Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(Section 10 and Rule 13)

1. TITLE OF THE INVENTION:
THERMOCOUPLE FAILURE DETECTION SYSTEM FOR AN EXTRUDER
2. APPLICANT:
Meril Life Sciences Pvt. Ltd., an Indian company of the address Survey No. 135/139 Bilakhia House, Muktanand Marg, Chala, Vapi-Gujarat 396191, India.

The following specification particularly describes the invention and the manner in which it is to be performed:

 
FIELD OF INVENTION
[001] The present invention relates to the field of extruders. More specifically, the present invention pertains to a thermocouple failure detection system for an extruder.
BACKGROUND OF INVENTION
[002] Extrusion is a widely used manufacturing process in the plastics and polymer industries, where raw materials such as plastic pellets, powders, or granules are melted and continuously pushed through a heated extruder barrel using a rotating screw. The molten material is then forced through a die to form products such as tubes, pipes, films, sheets, profiles, or cables. To ensure proper melting, flow, and shaping of the material, the extruder barrel is divided into multiple heating zones, typically three or more, each of which is controlled to maintain a specific temperature suited to the stage of the process occurring in that zone.
[003] In a conventional extruder, the temperature of each heating zone of the barrel is controlled using one or more electric heaters and monitored using a thermocouple sensor for each heating zone. The thermocouple sensor is generally positioned on the wall of the barrel but is not in direct contact with the molten material. This thermocouple sensor provides temperature data to a control system. The control system is pre-configured with a threshold value. The control system uses the threshold value and monitored thermocouple data to regulate the heater activity of the heating zone. When the temperature of any of the heating zones of the barrel increases or decreases beyond or below a threshold, the control unit activates cooling systems, such as fans or water-cooling lines, to maintain the desired temperature in each heating zone of the barrel. This setup forms a closed-loop control system that operates automatically based on the thermocouple feedback to the control unit.
[004] Fig. 1 depicts a conventional extruder barrel 100 (or barrel 100) in accordance with the prior art. The barrel 100 is configured to melt incoming polymer granules and guide the resulting molten polymer towards an extrusion head of an extruder. The barrel 100 includes a plurality of heating zones 102 positioned along its length. Each heating zone 102 is equipped with a thermocouple 104 installed at a predefined location. The thermocouple 104 is configured to monitor the temperature of the respective heating zone 102 of the barrel 100 and transmit the monitored temperature to a control system (not shown). Based on the temperature received from each thermocouple 104, the control system regulates the heating elements associated with the heating zones 102 of the barrel 100 in a closed-loop configuration.
[005] The thermocouple presents a significant limitation. If the thermocouple 104 becomes faulty due to disconnection, mechanical looseness, sensor drift, insulation breakdown, or other failure modes, the thermocouple continues to reflect a temperature value even though it is incorrect. Further, there is no built-in redundancy or verification mechanism to detect the anomaly in real-time. A failed or inaccurate thermocouple reading can lead to incorrect temperature regulation within the corresponding heating zone 102. For example, a thermocouple that reports a lower-than-actual temperature may result in overheating of the barrel 100. This can cause the processed plastic material to undergo thermal degradation, including charring, chemical decomposition, or off-gassing, which can in turn affect product quality and cause complications such as die blockages or elevated back pressure. Conversely, a thermocouple that falsely reads a higher temperature may cause premature deactivation of the heating system or trigger excessive cooling, leading to underheating. This condition can prevent proper plasticization of the raw material, increase mechanical stress on the extruder components, and ultimately result in pressure instability or physical damage to the screw and barrel 100.
[006] Thus, there arises a need for a temperature monitoring system for an extruder that overcomes the problems associated with conventional extruders.
