Situations that permit complete recuperation
Replacing the protected cable or tightening the terminals can completely eliminate signal interference or drift brought on by loose connections, broken shielding, or oxidised terminals.
By recalibrating compensation parameters and updating the temperature controller's calibration data, accuracy may be 100% restored if the parameters of temperature compensation components move significantly, making the previous compensation curve no longer cover the current temperature range.
By cleaning the interface and retightening fasteners to the required torque, mistakes caused by metal debris or oil residue on the mounting interface that cause variations in force or heat transmission may be corrected and brought back within allowable bounds.
Software calibration alone can fully restore accuracy if output deviations at 20%, 50%, and 80% of the specified range stay under 0.3% of full scale in a constant 25°C environment and there is no irreparable damage to the core sensing device.
Scenarios requiring hardware repair Replace high-precision resistive/capacitive components (with a temperature drift coefficient ≤0.00005/°C) on a dust-free, temperature-controlled workbench to restore original performance if drift exceeds 1% of full scale with non-linear error distribution across different points-or if the core sensing unit has experienced a minor physical impact. This is followed by a 24-hour powered burn-in test and recalibration.
Extreme scenarios where recovery is impossible The sensor must be completely replaced if the internal micro-lattice completely dislocates or if the core alloy strain structure or ceramic sensing diaphragm experiences severe, irreversible fracturing or carbonization/burnout; accuracy cannot be restored through calibration or repair.
More than 60% of hot runner sensor drift problems in industrial settings are caused by changes in circuit board temperature compensation component parameters. In these situations, original accuracy may be restored using regular calibration and repair techniques, greatly lowering operating and maintenance costs. This eliminates the need to replace the core hardware.
