Tenko

Autodesk Fusion 360

Injection molding

Welding, including in an inert gas environment

Pipe bending

Filling pipes with quartz sand

Brass casting and turning

Pad printing

The device must be designed for different power consumption levels, which, of course, affects the length of the electric heater and the volume of coolant that the device can effectively heat.

The tubes of the electric heater must be made of stainless steel or copper. Taking into account the characteristics of the materials, various welding processes are used.

The ready solution is a simple, inexpensive device for heating coolant in common locations, such as radiators (cast iron, aluminum), various tanks without direct heating, or in closed heating systems.

The ready solution has two main components: an electric heater and a thermostat (the project uses a rod thermostat), which sets the temperature limits for the electric heater. The housing is connected to the electric heater flange with a screw, and then the thermostat is installed. The cover has a transparent insert, which is a decorative element, and an LED is also attached to the cover, which lights up when the device is turned on. The handle with the shaft transmits torque to the thermostat to set the required temperature. The power cable has a cable entry that is installed between the housing and the cover.

Electric heater type: straight, tapered-straight;

Tube material: stainless steel, copper;

Flange material: brass.

Stainless steel tubes are welded to the flange using inert gas welding, while copper tubes are soldered using a special solder. Stainless steel terminals are also welded to the electrodes. An empty tube with a flattened end is required for the temperature sensor; in this project, the temperature sensor is a rod type.

Material: ABS/PC;

Color: white;

Surface: glossy.

The housing assembly comprises elements such as an electric heater, which is installed and secured to the housing itself with a screw, and a thermostat, which completes the assembly and also serves as a rigid connection element. Therefore, when replacing the thermostat or electric heater, the rigidity of the connection must be taken into account, and special tools must be used for disassembly and reassembly. The thermostat operates within a range of 25-75 degrees Celsius; therefore, ABS/PC is used as the main material for the housing.

The cover consists of two parts: the cover itself and a transparent insert. An LED indicator is also attached to the cover. The cover has special snaps that attach it to the housing and a special socket into which the LED is installed. The top of the cover has a special cavity for installing a decorative transparent insert.

The system for transferring torque from the hand to the thermostat consists of a handle and a shaft. There is a special hole in the cover for inserting the handle. The shaft has a special grooved surface on top, which helps to create a “rigid” connection between the shaft and the handle. A special slot on the shaft and a rib in the handle help to install them correctly on the thermostat and prevent the shaft from rotating in the handle.

Special openings with fixed dimensions are provided in the housing and cover to prevent the cable from twisting and jerking as it enters the opening.