SUMMARY OF INVENTION
[007] The present invention relates to a system for detecting failures of one or more thermocouples in an extruder. The system includes at least two thermocouples disposed in a heating chamber of a barrel of the extruder, each thermocouple configured to monitor a real-time temperature of the heating chamber and a control unit operatively coupled to the thermocouples, the control unit comprising a processing unit and a memory configured to store one or more predefined parameters, including one or more temperature threshold values and allowable deviation ranges. The processing unit is configured to: (i) receive a real-time monitored temperature data from each of the thermocouples associated with the heating chamber, (ii) compare the received temperature data of the thermocouples with each other to determine whether a deviation is present between the two readings, (iii) compare whether the deviation exceeds a predefined allowable deviation range, if the deviation is present, (iv) compare each thermocouple’s temperature reading individually against a preconfigured upper and lower threshold temperature value, (v) identify failure of a thermocouple based on the comparison in steps (ii-iv), and (vi) generate an alert signal to notify an operator upon detection of the thermocouple failure.
[008] The foregoing features and other features as well as the advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
[009] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the apportioned drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale.
[0010] Fig. 1 depicts a top view of a barrel 100 of a conventional extruder, in accordance with a prior art of the present disclosure.
[0011] Fig. 2 depicts an exemplary block diagram of a system 200 for detecting failure of one or more thermocouples 206, in accordance with an embodiment of the present disclosure.
[0012] Fig. 3A depicts a top view of a barrel 202 of an extruder, in accordance with an embodiment of the present disclosure.
[0013] Fig. 3B depicts a side view of the barrel 202 with thermocouples 206, in accordance with an embodiment of the present disclosure.
[0014] Fig. 4 illustrates a flowchart of a method 400 for detecting failure of one or more thermocouples 206 of the extruder, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0015] Prior to describing the invention in detail, definitions of certain words or phrases used throughout this patent document will be defined: the terms "include" and "comprise", as well as derivatives thereof, mean inclusion without limitation; the term "or" is inclusive, meaning and/or; the phrases "coupled with" and "associated therewith", as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have a property of, or the like; Definitions of certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases.
[0016] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, but mean “one or more but not all embodiments” unless expressly specified otherwise. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.
[0017] Although the operations of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that the disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed herein. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed system, method, and apparatus can be used in combination with other systems, methods, and apparatuses.
[0018] Furthermore, the described features, advantages, and characteristics of the embodiments may be combined in any suitable manner. One skilled in the relevant art will recognize that the embodiments may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments. These features and advantages of the embodiments will become more fully apparent from the following description and apportioned claims, or may be learned by the practice of embodiments as set forth hereinafter.
[0019] The present disclosure relates to a thermocouple failure detection system (or system) for an extruder. The system is configured to detect a failure of one or more thermocouples provided in the extruder. Failures include without limitation physical damage, deviation in the thermocouple's reading from a pre-configured threshold range, absence of temperature data from one or both thermocouples, indicating possible sensor failure or disconnection, abnormal or rapid fluctuations in the temperature readings, which may suggest instability or malfunction in the extruder, physical damage of thermocouple, etc. The extruder includes a barrel with a plurality of heating chambers, each heating chamber equipped with at least two thermocouples. For example, each heating chamber has a first thermocouple and a second thermocouple, both operatively connected to a control unit that is configured to manage the heating and cooling operations of the extruder.
[0020] The system further includes a processing unit configured to evaluate the temperature readings of the first and the second thermocouples to identify any discrepancies or abnormalities in the temperature data, such as sudden temperature loss, temperature mismatch between the thermocouples, or readings outside the expected range. If any discrepancy is detected, the system automatically triggers an alarm or alert, notifying an operator to take corrective action. This early warning mechanism helps to prevent damage to the extruder, degradation of raw materials, and/or deterioration in product quality. Additionally, the system is modular and adaptable, making it suitable for easy integration into existing extruder setups with minimal structural changes.
[0021] Referring now to figures, Fig. 2 depicts an exemplary block diagram of a system 200 for detecting failure of one or more thermocouples in an extruder, in accordance with an embodiment of the present disclosure. The system 200 is integrated into an extruder and is configured to detect failures or anomalies of one or more thermocouples, which are used for temperature measurement. The system 200 includes a barrel 202 with at least one heating chamber 204, a control unit 208, and a display unit 212. The heating chamber 204 is equipped with at least two thermocouples 206. Each thermocouple 206 is configured to monitor real-time temperature of the respective heating chamber 204. The control unit 208 is operatively coupled to each thermocouple 206 of the heating chamber 204.
