The design objective of creating a more compact and powerful electromagnetic overband magnet led the Bunting engineering team to develop the ElectroMax-Plus. The ElectroMax-Plus extends Bunting’s comprehensive range of overband and suspension magnets. In addition to standard sizes, Bunting also designs and manufactures bespoke models which are application-specific.
Electromagnetic overband magnets use an oil-cooled or air-cooled wire coil to generate a deep and strong magnetic field. The electromagnetic force radiates from a coil wound around a steel core and mounted inside a steel box with a thick steel back-bar.
This focuses the magnetic field in one direction: down towards the conveyed material. In operation, an overband magnet, suspended over conveyors, screens and vibratory feeders, lifts and removes ferrous metals such as iron rebar and beverage steel cans.
Overband magnets are a common feature on many mobile screens and crushers. In such applications, minimising weight and size is crucial and, subsequently, operators use standard ceramic ferrite or, less frequently, neodymium rare earth permanent overband magnets rather than electromagnets.
Neodymium permanent overband magnets produce a strong but shallow magnetic force and often experience problems with belt and motor damage due to large ferrous metal clamping against the magnet block. The magnetic field of the light and compact ElectroMax-Plus is both deep and strong, enabling excellent separation performance at higher suspension heights.
In addition, simply turning off the electromagnet releases any extremely large, entrapped tramp ferrous metal. The shape and nature of this magnetic field means there is less wear to the self-cleaning belt mechanism (for example, belt, motor gearbox and bearings).
Standing out
The ElectroMax-Plus stands out from its predecessors and competitors with its exceptional magnetic strength. At a suspension height of 500 mm, it boasts an impressive 105% stronger force index compared to the standard ElectroMax model. This remarkable increase in power translates into superior ferrous metal separation, even in challenging conditions. The incredible additional magnetic force removes small tramp ferrous metal commonly missed by permanent overband magnets.
The ElectroMax-Plus comes with several innovative features. Unlike traditional electro overband magnets, it utilises an air-cooled system instead of oil. This innovative approach significantly reduces the unit’s weight and size, while maintaining optimal performance.
The ElectroMax-Plus can operate at a suspension height of up to 600 mm, a substantial improvement over the 450 mm limit of standard models. This extended reach allows for more flexible installation options and improved separation efficiency.
Despite its enhanced power, the ElectroMax-Plus is 25% lighter than equivalent permanent overband magnets. This weight reduction is crucial for mobile crushing and screening equipment, where every kilogram matters.
Another major benefit is its versatility. The ElectroMax-Plus is designed to excel in various quarrying applications, including protecting crushers and screens from damaging tramp metal, removing ferrous contaminants from conveyed materials and enhancing product purity in aggregate production.
Its powerful magnetic field is capable of capturing a wide range of ferrous debris, from large steel plates to small wire fragments, ensuring comprehensive protection for downstream equipment.
Industry impact
The introduction of the ElectroMax-Plus addresses a critical need in the quarrying sector for more powerful yet compact magnetic separation solutions. Its ability to combine increased magnetic strength with reduced weight makes it an ideal choice for both stationary and mobile quarrying operations.
Alison Flower, General Manager of Bunting’s Redditch operation in the United Kingdom, emphasises the significance of this innovation: “The new ElectroMax-Plus provides a real alternative to neodymium rare earth overband magnets. There is the requested additional magnetic strength, without the operating problems – as experienced with some neodymium rare earth overband magnets.”
As quarries across Africa seek to optimise their operations and improve product quality, the ElectroMax-Plus overband magnet emerges as a game-changing solution. “Its blend of power, efficiency and versatility positions it as a top contender in the magnetic separation market, promising to elevate the standards of ferrous metal removal in the quarrying industry,” concludes Coleman.
