture environments.

What electrical tests are performed on heaters?

Heaters undergo 3 main electrical tests: Resistance, MegOhm and Hipot.

A resistance test is performed using a fluke meter to ensure that the heater is manufactured within the correct tolerances of the electrical specifications. Heater leads are connected directly to the fluke meter leads to perform the test.

A MegOhm or Insulation Resistance test is performed using a megohmmeter. As its name implies it tests for any breakdown in a heater’s insulating material. The test is performed by supplying low to medium voltage to the insulating material for a small period of time.

A Hipot test is also used to assess the dielectric strength of the heater’s insulating material. In addition to performing a Dielectric Withstand Test like the Megohm, it can also perform a Dielectric Breakdown Test. This means that the heater insulating material is shocked at very high voltages until failure is achieved. This is more commonly performed on samples as it destroys the heater.

What is a thermocouple?

A thermocouple is a thermoelectric device that measures temperature. When the wire junction of its two dissimilar metals changes in temperature, a small voltage is created. The voltage is then used to calculate the temperature using the thermocouple’s reference table.

What is an RTD?

RTD stands for "resistance temperature detector". It is generally constructed of a fine and pure metallic wire wound around a ceramic or glass core. The relationship between wire resistance and temperature is used to sense the temperature of other devices.