Wire routing is a trivial but crucial detail in hot runner installation. Unreasonable wiring extrusion, sharp bending, crossing high-temperature areas and mixed arrangement with power lines are the main artificial causes of thermocouple insulation damage, signal interference and premature wire breakage. Standard routing specifications can effectively avoid most hidden failures, extend service life and maintain stable temperature signal transmission.
Thermocouple signal wires must follow the reserved mold wiring grooves, avoiding direct extrusion by mold clamping surfaces, sharp steel edges and sliding modules. Long-term extrusion will wear the outer insulation layer, causing internal wire short circuit or leakage. The wiring path should reserve enough bending margin for mold opening stroke, preventing the wire from being pulled tightly and fatigued during repeated mold movement. Sharp right-angle bending should be avoided; natural arc transition can protect the internal alloy core from hidden fracture.
It is strictly forbidden to arrange thermocouple low-voltage signal wires together with high-power heating lines and power cables in the same groove. High-current power lines generate strong electromagnetic radiation, which interferes with the weak millivolt-level thermoelectric signal and causes temperature jumping and unstable reading. Signal wires should be routed independently and kept a safe distance from frequency converters, servo motors and high-temperature heating rings to reduce radiation interference and high-temperature aging of insulation materials.
In addition, wiring terminals should be arranged in dry and ventilated positions, away from cooling water leakage, oil mist erosion and direct air-conditioning airflow. Regularly tidy up loose wiring, fix the wire harness with high-temperature cable ties, prevent swing friction during equipment vibration, and avoid terminal looseness and poor contact. Standard routing is not only a construction norm, but also an effective means to eliminate hidden troubles from the source, reduce failure rate and maintenance cost of hot runner thermocouples.
