What impact does oven with rust have on production? How can rust be prevented? Which type of oven should be selected for the production process?

Industrial ovens made of metal may rust if wrong materials are chosen due to volatile substances or temperature variations during production. 
Tips for selecting right materials and preventing rust :

1. Rust can lead to dust accumulation inside drying equipment. If a dust-free environment is essential, rust issues must be addressed.

2. Industrial drying equipment are typically made of stainless steel like SUS430, SUS304, or SUS316. The higher the chromium and nickel content, the less prone they are to rust, albeit at a higher cost.

3. In the product baking process or the production environment, whether there are volatile gases or solvents (acids, alkaline substances), it is important to proactively inform the manufacturer. The manufacturer will then choose the appropriate material based on metal characteristics, ensuring a reasonable balance between cost and functionality.
4. Due to differences in product baking temperatures and considering purchase costs, the choice of oven material is also a selection factor.

For low-temperature industrial ovens (below 200°C), suggest to select stainless steel with 'lower' chromium and nickel content. High-temperature industrial ovens (200°C~500°C) require stainless steel with 'higher' chromium and nickel content. Products emitting acidic or alkaline substances recommend to use SUS316 or higher-grade stainless steel."

 
How is the internal size typically chosen for an industrial drying oven to achieve the best even heating effect?

The interior dimensions of an industrial drying oven should take into consideration the following factors to ensure both high-quality production and be user-friendly:

1. Considering if the chamber provides sufficient space for easy loading and unloading of products.
2. Considering if there is a buffering area within the chamber to facilitate proper air circulation without being obstructed by the products, ensuring smooth airflow.

In response to these considerations, "weisun," with years of experience in manufacturing drying equipment, designs industrial ovens with a buffering zone of 7-10 centimeters in order to achieve optimal even temperature distribution and usability.

 
What are the common malfunctions encountered in industrial ovens? How can they be easily inspected and resolved?


A. Power Supply Issues
(1) When experiencing power problems, first check the specifications of the power supply using a multimeter.
(2) Inspect the fuses in the machine.
(3) Check if the main power switch is malfunctioning.

B. Abnormal Heating and Temperature Increase
(1) If temperature operation issues arise, first check if there are any errors in the temperature controller settings.
(2) In case of abnormal over-temperature, verify if the over-temperature protector (O.T.P) settings are correct or if there are errors in the temperature controller settings.
(3) Inspect if the electromagnetic contactor (MC) has poor contact.
(4) Check if the electric heater is faulty (measure resistance with a multimeter to confirm correctness).
(5) Examine if the Solid-State Relay (SSR) is faulty.
(6) Inspect whether the fuses are blown.
(7) Assess if the ventilation in the installation area is inadequate.

C. Fan Malfunction and Maintenance
(1) Check if the electromagnetic switch (MS) has tripped.
(2) Inspect if the motor (M) is malfunctioning.
(3) Verify if the fan blades are loose or detached.


 
What are the precautions to be taken when using an industrial oven for the first time?

Here are the precautions to be taken when using an industrial oven for the first time:

1. When initially connecting the power supply or re-connecting the machine after moving it, follow the electrical specifications indicated on the oven's nameplate. Ensure proper grounding to prevent electrical leakage accidents.

2. Industrial ovens are designed for specific industrial baking purposes as specified during customization. Do not use them for any other unspecified purposes.

3. Industrial ovens are general-purpose high-temperature heating equipment. Do not use them to bake flammable or explosive materials.

4. Do not place any items above the industrial oven, and do not obstruct the oven's ventilation openings.

5. Keep items away from exhaust vents, valves, safety pressure relief valves, etc., to prevent blocking the ventilation space, which could pose a danger.

6. Environmental requirements:
   (1) Install the oven in a flat environment to ensure stable operation.
   (2) Ensure good ventilation and minimal dust accumulation. It is recommended to keep a distance of at least 10cm from the wall for heat dissipation.
   (3) Do not place the oven in a damp area, as high humidity in the surroundings during oven operation can lead to temperature differences.
   (4) Do not expose it to flammable or corrosive gases (excluding special ovens).
   (5) Keep it away from combustible materials.
   (6) Maintain an environmental temperature within the range of room temperature to 30°C.

7. When turning on the power switch, confirm that the direction of the fan motor matches the direction indicated by the arrow on it to ensure proper circulation. If the rotation direction is incorrect, change the power phase sequence promptly.

