How Does Dual-Sensor Redundancy Comparison Technology Work?

Dual-sensor redundancy comparison technology relies on "dual measurement from the same source, mutual deviation calibration, and anomaly alarm." It works in three steps and has an easy-to-understand concept and functioning logic:

1. Installation and Initialization: Within the same hot runner, two sensors of the same model and batch are placed side by side in the same spot. In order to guaranty an initial output deviation of less than 0.05%FS, both sensors are simultaneously calibrated at the factory and detect precisely the same melt pressure and temperature.

2. Real-Time Synchronous Acquisition and Comparison: The control system concurrently obtains the output data from both sensors during injection molding and instantly compares the variances between them:

The control system uses the average of the two outputs as the final measurement result if the deviation is less than a certain threshold (usually 0.1%FS). This improves measurement accuracy by countering the modest random drift of a single sensor.

The system automatically labels the abnormal sensor if the deviation is greater than the threshold, which signals that one of the sensors has experienced accuracy degradation.

3. Automatic Alarm and Correction

The system will immediately adjust the current measurement value based on the output of the normal sensor if only one sensor over the deviation limit. It will also simultaneously send out a warning message, "Sensor number X is abnormal; please arrange for replacement," without stopping production.

In order to prevent the manufacturing of faulty goods, the system will immediately sound an accuracy over-limit alarm if two sensors exceed the limit at the same time. This alert will remind operators to halt the machine for calibration or replacement.

This technique is appropriate for high-end precision injection molding scenarios with very high product yield requirements since, in theory, it prevents batch scrap caused by the abrupt failure of a single sensor. However, the total cost doubles because it needs an extra set of sensors.