Modification of Cimdor 15 Kilowatt Microwave System

Initial Problem

The original Cimdor system was configured with five 3-kilowatt microwave generators, each powering an individual heating zone. This setup handled most rubber profiles adequately. However, after securing a new customer with larger rubber profiles, the system had to operate at maximum power output and minimum conveyor speeds (2–3 ft/min) just to meet curing requirements.

While this setup produced acceptable results, it was not operationally profitable and placed excessive strain on the system, leading to reliability concerns and potential premature failure from running flat out.

Objective

Increase overall microwave power capacity to handle larger rubber profiles.
Reduce system strain by distributing workload across higher-output generators.
Improve line speed and production throughput to meet profitability requirements.
Maintain centralized operator control.

MES Solution

Engineered and installed two free-standing 6 kW microwave generators, increasing total system power from 15 kW to 27 kW.
Split the waveguide output of each new generator into two outputs, each delivering 3 kW of energy, routed to two heating zones.
Modified original heating configuration:
The original five zones were heated via top-mounted waveguide resonators.
The new waveguide feeds were installed below the conveyor, so that four of the five zones now receive up to 6 kW of energy (3 kW from above and 3 kW from below).
The remaining zone retained the original 3 kW top-fed configuration.
Fabricated a new compact control cabinet for the two added generators.
Mounted the new cabinet adjacent to the original control panel to allow centralized operation by a single line operator.
Completed integration and full operational testing to ensure performance and safety.

Results

Line capacity significantly increased, allowing for faster conveyor speeds and greater production throughput—especially critical for large-profile rubber products.
System strain reduced, enabling more sustainable operation at lower output levels.
Extended the lifespan of key components, including magnetrons and transformers.
Delivered a cost-effective upgrade path without requiring full system replacement.

Before

After