8. Non-technical personnel should not alter the temperature controller or timer parameters.

9. If the industrial oven is equipped with a baking timer, first set the desired baking time and then turn on the timer switch. Do not adjust the time after turning on the timer switch, as this can lead to timing errors.

10. During high-temperature operation or when the internal temperature of the oven has not cooled down to a safe range, do not open the oven door to retrieve baked goods. This can prevent injury from hot gas or direct contact with hot items. If you need to work in high-temperature conditions, wear protective gear to prevent burns.
 
What are classifications of temperature control in industrial ovens? How do you choose an appropriate one?

Temperature control and achieving uniformity in ovens are ongoing technological challenges for manufacturers and often result in significant cost differences. Here are the different temperature control methods based on the temperature control mode:

1. Traditional ON/OFF Relay-Based Temperature Control:
Principle: The heating circuit is controlled using electromagnetic relays, which detect whether the temperature has reached the setpoint and determine when to turn the electromagnetic relay on or off.
Operation: If the set temperature has not been reached, the electromagnetic relay remains in the ON state until the "set temperature" is equal to or greater than the "detected feedback temperature." When the temperature reaches the setpoint, a signal is sent to turn off the relay, and heating stops.
Application: This temperature control method is less accurate but relatively cost-effective. Due to the precision requirements of temperature control, it is rarely used in industrial ovens today.

2. PID + SSR Temperature Control:
Operation: When the set temperature has not been reached, the heating signal from the temperature controller continues to output the PID algorithm until the "set temperature" is equal to or greater than the "detected feedback temperature." When this happens, the temperature control signal stops outputting, and the electric heater stops heating.
Principle: The temperature controller outputs a voltage signal (DC 0V~12V) and uses a Solid-State Relay (SSR) as a pulse control device. The temperature controller's PID algorithm output, combined with the SSR, allows for stable temperature control.
Application: This temperature control method is accurate and cost-effective, making it the prevailing temperature control method in industrial ovens today.

3. PID + SCR Temperature Control:
Principle: The temperature controller outputs a current signal (DC 4~20mA) and uses a Silicon-Controlled Rectifier (SCR) as a phase control device. The temperature controller applies PID control to achieve precise output control of the heater. It effectively controls temperature accuracy requirements by modulating the phase output.
Application: SCR temperature control offers higher accuracy than SSR-based control but comes at a slightly higher cost. It is currently the best choice for precise temperature control.
 
What are safety features of industrial ovens, and how should users choose them?

 Industrial ovens has a heating system. During a temperature rising process, it has a larger load capacity. Therefore, it is essential to ensure safety protection for both furnace temperature control and control circuits. However, please consider your specific usage requirements. Here are some safety features and considerations:

1. Over-Temperature Protection: 
This protection is triggered when there is an abnormal temperature condition. Temperature control elements have a limited lifespan, and if a temperature control abnormality occurs, the temperature detection signal will immediately provide feedback. The oven circuit will activate an abnormal alarm (audible alert), and the heater will be disconnected.

Note: "Weisun" industrial drying ovens have multiple sets of over-temperature detection signals to reliably prevent high-temperature fires in case one set of protection fails.

2. Reverse Prevention Device: 
When a drying oven is in operation and the power system is three-phase (R, S, T), it is crucial to confirm the "direction of rotation" for proper airflow circulation. Incorrect rotation direction can disrupt the heat source circulation, often caused by differences in the power supply system. To prevent this, install a reverse prevention device during equipment setup. The control system can immediately detect whether the direction is correct, and if there is an error, simply change the "power phase sequence."

3. Air Pressure Detection: 
During the operation of the oven, external factors or sudden environmental changes may lead to poor airflow circulation. To address this, you can install an "air pressure detection device" in the airflow circulation system. When a signal is triggered, it activates an alarm (audible alert) and ensures equipment safety.

4. Safety Door Switch:
 When the oven operates at high temperatures, it may be necessary to prevent unauthorized opening of the furnace door to prevent harm from sudden temperature changes and product damage due to improper operation. You can install an electronic lock and sensing device on the oven door, providing a control mechanism for management, enhancing equipment safety and reliability.

5. Over-Current (Load) Protection:
Over time, various factors such as component lifespan and power supply issues may lead to abnormal conditions in the oven. During the design phase, safety measures for "over-current" and "over-load" are considered. Protection features may include circuit breakers, control circuit fuses, electric heater over-current protectors, motor over-current protection, and more. Whenever an abnormal load occurs, the circuit will disconnect to ensure equipment safety.
  
How is an industrial oven composed, and how should accessories and functions be selected?

