I. Pre-processing and Optimization Steps
Tool Preheating and Testing: One hour in advance, power on and preheat the CNAS-calibrated multi-channel high-precision temperature monitoring instrument. Import the parameters from the Husky hot runner full-channel K-type thermocouple calibration table and complete the communication connection test.
Pre-arrange the complete set of tools, including heat-insulating gloves, a 0.8 N·m torque screwdriver, high-temperature thermal grease, and high-temperature resistant polyimide tape, next to the equipment in the order of operation.
Benchmark Preloading: Retrieve historical calibration deviations and qualified PID parameters for all channels of the Husky hot runner system from the MES system and import them into the calibration parameter template of the temperature control system in advance. This allows for direct on-site access without the need for temporary data entry.
Generate a blank calibration data automatic acquisition table in advance, pre-setting the temperature recording positions for each channel to avoid wasting time manually drawing tables on-site.
Staggered Pre-heating Operation: Utilizing non-production breaks, the hot runner is preheated to 280℃ and held at that temperature. 30 minutes before calibration, the temperature is increased to 320℃, skipping the usual 2-hour pre-heating wait period.
II. Optimized Parallel Operation Steps:
Parallel Calibration During Heating Wait: After the hot runner reaches 320℃, a 2-hour heating wait window is used to simultaneously complete sensor visual inspection, high-temperature insulation retesting with a 500V megohmmeter, and terminal tightening, without interrupting calibration downtime.
Simultaneously, all standard temperature probes are secured to their corresponding flow channel temperature measurement points using polyimide tape, completing probe pre-installation.
Multi-channel Parallel Sampling: The multi-channel temperature monitoring instrument is activated, set to collect one set of data per minute, continuously and automatically collecting 10 sets of simultaneous temperature measurement data across all channels, replacing the traditional single-channel point-by-point sampling mode.
A pre-written Python automatic sampling script is run, directly connecting to the Husky temperature controller via PTP industrial communication, synchronously and automatically collecting temperature data from the controller, eliminating the need for manual recording. Probe Calibration Without Disassembly: After confirming the sensor is free from displacement and physical damage, there's no need to remove the probe and reapply thermal grease. The average deviation is calculated directly based on the two sets of collected data, eliminating the probe disassembly and reassembly pre-processing step.
If the sensor is displaced, only the probe of that single channel needs to be removed, thermal grease applied, and then it reset. The remaining channels remain in a non-disassembly state, reducing disassembly and reassembly workload by 80%.
III. Parameter Correction and Verification Optimization Steps
Batch Parameter Import: After the automatic script completes the deviation calculation, it batch imports the reverse compensation parameters of all channels into the Husky temperature control system's calibration menu, replacing manual input for each channel. Parameter setting time is reduced from 30 minutes to less than 5 minutes.
Directly call pre-stored historical qualified PID parameters; no on-site readjustment is required. Confirm the temperature overshoot is ≤2℃, saving over 30 minutes of PID debugging time.
Parallel Stability Verification: After the calibration parameters are saved and effective, low-speed trial production is started simultaneously. Temperature stability is monitored for 1 hour during production, without the need for a separate shutdown to wait for verification completion.
A lightweight interface built with LabVIEW Community Edition provides real-time visualization of temperature measurement deviations across all channels, automatically determining whether the temperature measurement error of all channels is stably controlled within ±1℃.
Automatic Archiving and Closed-Loop: After calibration, the system automatically uploads all calibration data to the MES system, generating a compliant calibration report with CNAS traceability, eliminating the need for manual paper record keeping.
Automatic Updates to Sensor Calibration Cycle Records: For sensors with three consecutive calibration deviations < ±0.5℃, the calibration cycle is automatically extended from 3 months to 6 months.
IV. Emergency Optimization Steps for Special Scenarios
If a heater leakage fault has occurred previously, high-temperature insulation retesting is performed simultaneously during the parallel verification phase. The sampling phase only proceeds after confirming that the insulation resistance of all channels is ≥5MΩ, without additional downtime.
If the equipment has previously operated at high load for 24 hours continuously, the parallel stability verification time is extended to 2 hours, completing aging drift verification during trial production without additional downtime.
