I. Direct Impact on the Production Process
Temperature Sampling Abnormalities: When the RC filter fails due to drift, high-frequency interference at the input cannot be effectively filtered out. The temperature controller reading will fluctuate irregularly by more than ±2℃, causing the system to misjudge the temperature status.
Temperature Control Uncontrolled: When the RC total time constant drift exceeds 200ms, the temperature measurement signal will be severely delayed, resulting in significant overshoot during the heating process, with overshoot reaching over 10℃.
Production Cycle Disruption: Temperature fluctuations and overshoot will trigger frequent start-stop cycles of the temperature controller, extending the heating waiting time. The production cycle for a single batch may be extended by 10%~20%.
II. Differentiated Impacts on Different Process Scenarios
Ordinary Structural Component Processes: This may result in defects such as insufficient glue and flash, reducing the yield by 5%~15%, but will not pose serious safety hazards.
Engineering Parts Injection Molding Process: Temperature overshoot can cause molecular chain breakage in materials such as PC and PA, resulting in substandard mechanical properties and batches of defective products.
High-Precision Optical Grade Process: A temperature difference exceeding ±1℃ across the entire runner can lead to poor light transmission and stress marks, resulting in immediate scrapping and a yield rate potentially dropping below 30%.
Processes Using Highly Degradable and Sensitive Materials: Temperature overshoot exceeding the material decomposition threshold can trigger the decomposition of materials such as PVC and POM, producing corrosive gases. In severe cases, this can lead to abnormally high runner pressure, posing safety hazards.
III. Secondary Impacts
Frequent temperature anomalies accelerate the aging of heating coils and thermocouples, shortening the lifespan of core components and increasing equipment maintenance costs.
Abnormally degraded melt residue remaining in the runner requires additional disassembly, cleaning, and material replacement steps in subsequent production, further extending downtime.
