In the daily application of wireless furnace temperature testers in overseas industrial factories, the service life and test accuracy of thermocouples are often affected by various irregular misuse behaviors. Most users lack systematic professional operation knowledge, and many habitual wrong operations will cause cumulative damage to thermocouples, resulting in frequent faults such as wire breakage, short circuit, curve distortion and data drift. Summarizing common misuse behaviors and targeted troubleshooting solutions can help overseas users quickly eliminate faults, standardize operation, and reduce equipment loss.
Blind bending and knotting is the most common misuse behavior. In order to adapt to the on-site wiring layout, many operators bend the thermocouple wire at a sharp angle or even knot it at will. This operation causes irreversible damage to the internal fine wire cores. After hidden cracks appear in the wire cores, the thermocouple can work normally in a short time, but it will break completely after slight vibration and temperature cycle changes. The troubleshooting method is to standardize the bending operation, use large-angle natural bending, prohibit knotting, and replace the damaged thermocouple in time once intermittent signal interruption is found.
Pulling the wire body to plug and pull the interface is a common operational error of glass fiber thermocouples. Long-term wire pulling causes the protective sleeve to fall off and the wire core to be exposed, leading to frequent short-circuit faults. The solution is to popularize the standard operation of holding the plug for plugging and pulling, regularly check the tightness of the protective sleeve and the plug joint, and use insulating glue to reinforce the loose joint to avoid wire core exposure. For severely loose and failed products, replace them in time to prevent repeated faults.
Unfit pasting and suspended solder joints are the main causes of abnormal temperature curves. Many operators pursue fast construction and fix the thermocouple casually, resulting in suspended shaking of solder joints and metal contact jump. The troubleshooting scheme is to re-fix the solder joint to ensure close fitting with the workpiece, clean the surrounding metal burrs to avoid accidental contact, and re-test after ensuring stable fixation to obtain standard and effective temperature curves.
Wrong positive and negative wiring and incomplete jacking are common electrical faults. Wrong wiring leads to data inversion, and incomplete jacking leads to short circuit and signal instability. The solution is to re-wire strictly according to the red-negative and yellow-positive standard, jack the wire core to the limit position, do a good job of insulation protection, and test the signal stability after wiring. Regular equipment inspection and standardized operation can effectively reduce the failure rate of thermocouples, improve the efficiency of overseas furnace temperature testing work, and reduce enterprise operating costs.
