Machlett’s MACHWAVE™ Circular Polarized Feeds introduce a true circular polarity design, differing from traditional rectangular waveguides that do not generate rotational energy. This design provides improved uniformity of the electrical fields by improving the overall microwave electrical characteristics of previous designs. It allows for more even energy distribution, reducing peak voltage patterns and improving overall system performance.
One of the primary challenges in microwave heating systems is energy loss and uneven field concentration. Traditional feeds, including many rotary models, often generate high peak electric fields, leading to increased arcing and inconsistent heating. MACHWAVE™ addresses this by utilizing a phase-changing electrical signal within the waveguide structure, rotating energy at 915 million cycles per second—the same speed as the magnetron tube. This approach reduces energy loss and the potential for arcing, leading to more consistent heating.
Key Design Features
MACHWAVE™ feeds do not rely on moving parts, unlike rotary feeds, which use mechanical components that can degrade over time. By eliminating these components, MACHWAVE™ reduces maintenance requirements and improves long-term reliability. Additionally, the system is not frequency-dependent, meaning it can respond uniformly to different signal types, avoiding voltage spikes that often cause arcing and burning in traditional systems.
The design also features the lowest measured power reflection in the industry, which contributes to lower cooling requirements and improved heat transfer efficiency. The reduction in power reflection means less wasted energy and a more stable operating environment.
Rotary Antenna Feeds and Material Considerations
Machlett also manufactures rotary antenna feeds with a focus on material selection and tuning efficiency. Many competitor feeds use brass, aluminum, or copper tubing, which can introduce conductivity inefficiencies. In contrast, Machlett’s rotary feeds use solid copper shafts, providing improved electrical conductivity and reducing arcing and burning within the system.
The rotary feeds incorporate an improved mounting flange design, which enhances system integrity and simplifies maintenance. The addition of a removable cavity mounting plate allows for easier repairs and system adjustments. Designed for applications of 75 kW and above, these rotary feeds support higher power levels with more stable performance characteristics.
Impact on System Efficiency and Maintenance
Replacing rotary feeds in bacon processing and tempering systems with circular polarized feeds can result in a 10-15% increase in delivered power, improving throughput. Additionally, by removing the need for frequent rotary feed maintenance, operations can reduce maintenance costs, which can total $100,000-$150,000 per year in some processing environments.
Machlett claims that some competitor feeds have been reported to cause arcing and burning within microwave heating systems, leading to increased downtime and repair costs. The use of enhanced tuning and solid copper shafts in Machlett’s direct replacement rotary feeds addresses these issues by offering improved frequency matching and energy transfer efficiency.
Technical Support and System Optimization
Machlett provides on-site technical support for various microwave heating systems, including those from AMTek, Ferrite, Amana, and Raytheon. 24/7 support availability ensures that systems can be maintained at peak efficiency with minimal disruption to operations.