As a core measuring component in high-temperature industrial scenarios such as chemical fiber spinning, plastic rubber, metallurgy and chemical engineering, the stability of high-temperature melt pressure sensors directly affects product quality and production safety. Developing a scientific daily maintenance plan can extend the lifespan of sensors to5Over years and reduced30%The failure rate. Build a maintenance system from four dimensions: installation, cleaning, environmental control, and calibration:

1、 Installation Specification: The Core of Preventive Maintenance

Standardization of installation holes

strictly adhere to1/2-20 UNF 2BIndustrial thread standard, using specialized measuring instruments to detect aperture tolerances（±0.05mm）. A certain chemical fiber enterprise suffered from excessive coaxiality of installation holes0.3mm, leading to3Damaged within a month12Support sensors, use laser positioning processing to reset the fault to zero.

Torque control and anti loosening

Using a digital torque wrench, set the torque value according to the sensor specifications (usually15-20N·m）. Apply Loctite to the threaded area243Anti loosening adhesive, can withstand1000Disassemble and assemble without slipping.

position optimization

Before the filter screen300mmThis is the best installation point to avoid the impact of unmelted particles on the membrane. A certain plastic factory moved the sensor back to the melt pump, but the pressure signal was distorted due to the stagnation zone of the melt, resulting in a decrease in the product qualification rate18%.

2、 Cleaning and maintenance: prevent residue erosion

Cleaning standards for machine barrels

Before dismantling, the temperature of the machine barrel needs to be raised to280℃Above, ensure that the material is completely softened. Clean the top of the sensor with a non-metallic soft brush and use compressed air to blow away any remaining material in the hole. A certain rubber and plastic enterprise failed to carry out high-temperature dismantling, resulting in the membrane being scratched by hard materials and causing annual sensor wear and tear23Support.

Maintenance of installation hole depth

each500Use an endoscope to check for wear at the bottom of the hole when the depth deviation exceeds0.5mmAt that time, ceramic coating repair technology was used to restore the size.

Waterproof and moisture-proof

Regularly check the sealing of the water cooling system of the barrel, and replace it immediately if any leakage is foundOCircle shape. Install sensors for working in humid environmentsIP68Protective cover, filled with silicone desiccant inside.

3、 Environmental control: responding to extreme working conditions

Temperature management

The working temperature of the sensor needs to be strictly controlled within-20℃to+350℃section. During winter shutdown, an electric heat tracing belt is used to maintain the temperature of the engine barrel150℃Above, prevent condensation water from freezing, expanding, and damaging components.

Pressure overload protection

When selecting, the range should be the actual working pressure2Twice. A metallurgical enterprise uses sensors with a small range to continuously operate under high pressure conditions3The membrane will permanently deform after secondary overload.

Electromagnetic interference isolation

The sensor signal line needs to use twisted pair shielded cables and be kept away from the frequency converter (distance>1m）. For strong interference environments, installing a magnetic ring filter can reduce signal noise to0.1%FSfollowing.

4、 Calibration and Monitoring: Precise Maintenance Driven by Data

periodic calibration

each3Use standard pressure source for months (accuracy)±0.05%FS）Perform three-point calibration（0、50%、100%Range). Calibration data passed throughHARTUpload the protocol toMESSystem, generate deviation trend chart.

Intelligent Diagnosis

Integrated vibration sensor for monitoring membrane fatigue, when the vibration frequency deviates from the reference value15%Triggering an alert at the moment. A certain new energy enterprise uses this function to advance48Replace sensors every hour to avoid unplanned downtime and losses50Ten thousand yuan.

Life cycle management

Establish sensor archives and record maintenance data for each maintenance. When the accumulated working time reaches20000Excessive wear or tear on the membrane thickness due to hours30%Force the replacement process to start.

Through the above maintenance plan, a certain chemical fiber group has achieved a reduction in the average lifespan of sensors32Extended to one month48Months, annual maintenance costs reduced42%In industry4.0In this context, combining IoT technology to achieve real-time monitoring of maintenance data will become the next generation solution for managing high-temperature melt pressure sensors.