[0022] In an embodiment, the control unit 208 is provided on the extruder and is coupled to each thermocouple 206 and the display unit 212 using thermocouple wire. The control unit 208 is configured to manage the extruder’s operation based on one or more preconfigured parameters. The control unit 208 is configured to receive temperature data from the thermocouples 206. The control unit 208 includes a processing unit 210 and a memory 211. The memory 211 may include various types of storage, such as read-only memory (ROM), random-access memory (RAM), flash memory, or hard disk drives. These components collectively enable the control unit 208 to perform tasks such as monitoring temperature data, executing control logic, and generating alerts. In an embodiment, the memory 211 is configured to store one or more predefined parameters, including one or more temperature threshold values and allowable deviation range, temperature analysis algorithms, and historical temperature data and temperature deviation trends for predictive or pattern-based anomaly detection, etc.
[0023] The processing unit 210 is configured to receive real-time monitored temperature data from each of the thermocouples 206 associated with the heating chamber 204. The processing unit 210 is configured to execute computer-readable instructions stored in the memory 211 to identify any discrepancies or abnormalities in each thermocouple 206 by comparing the thermocouples' data with each other and a preconfigured threshold temperature value, as described in detail below. The discrepancies or abnormalities, such as sudden temperature loss, temperature mismatches between the thermocouples, or readings outside the expected range.
[0024] Upon identification of any such discrepancies, the processing unit 210 flags a potential thermocouple failure or malfunction. This allows for prompt operator intervention and maintenance, minimizing the risk of equipment damage due to undetected thermal anomalies. In an embodiment, the processing unit 210 may be a microcontroller, microprocessor, application-specific integrated circuit (ASIC), or any other suitable processing component.
[0025] The barrel 202 is configured to convert solid polymeric raw material(s) into a pressurized molten state using a screw (not shown) and guide the material towards a die head (not shown) to shape them into one or more tubes. In an embodiment, the barrel 202 is an elongated, cylindrical housing aligned along a longitudinal axis and configured to accommodate the screw (not shown) for processing the polymeric material. The barrel 202 has a feeding end 202a and an extrusion end 202b as depicted in Fig. 3A. The feeding end 202a of the barrel 202 is coupled to a feed hopper (not shown), and the extrusion end 202b of the barrel 202 is coupled to the die head (not shown).
[0026] In an embodiment, the heating chambers 204 of the barrel 202 are arranged sequentially along the axial length of the barrel 202. In an embodiment, each heating chamber 204 includes at least two holes 302 configured to accommodate the corresponding temperature-sensing elements of the system 200. The temperature-sensing elements may include, but are not limited to, thermocouples. In an embodiment, the at least two holes 302 include a first hole 302a and a second hole 302b. Alternately, the number of holes may vary depending on the number of thermocouples. These holes 302a, 302b are configured to receive the corresponding thermocouples, facilitating real-time temperature monitoring of the respective heating chamber 204. In an embodiment, the heating chamber 204 of the barrel 202 is made from corrosion-resistant and medical-grade steel alloys, with internal surface finishing to minimize material degradation and contamination risks.
[0027] The at least two thermocouples 206 are disposed in the heating chamber 204 of the barrel 202. In an embodiment, each thermocouple 206 is configured to be attached to the corresponding holes 302 of the heating chamber 204 as depicted in Fig. 3B. In an embodiment, the at least two thermocouples 206 include a first thermocouple 206a and a second thermocouple 206b. The first thermocouple 206a resides in the first hole 302a, and the second thermocouple resides in the second hole 302b. The bottom end of each thermocouple 206 is in contact with the interior of the heating chamber 204. In an exemplary embodiment, the bottom ends of thermocouples are in contact with the heating chamber 204 (as depicted in Fig. 3B), enabling precise and responsive temperature readings. The top ends of the thermocouples 206 extend outwardly from the barrel 202 and are operatively connected to the control unit 208 through a cable or wire, as depicted in 3B. The top ends may include connectors or terminals that interface with data acquisition units, controllers, or display modules to provide real-time temperature data as needed. In an embodiment, the first thermocouple 206a resides in the first hole 302a of the heating chamber 204, and the second thermocouple 206b resides in the second hole 302b of the heating chamber 204. The first thermocouple 206a and the second thermocouple 206b are coupled to the control unit 208 to transmit the data to the control unit 208.