Different drying ovens designed for various functions or purposes have distinct constructions, so it is essential to pay special attention to avoid purchasing an unsuitable product. 
Here are the components and features to consider when selecting an industrial oven:

1. Structural Hardware:
   (1) Oven Structure: Depending on the usage environment, the outer casing of the oven can be made using methods such as powder coating or stainless steel 
        (SUS material).
   (2) Circulation Structure: The way air circulates within the oven can be categorized as "horizontal" or "vertical," depending on the airflow path.
   (3) Optional Structures: Depending on the production requirements, various design modules are available, including dust-free filtration modules, oxygen-free gas
         pipelines, vacuum pump pipelines, and more.

2. Heating System:
   (1) Insulation Structure: The thickness and material of the insulation layer are designed based on the operating temperature.
   (2) Electric Heating Specifications: Depending on the characteristics of the customer's products, heating elements can include bare wire heaters, stainless steel
        heating tubes, infrared lamps (with   selectable wavelength), overheated steam, hot oil, and more.

3. Cooling System:
    Cooling systems are designed based on the cooling efficiency required for the production material and may include modules like manually adjustable air dampers,
    automatic air dampers, forced intake and exhaust, water-cooled heat exchange systems, and more.

4. Control System and Safety Protections:
   (1) Control Solutions: Control options may include traditional control circuits, programmable software control, human-machine interfaces (HMI), multi-stage
        temperature control, oxygen concentration detection, CIM (Computer Integrated Manufacturing), Ethernet, SECS/GEM communication protocols, and more.
   (2) Safety Features: Safety measures include power overload protectors, control circuit safety devices, over-temperature protectors, electric heater over-current
        protectors, motor over-current protection, abnormal alarms, reverse prevention devices, safety door switches,etc.
 
What are classifications of industrial ovens? How should users choose the right one?

An oven is a generic term that can be selected based on various specifications depending on the different production processes and functions. 
Here are the specifications users can choose from:

1. Temperature:
   (1) Low-Temperature Oven: Below 200°C.
   (2) High-Temperature Oven: 200°C to 500°C.
   (3) Specialized Oven: Above 500°C.

2. Pressure:
   (1) Pressurized Oven: Used within a sealed chamber with inert gas for baking.
   (2) Atmospheric Oven: Used within a sealed chamber with hot air circulation for baking.
   (3) Negative Pressure (Vacuum) Oven: Used within a sealed chamber with a vacuum pump to remove gases for baking.

3. Usage and Control Methods :
   (1) Batch Oven (Batch): This includes traditional precision ovens, cart-type ovens, dust-free ovens, oxygen-free ovens, and environmental aging test furnaces,
        among others.
   (2) Programmable Semi-Automated Oven :
        This category includes tunnel-type conveyor ovens, ovens with automatic door opening/closing mechanisms (compatible with AGV / RGV / MGV),
        and multi-process recipe-controlled ovens, among others.
   (3) Fully Automated Oven: These ovens can be integrated with AGV (Automated Guided Vehicle), EFEM (Equipment Front End Module), Robot, Loader, or
        Unloader systems. Depending on the production materials 
       and capacity requirements, they can upload process data to the control system, achieving the goal of a fully automated, unmanned factory.

4. Size:
   The size of an oven is defined by the internal chamber space, and it distinguishes oven sizes. Small ovens are designed for small-scale production and verification
   needs. The specifications and size are  not strictly defined, but "Weisun" standard models have a minimum size of W300xD300xH300 (mm).

