How to Verify Hot Runner Sensor Position Adjustment

The effect can be confirmed by TUS furnace temperature uniformity testing, actual melt temperature measurement comparison, and infrared thermal imaging scanning after the hot runner sensor position has been adjusted. This ensures that the temperature measurement point accurately reflects the actual temperature and is minimally affected by frictional heat interference.

1. Rapid Initial Screening: Infrared Thermal Imaging Scan Open the mold right after high-speed injection molding and scan the hot runner's surface temperature distribution using an infrared thermal imager; After correction, a more uniform temperature field with a notable decrease in local temperature variations should be seen. Pay particular attention to looking for "hot spots" in the initial high-shear areas (such as nozzle tips and flow dividers).

Practical Value: Following correction, the temperature differential in a medical mold's nozzle area dropped from ±15°C to ±3°C, suggesting a notable decrease in the effect of frictional heat.

2. Standard Calibration TUS Oven Temperature Uniformity Test

Conduct multi-point temperature measurements in accordance with AMS 2750 or CQI-9 standards while there is no load;

Measure the temperature variation of several calibrated thermocouples placed around the sensor;

To prove representativeness, the temperature deviation at each measurement point should be ≤ ±2°C.

Note: This test should be repeated every three months or following modifications to the process in order to serve as an acceptance standard.

3. Comparison of Melt Temperature Measurements (Final Verification)

To determine the actual temperature of the plastic, install an insertion-type melt temperature gage at the mold output;

Compare this value to the one shown on the temperature controller for the hot runner:

Error = Actual melt temperature minus the hot runner's displayed temperature. The frictional heat error should drop from +10~30°C to within +5°C when the position adjustment is successful.

Case Study: Following modification, the short-shot rate went back to zero and the error of a particular automotive connector mold dropped from +22°C to +4°C, confirming success.

4. Ongoing Observation and Data Storage

Create sensor location profiles and note each adjustment's angle, depth, and distance;

Monitor variations in the failure rate and temperature in the process log;

Reach "adjustment-verification-consolidation" closed-loop management to stop issues from happening again.

The triple verification of "infrared initial screening + TUS calibration + melt measurement" is a safety principle that guaranties consistent and dependable adjustment outcomes.