Shorten preparation times with our resistance and induction-heated fusion technologies

Fully automatic fusion devices

HAG-HF Fully automatic fusion system

The HAG-HF fully automatically prepares 29-, 32- or 34-mm diameter glass bead samples for spectroscopic analysis. The HAG-HF covers the following preparation steps: Dosing, fusion, quality control, and cleaning (option). The inductive fusion system is suitable for cement, iron ore, geological samples, slag, fly-ash, bauxite and other oxidic material. All modules are integrated within one compact machine base. The robot and linear conveyor systems handle and transport the samples within the HAG-HF. The system is fully automatic and monitors itself during operations for reduced sample processing time and trouble-free operation around the clock. The HAG-HF improves reproducibility and increases precision. Sample preparation times are significantly reduced.

Flexible configuration - The HAG-HF can be used as a stand-alone machine or flexibly integrated into various laboratory automations. As an example, the sample material is sent into the laboratory by airtube. The sample material is unpacked from the airtube capsule, pulverized, dosed into cups, and transported to the HAG-HF. For different types of sample material, different preparation and cleaning programs can be defined. Furthermore, special sets of crucibles and casting dishes can be assigned to special sample groups to avoid contamination and reduce the sample processing time.

Precise and accurate dosing - A high-precision balance is used for dosing of sample material, flux, and oxidizing agent into the crucible. Different dosing modes can be defined to control the weighing procedure for different sample types. As an option, hygroscopic material can be protected from moisture absorption. Solutions of wetting agent (like, e.g., lithium bromide) can be added using a high-precision peristaltic pump. Previously in a muffle furnace oxidized samples can be transferred into the Pt- crucible. Typically, a larger sample amount is prepared in a ceramic crucible and then fed into the fusion machine. Afterwards, flux and, when indicated, wetting agent can be added. This method helps saving preparation time and protects the Pt crucibles.

Optimized fusion processes - The HAG-HF uses modern high-frequency generators. The infinitely adjustable temperature (ranging from 385°C to 1300°C) is continuously controlled using infrared pyrometers. This allows a reliable temperature control during all fusion steps. Moreover, permanent temperature monitoring permits direct oxidizing of certain materials within the Pt-crucible. The crucibles are oscillated in a circular movement to improve homogenization of the melt. Additionally, the crucible can be tilt by 45°. The molten material is poured into a preheated casting dish. Afterwards it cools down to the ambient temperature. After solidifying, the casting dish is further cooled down by blowing with compressed air. Fused beads with standard diameters of 29 mm, 32 mm and 34 mm can be produced.

High-precision temperature control - The inductive fusion process not only allows the temperature of the melt to be set quickly and exactly to the desired target value. The technology also ensures precise temperature control. With the temperature calibration unit (optional), the individual emissivity of each crucible can be determined and monitored over the lifetime of the crucible. This enables even more precise temperature determination during the fusion process. The automatic vision system can also be used for automatic crucible identification. In addition, the crucible can be oriented before each digestion process so that the pyrometric temperature measurement always takes place at the same crucible position.

Transport to the XRF spectrometer - The HAG-HF transfers only intact castings to the transport system. A sensor detects crystallized or broken beads and ensures that they are discarded. To prevent contamination of the analysis surface during transport, the beads are not transferred directly to the transport system. With the side to be analyzed facing downward, they are placed on the edges of a holding ring. This ensures that only perfect glass beads are transported to the analysis equipment.

Cleaning - After the fusion process, crucibles and casting dishes are automatically cleaned using a heated ultrasonic bath system (option). The cleaning fluid in the bath is automatically renewed at freely selectable intervals. The cleaned crucibles and casting dishes are rinsed by distilled water and blown dry with hot air. After the cleaning process, the weight is measured to guarantee perfect cleanness.

HAG Fully automatic fusion system

The HAG system prepares oxidic sample materials by borate fusion for spectroscopic analysis. It uses high frequency fusion process which produces 29-, 32-, 34-, 36- or 39-mm diameter glass beads of exceptional analysis precision. All the following steps are fully automated within the HAG system: Sample dosing, flux weighing, fusion and transport of glass beads to the XRF, cleaning of crucibles and casting dishes. All processes are under control of PrepMaster. The software provides a complete sample management system, monitors all critical parameters, and ensures trouble-free operation.

Input tray magazine - Several options of the sample input magazine are available including 62 position sample magazine and a 200, 300 or 400 vial position tray magazine. The magazine can be connected to the preceding preparation cell or can be manually loaded. There is also a 10-position manual sample input magazine in the weighing unit where samples can be registered. The tray magazine has a x-/y/z- gripper transporting the vial inside the unit and into a barcode reading position where the sample ID can be established. The vial is placed on a transport system and transported to the fusion machine. Priorities can be set and changed on the fly. The PrepMaster control system visually indicates the status of each vial like, e.g., ‘to be analyzed’, ‘already analyzed’, ‘in fusion machine’, ‘high priority’ etc. In case that a bead is rejected within the system, the sample is collected from the magazine and automatically re-run on the system.

Dosing Module - The HAG system provides extremely accurate and precise dosing of sample and additives. The dosing unit consists of up to three dosing stations, a sample mixing station, buffer position for Platinum crucible, and a release agent dosing station. All stations are operated by a small robot. Samples in vials are placed into one of the three dosing units. For the fusion process, flux and sample are alternately weighed into the crucible to achieve an optimal dilution of both substances. Subsequently, the crucible is transferred to the mixing station, where flux and sample are homogenized. Optionally, a release agent can be added. Finally, the crucible is placed on a turntable ready to go to fusion. In every case, the control system allows dosing of different types of flux as well as different sample and flux volume.

Fusion Module - According to the sample load, the fusion module consists of 4, 6 or 8 heating units. Each heating unit has two heating positions for the crucible and the casting dish. A linear system transports the sample from the turntable to the heating unit, fused bead to the XRF belt, and dirty crucibles and casting dishes to the cleaning module. The crucible is heated by induction. During this process, the sample can be swirled to aid the mixing. In parallel, the casting dish is heated to a predefined temperature. When the heating cycle is complete, the sample is automatically poured into the casting dish. The bead is allowed to cool within the casting dish. Depending on the sample type different cooling regimes can be used such as fast cooling with compressed air. The heating station is under control of a pyrometer. Therefore, it is possible to setup individual heating profiles for every sample type like, e.g., 500°C for 2 min, 1000 °C for 3 min and 1100 °C for 1 min. Before transported to the XRF, a special detector confirms that the fused bead is not cracked or moon shaped. 

High-precision temperature control - The inductive fusion process not only allows the temperature of the melt to be set quickly and exactly to the desired target value. The technology also ensures precise temperature control. With the temperature calibration unit (optional), the individual emissivity of each crucible can be determined and monitored over the lifetime of the crucible. This enables even more precise temperature determination during the fusion process. An automatic vision system can also be used for automatic crucible identification. In addition, the crucible can be oriented before each fusion process so that the pyrometric temperature measurement always takes place at the same crucible position.

Cleaning Module - The automated cleaning module for dirty crucibles and casting dishes (option) consists of one or two ultrasonic baths, a washing unit, and a drying unit. 14 crucibles and casting dishes can be cleaned simultaneously in the ultrasonic cleaning module. Crucibles and casting dishes are placed in the ultrasonic bath at elevated temperature in citric acid. Afterwards, they are transported to the washing unit where they are washed with normal tap and demineralized water. Before being returned to the dosing module they are dried with hot air blowers. All cleaning parameters can be adjusted with the PrepMaster system.