Long-term uncleaning of hot runner sensors will gradually worsen performance degradation, eventually leading to premature failure. The specific consequences, in descending order of severity, are as follows:
Early Stage: Decreased accuracy and fluctuating product quality: Accumulated material and corrosion residue alter the stress characteristics of the diaphragm, causing zero-point drift and decreased sensitivity, resulting in inaccurate pressure measurements. This leads to frequent issues such as insufficient glue, flash, and dimensional deviations, resulting in a continuously decreasing finished product yield.
Mid-Stage: Accelerated aging and shortened lifespan: Residual corrosive materials continue to corrode the diaphragm, accelerating oxidation and fatigue. The accuracy retention time will be shortened by 1/3 to 1/2. A sensor that could have a 3-year lifespan may fail in 1.5 to 2 years.
Late Stage: Causes sealing failure and damages the hot runner: Accumulated material compresses the diaphragm, damaging the sensor's sealing structure. This allows molten metal to leak into the sensor, directly burning it out. The leaked high-temperature molten metal may also damage the hot runner template, resulting in more expensive repairs. Even if the sensor does not drift significantly, regular cleaning after processing corrosive materials can extend its service life by about six months and reduce long-term operating costs.
