A temperature swing sensor should be replaced within 2 hours of malfunction, especially in Wuhan's high-temperature and high-humidity environment. To avoid escalating the problem and causing mass scrap or cascading damage, it is recommended to complete the replacement within the next downtime window (such as mold change or shift handover).
1. Replacement Timeliness Requirements
Urgency Level: High
After a sensor malfunctions, the system relies on backup channels or manual temperature control, leading to decreased stability. The replacement process must be initiated within 2 hours.
Ideal Window: Complete the replacement during natural downtime such as mold change, shift handover, or planned shutdown to avoid additional production stoppages.
Maximum Tolerance Time: No more than 24 hours; otherwise, moisture, coking, or thermal stress may cause malfunctions at adjacent points.
2. Replacement Priority under Different Operating Conditions
|
Operating Condition |
Replacement Requirements |
Basis |
|
Main Sensor Damaged, Backup Sensor Normal |
Prepare within 2 hours, replace during the next shutdown window |
Prevent backup sensor from also failing. |
|
Both Main and Backup Sensors Abnormal or Frequent False Alarms |
Immediately stop and replace. Avoid temperature control failure leading to batch scrapping. |
|
|
High Humidity Environment (>85%RH) |
Start within 1 hour of damage to prevent further insulation deterioration |
Typical risk during Wuhan's rainy season. |
|
Production of High Value-Added Products (e.g., Medical Components) |
Stop and replace immediately upon damage, no delay exceeding 1 hour |
Single module value exceeds ¥100,000, extremely high risk. |
Operational Recommendation: Establish a full-process tracking mechanism of "Damage-Response-Replacement" to ensure closed-loop management.
3. Closed-Loop Actions Required After Replacement
Recalibration: Perform a step response test, update the time constant T, and reset the primary/standby temperature difference baseline;
72-Hour Steady-State Verification: Primary/standby temperature difference < 0.5℃, infrared comparison deviation < 3℃;
Generate Electronic Record Card: Record replacement time, model, operator, and ambient temperature and humidity for traceability.
Project Value: Jiangsu Kangfeite improved the first-time mold pass rate after replacement from 76% to 95.2% through closed-loop management.
