1、 Daily maintenance

1. Clean the surface of the sensor
   • methodRegularly clean the sensor housing with a clean soft cloth or compressed air to avoid the accumulation of oil, dust, or metal debris.
   • AttentionDo not use corrosive cleaning agents or hard objects to scrape, to prevent damage to the sensor surface or seals.
2. Check the connection line
   • Content：
     • Check whether the signal and power lines are loose, damaged, or aged to ensure a secure connection.
     • Regularly check whether the wiring terminals are oxidized, and if necessary, use sandpaper to polish and apply conductive paste.
   • frequencyCheck daily or before each shift operation, and increase the number of inspections for key equipment.
3. Observe the operating status
   • Content：
     • Listen for any abnormal noise (such as friction or vibration) when the sensor is running.
     • Check if the sensor housing is heating up (the normal operating temperature should be below 65 ℃).
   • exception handlingIf noise or overheating is detected, immediately stop the machine for inspection to prevent the fault from expanding.

2、 Regular maintenance

1. Calibration and Calibration
   • CycleBased on usage frequency and environmental conditions, it is recommended to calibrate every 6 months to 1 year.
   • method：
     • Use a standard torque calibrator (such as a weight type or torque wrench) to perform static calibration on the sensor.
     • Dynamic calibration can verify sensor response by simulating actual operating conditions (such as loading/unloading cycles).
   • RecordSave calibration data, establish sensor performance files for trend analysis.
2. Lubrication and rust prevention
   • Applicable ScenariosWhen there are mechanical transmission components (such as gears and bearings) inside the sensor.
   • method：
     • Use specialized lubricating grease (such as high-temperature lithium based grease) recommended by the manufacturer to lubricate bearings or gears.
     • Apply rust proof oil to metal parts to prevent corrosion in humid environments.
   • Attention: Avoid contaminating the elastic components or strain gauges of the sensor with lubricating grease.
3. Check the sealing performance
   • Content：
     • Check whether the sealing ring of the sensor housing is aged, cracked, or deformed.
     • For waterproof sensors (such as IP67 level), a water immersion test can be conducted (check for water ingress inside after short-term immersion).
   • processIf a sealing problem is found, replace the seal immediately to prevent moisture or dust from entering and causing a short circuit.

3、 Environmental management

1. Control temperature and humidity
   • temperatureThe working temperature range of sensors is usually from -20 ℃ to+80 ℃, to avoid long-term exposureharshTemperature environment.
   • humidityThe relative humidity should be below 85% to prevent internal condensation or circuit board short circuits.
   • MeasureInstall temperature control devices or dehumidifiers in high temperature or humid environments.
2. Anti electromagnetic interference
   • Measure：
     • The sensor signal line uses shielded cables and is grounded at one end (to avoid multiple grounding points forming a circulating current).
     • Stay away from interference sources such as high-power motors and frequency converters, and install filters if necessary.
   • verificationCheck whether the signal waveform is stable and eliminate interference effects through an oscilloscope.
3. Avoid mechanical impact
   • Attention：
     • Do not strike or impact the sensor to prevent the internal strain gauges from falling off or the elastic components from deforming.
     • Use specialized tools during installation to ensure that the coaxiality between the sensor and the measured axis is ≤ 0.1mm.
   • protectionInstall protective covers or shock absorbers in locations that are susceptible to impact.

4、 Operating standards

1. Preloading and Unloading
   • preloadApply a slight torque (such as 10% of the rated value) to the sensor before use to eliminate installation stress.
   • uninstallWhen shutting down, unload the torque first and then turn off the power to avoid residual stress damaging the sensor.
2. Avoid overloading
   • limitEnsure that the actual torque does not exceed 80% of the sensor range (such as a maximum of 80N · m for a 100N · m sensor).
   • ProtectInstall overload protection devices (such as torque limiters) to prevent sensor damage from instantaneous overload.
3. Standardize installation and disassembly
   • Installation：
     • Tighten high-strength bolts (such as grade 12.9) in three diagonal steps to ensure a smooth contact surface.
     • Choose an elastic diaphragm type coupling to avoid rigid connections transmitting vibration.
   • disassembleOperate in reverse order to avoid forcefully pulling and damaging the circuit.

5、 Fault prevention and emergency response

1. Establish an early warning mechanism
   • methodReal time recording of sensor output signals through monitoring systems, setting threshold alarms (such as triggering alarms when output fluctuations exceed ± 5%).
   • toolUse data acquisition cards or specialized software (such as LabVIEW) to achieve remote monitoring.
2. Spare Parts Management
   • Content：
     • Reserve commonly used spare parts (such as sensors, couplings, seals) to ensure quick replacement in case of malfunction.
     • Regularly check the status of spare parts to avoid performance degradation caused by improper storage.
3. Emergency response process
   • step：
     1. Immediately shut down and cut off the power to prevent the fault from escalating.
     2. Record fault phenomena (such as output values, abnormal sounds, environmental conditions).
     3. Contact the manufacturer or professional maintenance personnel to avoid non professionals disassembling the sensor.
   • caseIf the sensor is short circuited due to water ingress, it needs to be recalibrated after drying; If the strain gauge falls off, it needs to be returned to the factory to replace the elastic body.