Large-scale injection factory accumulates years of maintenance replacement and calibration data of thermocouple equipped on mixed-brand Husky/YUDO/domestic hot runner; statistical analysis of historical operation data helps enterprise formulate scientific quantitative scrap standard instead of subjective empirical judgment for eliminating aging sensors reasonably. Collect three core index data including full-range calibration deviation, insulation resistance numerical change and monthly failure occurrence frequency: when thermocouple full-temperature-section measuring error continuously exceeds ±1.2℃ after two times parameter compensation adjustment, it reaches scrap threshold and cannot continue to stay on precision production channel.
If insulation resistance drops below industry specified safe limit and cannot recover after surface cleaning and drying treatment, internal insulation structure has irreversible damp or damage and needs mandatory scrapping regardless of current displayed reading status. For components whose intermittent failure frequency rises above three times per month due to internal loose wire or spring fatigue, list into scrap list during periodic overhaul to avoid unexpected sudden shutdown loss in subsequent mass production.
Many workshops still adopt subjective visual inspection to decide scrap or reuse, leading lots of potential drifting aging thermocouple long-term running on production line and triggering irregular batch defective products. Data-based quantitative scrap standard optimizes spare part consumption plan, controls annual thermocouple procurement budget scientifically and reduces hidden quality risk of hot runner molding process.
