How to Determine if a Hot Runner Sensor is Aging

Two phases make up the fundamental method: "calibration check + fault observation." Aging is indicated by fulfilling any two of these requirements. The particular technique is straightforward and simple to use:

1. Verify Accuracy Indicators Following Calibration (Core Judgment Basis)

Compare the sensor's parameters with those from the manufacturer after standard calibration. Aging is indicated by any of the following conditions:

Less than a month after calibration, the deviation surpasses the standard once more; zero-point drift reaches 0.1%FS;

Full-scale accuracy deviation is greater than twice the nominal accuracy of the sensor (e.g., 6125A nominal 0.25%FS, deviation exceeds 0.5%FS);

The sensitivity drops by more than 5% when compared to the factory sensitivity, and recalibration is unable to get it back into the acceptable range.

2. Check for Errors During Regular Use

The sensor has aged, as seen by the following anomalies during regular production:

Frequent signal fluctuations: When the pressure is stable, there are significant output variations that continue long after the injection molding machine and wiring issues have been ruled out;

Adhesive leaking: Consistent adhesive leakage at the mounting site that persists even after the gasket is replaced, suggesting that the seal has deteriorated and failed;

Accelerated component aging is indicated by increasingly rapid drift, which is defined as sagging above allowable limits fewer than six months following calibration.

Fast Reference

If the sensor has lived up to its expected lifespan: The existence of one of the aforementioned anomalies typically indicates that the sensor has aged for both common sensors used for more than two years and high-end corrosion-resistant types (like the 6125A) used for more than three years.