UV LED curing system F-1295UV designed for curing varnish and paint in-stream production lines

High-pressure gas lamps have an average service life of 2,000 hours, but also have a continuous decrease in radiated energy in the effective wavelength range and a continuous increase in energy consumption and IR radiation. This requires constant maintenance of the curing machine and periodic power adjustments.

The LED UV curing system significantly reduces ozone and IR emissions, which in turn reduces energy consumption and final production costs.

27/7 workload; the average time to recuperate the money from the initial investment is 18 months. And in some cases this can be shortened to 12-14 months or even less!

The LED curing system’s average power consumption is around 10-20% that of traditional mercury lamps. Also, the service life of its LED modules is 10+ times longer.

The curing system can only work in selective mode when the power is increased in areas where capacitive sensors detect moving parts.

Does not require an additional air exhaust system.

UV LED Curing system, capacitive sensors  side view

Technical data

Technical data

Wavelength

 395nm (365-420nm) 

Radiated power ( range ​​5mm )

 not less than 10w/mm

Typical radiated power output

 8w/cm²

Power is guaranteed at 405nm wavelength
when measuring the warranty period of LED
modules 5mm away from the protective glass.

 6w/cm²

Operating power adjustment limits

 10..100%

A lifetime of led modules when maximum output is guaranteed
the energy is at least 75% of the initial power

 >10 000h

The service life of LED modules

 >15 000h

Power consumption at maximum output power mode and
constant 100% load with chiller switched ON

 10 250w

Power consumption in 300-350mJ output energy mode and
constant 100% load

 2800-4500w *

Typical power consumption when working in selective
mode when energy is transferred to the surface
300-350mJ:

 1100-3000w *

Selective curing when power is increased
only in areas where moving parts are detected.

 Yes

Adjustable working height above the
working surface (conveyor belt)

 20-100mm

Working distance to the surface of the part

 5-35mm

The warranty period for LED modules

 12 months

The warranty period for curing system

 24 months

 

* - Power varies depending on whether chilleris running during measurement and if the curing system is in selective mode and mowing parts are detected.

Machine construction

Machine construction

  • Strong structural aluminium frame
  • Lenze PLC controller with 7” touch-sensitive screen
  • Water-cooled LED modules
  • Copper LED heatsinks
  • The flexible locking structure of the LED emitters and capacitive sensors is resistant to mechanical impact and collision with moving objects (the entire production line can be stopped at the moment of collision).
  • Soft-Start of AC power supplies, no current spikes on system start-up.
  • Capacitive sensors for moving part detection. (Selective dryer option when the power is increased to the operating value only when there is a part detected under the LED emitter)
  • Magnetic conveyor rotation WatchDog sensor that shuts off the curing system if the conveyor belt stops under emergency mode *optional
  • Integrated power consumption accounting system *optional
  • Integrated coolant distribution manifold without any additional mechanical mounting or extra space requirements
  • One chiller chiller can cool up to three LED curing systems at once.
  • Motorized UP / DOWN function *optional
  • Curing system can be ordered together with conveyor

*optional - Functionality is not included in the standard curing system set

 

Usages

Possibilities of use

Usually, high-pressure mercury lamps with a typical power consumption of 80-240w/cm2 are used in the production lines to activate the polymerization process of UV coatings. For a typical 1.3-meter wide production line, the energy consumed in one curing system of 20-30KW is read as the nominal power consumption.

The LED UV curing machines significantly reduce production costs and are increasingly used in the following industries and as well as many others:

 

Furniture, wood and other industries

 - Wood coatings
 - Metal surface protective coatings
 - Glass and ceramic adhesives, coatings, markings, and topcoats
 - Plastic marking and paint coatings
 - 3D Printing

 

Printing

 - Offset and dry offset printing
 - Silkscreen printing
 - Flexographic printing
 - Tampon/pad printing
 - UV inkjet printing
 - Letter press printing

 

Packaging and marking

 - Printing of stickers and labels
 - Mandrel printing
 - Injection marking of packages
 - CD / DVD production
 - Tampon/pad printing

 

Electronics industry

- Printed circuit board production
- Film exposure (microfilms, Diazo films, heliography)
- Drying of protective coatings
- Wafer exposure

 

FAQ

FAQ

 

The wavelength range of the LED dryer

LED emitters working wavelength in nanometers is selected according to the coatings used by the customer and can be in the range of 365-425nm. 395nm LED modules are most commonly used.

Due to the wavelength limitation and the width of the radiated spectrum, the LED UV curing machine can only replace mercury (HG) gas lamps, but cannot replace Gallium (GA) gas lamps.

 

Will power Xw/cm2 be guaranteed

Output power per surface area is not the common parameter for UV LED curing systems. In order for the coating to polymerize, an appropriate amount of energy must be transferred to the surface.

The LED modules used in our UV dryers emit up to 25w/cm2 of UV power measured at a distance of 5mm from the glass surface, as well as the modules are equipped with special optics that focus the beam and reduce reflections, improve penetration, reduce losses.

Paint adhesives and varnishes have their own polymerization barrier so if the UV output energy is below the required limit, the reaction does not start at all. By increasing the UV energy to the critical limit required for the coating, a chain reaction begins and the coating polymerizes.

Optimal results are obtained when a UV stream sufficient to initiate polymerization is transmitted over a longer time interval than an X times higher pulse in a short period of time.

For the reasons listed for LED curing machines, the direct definition of w /cm2 is not entirely correct as it has been applied to gas lamps with a different radiated spectral composition.

 

How to achieve optimal results using LED UV curing system

First, set the working distance of 10mm. from the emitter metal construction to the curing part surface.

Set output power to ​​about 6-10w/cm2, which is about 5-15 times higher than the minimum amount of UV energy required to start the polymerization process of the coating.

During the periodic measurement of the radiated power, the distance between the part surface and LED emitter gradually increased to the maximum distance until the total measured energy content still exceeds the coating manufacturer's recommended value 20-50%.

This is done in order to prolong the irradiation time because as the distance increases, so does the area of ​​the beam on the surface. Increasing the distance also solves the problem when the working gap to the part is very small (eg 5mm) and very precise adjustment of the height of the conveyors is required so that the parts do not jump under the curing system.

E.g. In the Visagino linija, LEDs transmit 300-330mj of UV energy to the surface when operating in 45% mode from the maximum available power. When the working distance is fixed at around 15-20mm, the power area could be about 2-3w/cm2, which is considered to be the optimal mode in this case. These parameters may vary depending on the type of coating, conveyor speed, and recommendations of the coating manufacturer.

 

Why does the UV LED curing machine not turn off completely when there are no moving parts under LED emitters

It takes about 2 seconds to turn on the selective LED curing system in full power output mode, which we don't have because the distance from the capacitive sensors to the LED bar is 35cm. and the conveyor speed can reach 30m/min.

The LED continuous output power in standby mode around 5% because the modules are sensitive to sudden thermal changes ( to reduce thermal shock) because the LED crystal loses its output power when heated and cooled too quickly.

Also, when the LED keep on at low power, you can see that the dryer is working, and the third argument is that no moisture condenses because the water in the chiller is constantly maintained at about 8C and under certain conditions, a dew point is formed so about 4-5% operating mode is always left on.

* Curing system beam length and width, wavelength, radiated energy, working height range and other parameters can be customized to customer requirements.