How to solve the abnormal heating system of HDPE welding machine

The heating system of the HDPE welding machine is its core component, which is mainly composed of a heating plate or hot air welding head, a temperature control sensor, a heating element (such as a resistance wire or a heating tube), a thermostat and related circuits. The working principle of this system is to generate high temperature through the heating element and effectively conduct heat energy to the welding surface to ensure that the pipe reaches the required melting temperature during the welding process and realize seamless connection of the pipeline. The temperature control sensor is responsible for real-time monitoring the temperature of the welding head or heating plate, and feeding back the data to the control system to adjust the amount of power supplied to the heating element to keep the temperature within the set range.

In actual applications, if the heating system is abnormal, the fault manifestation must be judged in time. Common abnormal manifestations include the temperature cannot rise to the set value, the temperature rises too fast or too slow, the temperature control display is unstable, the heating element does not heat up or heats unevenly, and the thermostat alarm. These problems may be caused by a variety of factors, such as damage to the heating element, failure of the temperature control sensor, circuit problems, failure of the control system, or unstable power supply.

The first step to solve the abnormality of the heating system is to perform a power-off inspection to ensure safe operation. Next, the heating element should be fully inspected to confirm its working status. Resistance testing is an important means of determining the continuity of the heating element. If the measured resistance value is abnormal or there is no resistance, it indicates that the heating element may be damaged and needs to be replaced. The causes of damage to the heating element may include overload, aging or short circuit, so regular inspection and replacement of the heating element is an effective strategy to prevent failure. When replacing, be sure to choose original accessories that meet the equipment specifications to ensure that their heat resistance and conductivity meet the requirements.

Failure of the temperature control sensor is also one of the important factors leading to abnormal heating. Sensor failure may be manifested as abnormal temperature display, drastic temperature fluctuations or control system alarms. The detection method includes using a multimeter to measure the resistance value of the sensor to determine whether it is within the normal range. If the sensor is found to be malfunctioning, it should be replaced in time, and the temperature control system should be recalibrated after replacement to ensure the accuracy of temperature detection. The calibration process usually involves placing the sensor in a known temperature environment and adjusting the control system parameters so that the displayed temperature is consistent with the actual temperature.

Circuit failure is also one of the important factors causing abnormal heating systems. There may be problems such as loose wiring, short circuit or open circuit in the circuit, which will cause the current to be unable to conduct normally, thereby affecting the working state of the heating element. During the inspection process, all connecting wires should be carefully checked to ensure that there is no looseness or damage. If a short circuit or open circuit is found in the circuit part, the damaged wires or components should be replaced in time, the circuit connection should be repaired, and the stable supply of current should be ensured. In addition, if the relay or switch of the control system fails, it will also affect the normal operation of the heating. It is necessary to use special instruments to detect its working status and replace it if necessary.

The instability of the power supply can also cause abnormalities in the heating system. Insufficient voltage or excessive fluctuations may cause the heating element to fail to reach the predetermined temperature or unstable temperature control. Therefore, the use of a stabilized power supply or a power filter is an effective means to ensure that the equipment obtains a stable voltage supply. At the construction site, avoid voltage drops caused by multiple devices using electricity at the same time. If necessary, a dedicated power supply line can be introduced for power supply to reduce external interference and ensure the normal operation of the heating system.