When the air tightness tester's sensor output signal becomes abnormal, quickly locating the fault is crucial to ensuring the equipment's normal operation. As the core component of the detector, the sensor's signal abnormalities can be caused by various factors, requiring a systematic troubleshooting process to gradually narrow down the fault range.
First, check the physical connection between the sensor and the controller. Loose connections or aging wiring are common problems, potentially causing signal transmission interruptions or distortion. Operators should disconnect the power supply and check if the plug at the sensor interface is securely inserted, observing for damage or cracks in the cable sheath. If poor contact is found, try re-plugging the cable, or use a multimeter to check for continuity, and replace any damaged cables. For equipment exposed to humid environments for extended periods, check for oxidation at the interface; clean the contacts with alcohol wipes if necessary.
Another important reason is the performance degradation or damage to the air tightness tester sensor itself. Prolonged use may cause aging of internal sensor components, or irreversible damage due to external factors such as overload or impact. In this case, verification can be done using the substitution method: swap the suspected faulty sensor with a known good sensor of the same model and observe if the signal returns to normal. If the problem is related to the sensor, the original sensor is likely damaged and needs to be replaced by the manufacturer. Some high-end devices support online diagnostics, allowing users to read real-time sensor status parameters through the interface to help determine its health.
Abnormalities in the pneumatic system can also indirectly affect sensor signals. Air tightness testers rely on a stable air pressure environment. Insufficient air pressure, blocked air lines, or a malfunctioning pressure regulating valve can cause the sensor data to deviate from the true value. During troubleshooting, check if the air pressure meets the equipment requirements, observe if the air lines are bent, damaged, or blocked by foreign objects, and test the pressure regulating valve's adjustment function. For example, if the pressure gauge shows pressure fluctuations while the air output is stable, the internal spring of the pressure regulating valve may be faulty or the seal may be worn out, requiring replacement of the valve body.
Environmental factors often overlook the impact on sensors. Temperature, humidity, or electromagnetic interference can alter the sensor's output characteristics. For example, high temperatures can cause sensor thermal drift, and strong electromagnetic fields can introduce noise signals. Operators should confirm that the equipment is within the operating temperature and humidity range specified in the instruction manual and check for interference sources such as large motors or frequency converters in the vicinity. If environmental conditions cannot be improved, consider adding a protective cover or shielding layer to the sensor, or selecting a model with stronger anti-interference capabilities.
Incorrect software parameter settings can also lead to signal abnormalities. Some air tightness testers support user-defined calibration parameters, measurement ranges, or filtering algorithms. Improper parameter configuration may cause the sensor output to deviate from the actual value. In this case, check the equipment's operation manual to ensure the parameter settings match the current testing requirements. For example, setting the range of a high-precision sensor beyond its actual measurement range may cause output signal saturation or distortion. Restoring default parameters or recalibrating the equipment is often an effective solution.
If the above steps still fail to locate the fault, it may be due to a mismatch in the communication protocol between the sensor and the controller, or a fault in the controller's internal circuitry. In this case, contact the equipment supplier or professional repair personnel, providing a detailed description of the fault symptoms, the equipment model, and usage records to quickly obtain technical support. Some devices support remote diagnostics; technicians can connect to the device via the internet to read log files or adjust parameters, further shortening the repair cycle.
Routine maintenance is crucial for preventing sensor failures. It is recommended to develop a regular cleaning schedule, wiping the sensor surface with a lint-free cloth to remove dust and prevent the adhesion of oil or corrosive substances; regularly inspect the gas path system and clean impurities from the filter; perform calibration according to the instruction manual and record the calibration date and results. Establishing standardized operating procedures can significantly reduce sensor failure rates and extend equipment lifespan.
