After repairing a hot runner multi-point redundancy temperature measurement fault, the repair effect needs to be confirmed through three steps: data comparison, functional testing, and environmental adaptability verification. This ensures that the system can achieve stable temperature control within ±0.3℃ in the high temperature and humidity environment of Wuhan.
1. Real-time Data Comparison Verification (Confirming Temperature Measurement Accuracy)
Primary/Backup Consistency Check: After repair, continuously monitor for 30 minutes. The temperature difference between the primary and backup sensors should be <0.5℃.
Adjacent Measurement Point Verification: The temperature difference between the two points on the manifold should be <1.5℃. If it exceeds this tolerance, the measurement points need to be re-distributed.
Environmental Parameter Monitoring: The humidity inside the temperature control chamber should be <80%RH, and the temperature should be <55°C to avoid signal drift.
2. System Functional Testing (Verification of Fault Tolerance and Response Capabilities)
Redundancy Switching Effectiveness Test: Simulate a main sensor disconnection; the system should automatically switch to the backup channel and trigger an alarm within 0.5 seconds.
Safety Degradation Mechanism Verification: Disconnect AI communication; the system should seamlessly switch to PID control mode, with temperature fluctuation ≤ ±1.0℃.
Filtering Anti-interference Test: Inject simulated noise signals to confirm that the 5Hz first-order low-pass filter effectively suppresses glitches.
Engineering Standard: Switching response time < 0.5 seconds and temperature control accuracy ≤ ±1.0℃ after degradation are considered合格 (qualified).
3. On-site Tool-Assisted Verification (Final Closed-Loop Confirmation)
Infrared Thermometer Comparison: Measure the nozzle's outer surface temperature; the deviation from the system reading should be <3℃.
Multimeter Circuit Resistance Check: Thermocouple circuit resistance should be between 2~10Ω; exceeding this range indicates a potential circuit malfunction.
Nitrogen Pressure Check: Maintain the purging module pressure at 0.2~0.4MPa to ensure continuous and effective moisture protection.
Operational Recommendation: Perform a quick comparison during each shift's inspection to form a repair-verification-recording closed loop.