 
Does the oven need regular maintenance and cleaning? What are the basic maintenance items?
When the oven is baking, it is inevitable that there will be volatile solvent residues in the oven. If you want to increase the service life, regular maintenance and cleaning must be done, and it can prevent accidents.
Swipe right or left for more information
  Check item Check method Check interval Identification method
1 Exterior * Visual inspection
* sound check		 Daily *The appearance is abnormally dirty, immediately maintain and clean
*Is there any sound other than normal operation?
2 power line * Visual inspection Weekly * Whether the line sheath is damaged
* Whether the joints of each part are loose.
3 Pneumatic line ※Visual inspection
※sound check		 Weekly ※Check the pressure gauge to see if the pressure is sufficient.
※Confirm whether there is a sound of gas leakage.
4 Bolts and nuts of various parts ※Check if the screws are loose Monthly ※The screws of each part should not be loosened, if found to be loose, they should be fastened immediately.
5 Emergency stop switch ※pressure test Monthly ※Pressure test the emergency stop switch to test whether the machine can stop immediately.
6 Over temperature protector ※Over temperature test
※Manual test		 Quarterly ※Make sure that the over-temperature protector has a set temperature lower than the actual operating temperature.
※ Check whether the protector works correctly, and check the content of the error message.
7 No fuse switch * Overload test Quarterly *Press the test button to confirm whether the overload has tripped.
8 Signal switch (Sensor) * Manual test Quarterly * Test whether the signal feedback is correct.
9 Intake and exhaust pipes * Visual inspection
* wipe clean		 Quarterly * Dust or solvent residue removal.
* Replace damaged tubing.
10 Filter (HEPA) * Check pressure gauge changes
* Internal particle detection
* Visual inspection		 Quarterly *If the pressure value exceeds or is higher, it needs to be replaced HEPA
* If it is detected that the Particle exceeds the limit, it is necessary to clean the furnace body or replace the HEPA.
*Use a visual inspection for damage.
11 Windmill motor * Visual inspection
* Sound check		 Quarterly *Is there any abnormal sound
* Whether the motor vibrates too much.
12 Furnace door tight * Visual inspection Quarterly Whether there is any exposure when the air supply of the machine is running.
Whether there is any damage or other loss.

Safety instructions

  • During maintenance, the main power supply must be cut off to avoid unnecessary damage to machine parts and the danger of electric shock to personnel.
  • Do not operate at high temperature, or perform cleaning inspection if the temperature in the furnace is not lowered to a safe range, to prevent burns and industrial safety.
How does the oven air circuit circulate? What is the direction of the wind? How to choose a suitable oven?

The principle of the box is to pass the cold air through the heater, and then circulate the heat energy through the wind, so that the temperature can be transferred to the product to meet the needs of the drying process, as shown in the figure below.

Choosing a suitable oven will deeply affect the quality and production capacity of production. The following items must be considered:

  • Assessing the "horizontal" or "vertical" air supply direction of the oven has a lot to do with the way the production materials are placed, because it will affect whether the air flow is smooth or not.
  • When the size of the product is too large, or a single furnace body needs to produce a large number of objects, and a large oven is required for production; the air flow from both sides can effectively control the temperature and improve the production quality.
    The following illustration briefly explains the selection of oven airflow and product matching. "WEISUN" has a design team with many years of experience, which can tailor-made planning for customers and meet the requirements of high-quality production of oven equipment.
Industrial ovens experience a wide range of temperature variations. What insulation materials can be used? How should they be chosen?
In response to product requirements, industrial ovens can provide a wide range of temperature usage. To prevent accidental burns, effective insulation is a crucial consideration.
The choice of insulation materials should be based on the temperature range at which the oven will be used. Selecting appropriate materials not only improves energy efficiency (better insulation) but also enhances safety. Of course, cost and functionality should also be reasonably balanced.

Based on temperature, insulation materials for oven applications can be categorized as follows :
Swipe right or left for more information
Types of insulation Characteristics cost Application scenarios remark
PU foam 1. Corrosion resistance.
2. High density with excellent insulation, soundproofing,
   and fire resistance.
3. Long service life.		 low 1. Cooling equipment for refrigerated and frozen storage rooms.
2. Suitable for industrial constant temperature and humidity
    chambers below 100°C.		  
Fiberglass insulation 1. Soft texture with strong resilience.
2. Easy to cut, convenient for construction.
3. Possesses insulation, soundproofing,
    and fire-resistant properties.		 medium 1. Temperature-resistant up to approximately 300°C.
2. Often used for insulation in ovens with temperatures
    below 200°C.		 Due to the construction process, fiberglass is prone to adhere to the skin, causing itching.
"Weisun" does not use it and opts for rockwool instead.
Rockwool 1. High density, minimal deformation.
2. Soft and highly elastic fibers.
3. Easy to cut, convenient for construction.
4. Possesses insulation, soundproofing,
    and fire-resistant properties.		 medium 1. Temperature-resistant up to approximately 590°C.
2. Frequently used for insulation in ovens
    with temperatures below 500°C.		  
Ceramic fiber 1. High corrosion resistance.
2. Excellent high-temperature stability.
3. Strong resistance to thermal shock.
4. Exhibits compression rebound and suitable
    for high-temperature sealing materials.
5. High-temperature resistance and lightweight insulation material.		 high 1. Temperature-resistant up to approximately 1,260°C.
2. Frequently used for insulation in ovens
    with temperatures above 500°C.