High-temperature melt pressure sensors are essential components in extrusion lines, playing a critical role in ensuring melt quality, enhancing production safety, and protecting equipment. These sensors are highly sensitive, and their performance depends heavily on proper installation and maintenance. Xiaogan High Temperature Melt Pressure Sensor Co., Ltd. offers reliable solutions for extrusion processes. Contact us at 15172194641.
In the extrusion process, maintaining precise control over extrusion pressure is crucial to meet product quality standards, such as dimensional accuracy or surface flatness of mineral filler parts. This is achieved through high-temperature melt pressure sensors, which are vital for optimizing the process. By installing a melt pressure sensor and a pressure control device at the mold inlet, the production yield becomes more stable, and material waste is minimized. These sensors not only improve melt quality but also enhance safety and extend the lifespan of equipment.
Measuring pressure through filters and melt pumps is equally important for ensuring safe operations and optimizing equipment performance. If the melt becomes blocked when entering the mold, the sensor under the filter will alert the operator. An alarm from the filter sensor may indicate excessive internal pressure in the extruder, potentially leading to screw wear. For melt pump manufacturers, monitoring both inlet and outlet pressures ensures continuous flow into the mold, preventing damage caused by blockages.
The high-temperature melt pressure sensors used in extrusion lines can be single-point devices or part of a network that covers the entire production line. These sensors are connected to data loggers and audible alarms, allowing the processing control system to adjust extruder parameters in real time. As sensitive components, they must be carefully installed and maintained to avoid damage and ensure accurate readings. Proper care significantly extends their lifespan and improves measurement reliability.
â— Correct Installation
Improper installation is one of the main causes of sensor damage. If the sensor is forced into a small or irregularly shaped hole, the diaphragm may be damaged due to impact. Using the right tools to machine the mounting holes ensures accurate dimensions. Appropriate torque is essential for forming a good seal, but too much torque can cause the sensor to slip. Applying an anti-seize compound on the threaded portion before installation helps prevent this issue, making it harder to move the sensor even with high torque.
â— Check the Mounting Hole Size
If the mounting hole size is incorrect, the sensor’s threads may wear during installation, affecting both sealing performance and sensor functionality. It may also create safety risks. Ensuring the mounting hole meets standard specifications (e.g., 1/2-20 UNF 2B) is essential. A mounting hole gauge can be used to check and adjust the size accordingly.
â— Keep Mounting Holes Clean
Maintaining clean mounting holes is crucial to prevent clogging and ensure smooth operation. Before cleaning the extruder, all high-temperature melt pressure sensors should be removed to avoid damage. If melted material enters the hole and hardens, it may damage the sensor when reinstalled. A cleaning kit helps remove residues, but repeated cleaning can damage the sensor. In such cases, raising the sensor’s position within the hole can help reduce wear.
â— Choose the Right Location
Installing the sensor too close to the upstream may expose it to unmelted material, causing wear. If placed too far downstream, a stagnant zone may form between the screw and the sensor, leading to melt degradation and signal distortion. If the sensor is too deep in the barrel, the rotating screw could damage its top. Typically, sensors are placed on the barrel before the screen, before or after the melt pump, or in the mold.
â— Careful Cleaning
All high-temperature melt pressure sensors should be removed before cleaning the extruder with a wire brush or special compounds. These methods can damage the sensor’s diaphragm. When the barrel is heated, the sensor should be wiped with a soft cloth. The sensor’s hole must also be cleaned using a clean drill and guide sleeve to avoid contamination.
â— Keep Dry
Although the circuit design of these sensors can withstand harsh environments, most are not fully waterproof. Humid conditions can affect their performance. It is important to ensure that the cooling system does not leak, as moisture can damage the sensor. If exposure to water is unavoidable, a specialized high-temperature melt pressure sensor with excellent water resistance should be used.
â— Avoid Low Temperature Interference
During extrusion, plastic materials need sufficient "soaking time" to transition from solid to molten state. If the extruder hasn’t reached operating temperature before starting, the sensor and equipment may suffer damage. Also, removing the sensor from a cold extruder can cause material to stick to its top, damaging the diaphragm. Always ensure the barrel is sufficiently heated and the material is softened before removal.
â— Prevent Pressure Overload
Even though some sensors are designed to handle up to 50% overload, it’s best to avoid exceeding the safe operating range. Choosing a sensor with a range twice the expected pressure ensures protection against extreme conditions. This allows the sensor to function safely even if the extruder experiences sudden pressure spikes.
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Tag: Melt Pressure Sensor, Melt Extrusion, Pressure Range
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