ATE Applicazioni Termo Elettroniche S.r.l.

Via Soastene, 4, 36040 Brendola (VI)
Italy
Telephone +39 0444 601455
Fax +39 0444 406434
sales@ate.it

Hall map

wire 2018 hall map (Hall 11): stand C77

Fairground map

wire 2018 fairground map: Hall 11

Contact

Massimo Borella

Sales Dept.

Phone
+39 335 752 9965

Email
m.borella@ate.it

Our range of products

Product categories

  • 01  Wire manufacturing and finishing machinery
  • 01.04  Surface and heat treatment
  • 01.04.01  Drying and baking ovens

Drying and baking ovens

  • 01  Wire manufacturing and finishing machinery
  • 01.04  Surface and heat treatment
  • 01.04.02  Annealing without inert gas (furnaces)

Annealing without inert gas (furnaces)

  • 01  Wire manufacturing and finishing machinery
  • 01.04  Surface and heat treatment
  • 01.04.03  Annealing with inert gas (furnaces)

Annealing with inert gas (furnaces)

  • 01  Wire manufacturing and finishing machinery
  • 01.04  Surface and heat treatment
  • 01.04.05  Induction annealing
  • 01  Wire manufacturing and finishing machinery
  • 01.04  Surface and heat treatment
  • 01.04.09  Hardening, tempering

Hardening, tempering

  • 01  Wire manufacturing and finishing machinery
  • 01.04  Surface and heat treatment
  • 01.04.13  Preheater
  • 01  Wire manufacturing and finishing machinery
  • 01.05  Wire cleaning, machining, forming and coating
  • 01.05.02  Coating
  • 01  Wire manufacturing and finishing machinery
  • 01.07  Fastener machinery (bolts, nuts, rivets, nails)
  • 01.07.11  Heat treatment

Our products

Product category: Preheater

Frequency Converter series PFC

The PFC series of converters is generally used in applications which require medium-high powers (from about one hundred kW up to 2000 kW and beyond) and frequencies up to about 10 kHz. These converters have been used in lines for the continuous heating of wire, bars, billets, pipes, etc., in systems for press-welding and braze-welding, and in high-capacity melting furnaces, etc. The reliability of these converters in operation is witnessed by more than 25000 kW installed in Italy and abroad.

THE POWER CIRCUIT : There are three sections in the circuit which converts the power from the mains frequency (50/60 Hz) to medium frequency (0.5÷10 kHz):
- SCR AC/DC converter
- DC Filter
- SCR medium frequency inverter

The AC/DC converter, for powers up to about 600 KW, consists of a fully-controlled unidirectional 6-pulse three-phase bridge directly supplied from the 3-phase mains with or without a supply transformer.
For higher powers, the AC/DC converter uses a dodecaphase conversion circuit consisting of the parallel of two three-phase bridges with insertion angles staggered by 30°, obtained from powering by a HV/LV transformer with double secondary winding, one star and the other delta.
The DC filter section is generally made up of a smoothing reactance which both filters the waveform from the converter and carries out the necessary decoupling with the MF inverter.
In higher powers, this section can include an L-C-L filter in which the presence of a capacitor allows the rating power of the inductance to be reduced.
The MF inverter is therefore of the impressed current type, in a configuration with a single-phase bridge with parallel resonant circuit and relative starting circuits.
The power semiconductors used are SCRs with very low turn-off, in disks version with water cooling, for the maximum exploitation of the performances of the components.


THE CONTROL ELECTRONICS: The control and regulation card of the AC/DC converter uses two feedback loops, a current one and a voltage one, with DC current integration and limitation circuit for protecting the unit itself and the M.F. inverter it supplies. The voltage/power settings and the acquisition of the service/alarm statuses are made by an RS485 serial line connected to a data display and setting unit on the control panel. The output power can be adjusted continuously from 5 to 100% of the rated value with the possibility of operation at higher powers (up to 120% with respect to the rating) for the time and intermittence permitted by the integral current protection device. The M.F. inverter is controlled by a regulation and control system with optimised management of the SCR firing pulses when starting, followed by hooking to the resonant frequency by means of a PLL circuit with automatic adjustmment to the impedance variations and the Q-factor of the load.

