Determining if a cooling system needs maintenance hinges on real-time monitoring of operating parameters, observation of product anomalies, and regular system status checks. The following three categories of signs can accurately identify maintenance requirements:
1. Abnormal Operating Parameters (System-Level Warnings)
Cooling Water Flow or Pressure Drop >5%: Flow meter or pressure gauge readings consistently low indicate potential blockage in the water circuit or decreased pump efficiency.
Inlet/Outlet Water Temperature Difference Increased: Normally, this should be controlled within 5°C. A temperature rise above 7°C indicates a significant reduction in heat exchange efficiency, requiring water circuit cleaning.
Mold Temperature Fluctuation >±2°C: Frequent temperature fluctuations on the mold temperature controller, exceeding the set range, may be caused by sensor malfunction or uneven cooling.
2. Frequent Product Defects (Result-Based Problem Inference)
Weight Difference of Multi-Cavity Products >2% or Dimensional Deviations: This suggests uneven cooling leading to inconsistent shrinkage, especially noticeable shrinkage in the far cavities.
Dimples, warping, or deformation in thick-walled areas: This indicates insufficient cooling in that area, potentially due to a blocked or poorly designed cooling circuit.
Local scorching or material degradation: Commonly found in main channels or at the bottom of deep cavities, indicating "hot spot" accumulation and insufficient cooling capacity.
3. System physical condition deterioration (found through direct inspection):
Turbid water outlet with rust, slag, or sediment: This indicates internal scaling or corrosion, requiring immediate pulse cleaning.
Leaks at joints or seals: This indicates aging O-rings, insufficient compression, or loose threads, posing a risk of leakage.
Increased noise from the cooling tower or water pump: This may be due to scale buildup causing poor circulation and affecting overall cooling efficiency.
Recommended actions: Upon discovering any of the above signs, immediately arrange targeted maintenance, such as cleaning the water system, replacing seals, and calibrating the mold temperature controller, to prevent minor issues from escalating into system downtime.
