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EDDY CURRENT SEPARATORS
Eddy current separators with concentric rotor are designed to automatically separate non-ferrous conductive metals, such as aluminum, copper, and brass, from inert material fractions.
In this configuration, the magnetic rotor rotates at high speed inside a cylinder made of dielectric material, positioned concentrically with respect to its rotation axis. The rotation generates a variable magnetic field that induces eddy currents (Foucault currents) in conductive metals.
In concentric rotor models, the magnetic field extends uniformly across the entire working width of the pulley and over approximately 180 degrees of its circumference, that is, from the point where the belt begins to wrap around the drum up to the discharge point. The concentric separator is particularly effective in processing shredded or ground materials with particle sizes greater than 20 mm, which require a wider and more distributed expulsion force along the working arc.
SPECIFICATIONS OF EDDY CURRENT SEPARATORS
How are they structured?
The concentric rotor eddy current separator is a machine designed with particular attention to functionality, mechanical stability, and ease of maintenance.
Its structure is based on a robust supporting frame, on which two main rollers are mounted on vertical supports resting on the frame (to facilitate replacement):
- the rear roller: motorized, it drives the belt;
- the front roller: fully magnetic, rotating at high speed, generates the magnetic field required for the separation of non-ferrous metals.
The belt, made of rubber or PVC depending on the type of material processed, runs supported by a series of idler rollers that ensure smooth and continuous movement. To keep it perfectly centered during operation, two vertical guide rollers are installed to prevent possible lateral misalignments.
A deflector acting as a splitter, adjustable in 3 positions, plays a fundamental role in the separation phase: it channels the expelled non-ferrous material and the inert fraction into their respective collection hoppers, ensuring a clear and efficient division of the two streams.
The drive and magnetic rollers are powered by motors both controlled by inverters, housed inside the electrical control panel, allowing precise adjustment of operating speeds according to throughput, particle size, and the plant’s specific operating requirements.
Operating principle of an Eddy Current Separator
The operating principle of the eddy current separator is based on the interaction between a variable magnetic field and the conductive materials present in the processed material flow.
The incoming material, after being iron-free and distributed as uniformly as possible, is conveyed by the belt towards the front end, where the magnetic pulley is located.
Inside the dielectric cylinder, there is a multipolar rotor rotating at high speed (typically between 2,500 and 4,000 rpm), generating a high-frequency alternating magnetic field. When conductive particles (such as aluminum, copper, or brass) pass through this area, they are exposed to the variable magnetic field.
As a result of the eddy currents (induced within the mass of the metal), a secondary opposing magnetic field (induced field) is generated. This interaction produces an instantaneous repulsive force between the rotor and the conductive material, causing a ballistic deviation of its trajectory.
The degree of expulsion depends on the electrical conductivity, specific mass, and shape of the material. Non-conductive particles, not influenced by the field, follow their natural ballistic trajectory and fall by gravity. The two fractions are separated by a deflector (splitter), positioned in a specific location to capture the smaller non-ferrous fraction while allowing the larger inert fraction to fall by gravity.
The particular concentric rotor configuration allows the material to remain immersed in the field over a wider section of the drum circumference, increasing both the surface area and the interaction time. This results in a stronger expulsion force, ideal for materials larger than 20 mm, where a more distributed and powerful push is required.
Eddy Current Separators: construction features
The eddy current separator has been designed with a strong focus on ease of use and quick maintenance, minimizing plant downtime and making operations easier for the operator.
Mechanical structureOne of the most effective construction solutions is mounting the bearings directly on the frame. This choice allows fast and easy replacement without the need for complex disassembly, ensuring operational continuity even during maintenance operations.
The conveyor belt, made of rubber or PVC depending on the type of material processed, is supported by idler rollers that guide its movement without generating friction, thus helping to reduce wear and extend the overall system lifetime. To ensure constant and aligned belt movement, two vertical guide rollers keep the belt centered even under uneven load conditions, minimizing the risk of misalignment.
The base frame is equipped with three discharge hoppers, designed to direct the different separated material fractions in an orderly way:
- one for residual ferrous content (if not completely removed upstream);
- one for non-ferrous metals expelled by the induced field;
- and a third for inert material, which follows the natural belt trajectory.
All these features make the separator a machine that is easy to operate, fast to maintain, and highly reliable, even under continuous working conditions.
Magnetic rotorThe core of the separator is the magnetic rotor, housed inside the dielectric cylinder. It is a 20-pole rotor, designed to generate a high-frequency alternating magnetic field, uniform across the entire working width of the drum.
Unlike more common configurations, this rotor uses high-performance magnets, capable of developing a stronger, more stable, and deeper field, improving separation efficiency. It proves particularly suitable for processing medium-to-large sized materials, even when irregularly shaped or with sharp edges, which require a wider and more distributed expulsion force along the magnetic arc.
The resulting effect is a precise, reliable, and well-controlled expulsion trajectory, even with difficult materials.
Electrical panelThe separator is equipped with an advanced electrical panel, designed to be fully compliant with Industry 4.0 requirements.
Thanks to integrated connectivity, the machine is ready for remote supervision and interfacing with centralized control systems. On the front of the panel, an HMI operator screen is installed, through which the user can intuitively manage all separator functions.
The dedicated software allows real-time monitoring of machine status, automatic notifications via email in case of alarms or anomalies, and precise scheduling of ordinary and extraordinary maintenance activities.
To support the operator, the system also integrates interactive video guides that provide step-by-step instructions for correct maintenance operations, reducing downtime and minimizing the risk of error.
Further specifications of Eddy Current Separators
- Simplified maintenance: the entire frame and each component have been designed to minimize intervention times, both for ordinary and extraordinary maintenance. For example, the bearings are mounted directly on the frame, making them easily accessible and replaceable without complex disassembly, with minimal impact on production continuity.
- Automatic and intuitive control: the HMI interface allows simple and immediate management of all machine functions. The system monitors operating status in real time, automatically reports any anomalies, and sends email notifications to ensure timely interventions. In addition, thanks to remote connection and a dedicated application, the machine can be controlled and monitored remotely, giving the operator greater flexibility and responsiveness in daily management.
- Guided assistance: the machine can communicate directly with the operator, sending visual signals on the HMI panel and email notifications in case of alarms, anomalies, or scheduled interventions. Proactively, the system reminds when to perform ordinary or extraordinary maintenance and guides the operator step by step, thanks to integrated video tutorials accessible directly on the panel. This approach reduces errors, speeds up interventions, and makes the operator independent, even without specialized personnel.
- No complex manual adjustments: the belt is kept centered by vertical side rollers, preventing misalignment and the need for frequent realignment. The idler rollers on which it runs do not generate wear, ensuring operational continuity.
- Minimal adjustment and easy control: the machine has been designed to minimize daily adjustments, such as belt centering, ensured by vertical guide rollers that maintain alignment without the need for continuous intervention. At the same time, wear components are easily accessible and inspectable, simplifying routine checks and allowing quick and precise preventive maintenance without unexpected downtime.
CUSTOM EDDY CURRENT SEPARATORS
- Dynamic approach to customer needs.
- Industrial Separators Made in Italy.
- Custom-made solutions.
- Post-sales support and service.