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Product category: Hardening, tempering, Heat treatment

Frequency Converter series IFC/S

These represent the latest generation of IGBT high-frequency converters, the result of ATE's research work and know-how, and are destined to constitute the technical benchmark solution for now and for years to come in the world of induction heating. The high output power (up to 800 kW) and the very broad range of working frequencies (from 10 to 150 kHz) mean that they can be used in the most varied applications (heat treatments of non-magnetic pieces, heating wires and bands with very small sections, both ferrous and non-ferrous, continuous annealing and welding of tubes, precious castings in insulating crucibles, etc

THE POWER CIRCUIT: The power conversion circuit from the mains frequency (50-60 Hz) to high frequency (10-150 kHz) comprises three sections:
. AC/DC converter
. DC filter
. High-frequency IGBT inverter
. The AC/DC converter, for powers up to about 500 kW, is composed of a one-way 3-phase total-control 6-impulse bridge with direct power from the 3-phase mains with or without the interposition of a supply transformer. For higher powers, a twelve-phase AC/DC conversion circuit is used; it consists of the parallel of two three-phase bridges with insertion angles staggered by 30°, obtained with power from a MV/LV transformer, double secondary winding, one star, the other delta. A leveling inductance is used in the direct current filter section; this both filters the voltage split by the AC/DC converter and also carries out the required decoupling with the H.F. inverter. The high-frequency inverter is of the impressed current type with parallel resonant circuit and consists of several modular units with 75 kW basic power. Each unit comprises a single-phase IGBT H-bridge and incorporates the board with the piloting drivers. The circuit includes a protection crowbar with the coordinated intervention of the control electronics in order to safeguard the inverter in the case of accidental failures (load short circuits, interruptions of discharges to the ground).


THE CONTROL ELECTRONICS: The control and regulation board of the AC/DC converter uses two feedback current and voltage loops, with DC current integration and a limitation circuit for the protection of the unit itself and of the H.F. inverter powered by it. The setting of the voltage power settings and the acquisition of the service/alarm statuses takes place by means of an RS485 serial line connected to a display and data setting unit located on the control panel. The output power can be adjusted with continuity from 5 to 100% of the rated value. The H.F. inverter is controlled by a control system set up for a configuration of up to 12 conversion modules. It manages the correct piloting of the IGBT, guaranteeing low loss switching (the soft-switching technique) at the resonance frequency of the load. This result is obtained by means of an appropriate digital algorithm which couples the inverter's operating frequency with that of resonance of the load, adapting itself to its variations.

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Product category: Heat treatment, Annealing without inert gas (furnaces), Annealing with inert gas (furnaces), Induction annealing, Preheater, Coating

MULTIWIRES INDUCTION SYSTEM FOR HEATING TREATMENT

ATE has recently developed two induction heating systems for treating wires in parallel, with the names IMW (independent control wire) and CMW (common control wire).
Through the use of the most advanced technologies in the field of power electronics, these systems represent a sophisticated and efficient solution for the simultaneous heating of multiple wires with the same or even with different diameters.
The main characteristics of the two systems are:
- for the IMW system the possibility of heating multiple wires of different diameter separately, wire by wire, with the same or different temperatures and speeds (upon request)
- for the CMW system the possibility of heating wires of the same diameter to the same temperature or wires of slightly different diameter to almost the same temperature, taking account of a suitable “Velocity x Diameter” relation (DV).

Compared to other types of furnaces, such as resistance, gas, fluid bed or lead bath heaters, the IMW and CMW multi-wire induction heating systems have the following advantages:
- no environmental pollution
- more compact
- higher efficiency
- closed loop process control (optional)

Besides wires, the aforesaid systems are also able to treat metal strips or bands. In these cases the systems are identified with the codes IMS or CMS, instead of IMW or CMW.
In addition to ferrous materials, the systems can also heat aluminium, copper, brass, etc. with efficiency values proportional to the type of material.

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

The IMW and CMW multi-wire induction heating systems can be used in various industrial processes, some of which are listed below:
- annealing (max temperature of around 720°c)
- stress relieving (max temperature of around 400°c)
- diffusion/brass coating of wires for steel cord (max temperature 550-600°c)
- preheating for galvanizing (around 500°c)
- preheating for painting or coating (max 200-250°c)
- preheating before of an existing gas furnaces in the case of increased productivity of the system

The IMW/IMS and CMW/CMS systems are completely modular and can heat a variable number of wires.
The configuration can be defined according to the Customer’s needs.
Given the flexibility of the system, any unit can be custom-designed to meet the application requirements.

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About us

Company details

ATE, Applicazioni Termo Elettroniche designs and manufactures induction heating equipment including process automation, control and supervisory systems. The company was founded in 1987, backed by several skilled experiences in power electronics, static energy conversion and electric heating applied to different industrial applications. Within EEI (Equipaggiamenti Elettronici Industriali) industrial group, ATE shares a common reachness of technical knowledge, designing methods and research activity.
Thanks to the experience and qualification of its technicians and designers, along with an extended collaboration with university departments, ATE's realizations are innovative, technically up-to-date, reliable and match the needs of today's market .
In 30 years of activity ATE can be summed up in a few data. The company has supplied and installed all over the world hundreds of induction heating systems with power units ranging from a few kW to 4000 kW, 60% of these have been delivered to a foreign country, either directly or indirectly through own qualified customers (Asia has the biggest concentration with over 40% followed by Europe with 30% and America with 15%). The company has always undertaken to assure, at any moment, the best quality and service to its customers, from the initial analysis of the project until the start-up of the equipment and for all the life of the plant.

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