[0028] The display unit 212 is mounted on the extruder. The display unit 212 is operatively coupled to the control unit 208. In an embodiment, the display unit 212 is mounted at a predefined position that ensures easy accessibility and visibility for the operator. The display unit 212 is configured to display one or more real-time operational parameters of the extruder, such as temperature readings of each heating chamber 204. In an embodiment, the display unit 212 is configured to display one or more real-time temperature readings, diagnostic alerts, and fault messages to the operator. The display unit 212 includes an input interface (not shown) that enables an operator to input or modify predefined parameters. In an embodiment, this includes configuring temperature threshold values specific to each heating chamber 204. The threshold values and allowable deviation ranges are user-configurable. The display unit 212 may comprise, but is not limited to, a human-machine interface (HMI), touchscreen panel, or programmable logic controller (PLC)-based graphical interface, a touchscreen interface, a graphical LCD or LED panel, or an integrated control panel with physical buttons and indicators. In certain embodiments, the display unit 212 functions as a human-machine interface (HMI) or forms part of a programmable logic controller (PLC) system, providing both monitoring and control capabilities. In an embodiment, the threshold values and allowable deviation ranges are user-configurable through a graphical user interface of the display unit 212.
[0029] The processing unit 210 is configured to detect thermocouple failure by comparing the received temperature data of the thermocouples 206 with each other to determine whether a deviation exists between the temperature readings of the first 206a and the second thermocouples 206b installed in the same heating chamber 204. If the deviation exists between the temperature readings of the first 206a and the second thermocouples 206b, the processing unit 210 is configured to flag the thermocouple failure (i. e. the processing unit 210 is configured to flag the thermocouple failure when the deviation between the temperature readings of the first 206a and the second thermocouples 206b is present). For example, the temperature of the heating chamber 204 is 70°C. However, the temperature reading of the first thermocouple 206a is 70°C, and the temperature reading of the second thermocouple 206b is 75°C. In this scenario, the processing unit 210 detects a 5°C deviation between the two sensors. As a result, the processing unit 210 identifies the discrepancy as a thermocouple failure or anomaly and triggers a fault flag.
[0030] Additionally, the processing unit 210 compares whether the deviation exceeds the predefined allowable deviation range. If the deviation exceeds a predefined allowable range, the processing unit 210 flags the thermocouple as faulty (i. e. the processing unit 210 is configured to flag the thermocouple failure when any one of the thermocouple's 206 temperature readings falls outside the preconfigured threshold range). For example, the allowable deviation is ±3°C. The first thermocouple 206a reads 65°C while the second thermocouple 206b reads 72°C, the temperature difference is 7°C, which exceeds the threshold value, prompting the processing unit 210 to flag thermocouple failure.
[0031] Further, the processing unit 210 compares each thermocouple’s 206 temperature reading individually against the preconfigured upper and lower threshold temperature values to identify potential anomalies. If any reading falls outside the accepted temperature range, the corresponding thermocouple 206 is flagged as defective. For instance, if the defined threshold range is between 50°C and 70°C, and the first thermocouple 206a records 75°C, the temperature exceeds the permissible limit and is marked as failed, even if the second thermocouple 206b is within range, and vice versa if the second thermocouple 206b records 75°C, the temperature exceeds the permissible limit and is marked as failed, even if the first thermocouple 206a is within range.
[0032] Furthermore, the processing unit 210 is configured to identify or flag the thermocouple failure when one of the thermocouples shows a static or non-changing temperature over a monitoring period, while the other thermocouple shows dynamic and expected variations. This indicates that the static thermocouple may be stuck or unresponsive. For example, if the first thermocouple 206a remains at a fixed reading of 60°C for an extended duration while the second thermocouple 206b fluctuates between 58°C and 62°C, the processing unit 210 recognizes the first thermocouple 206a as faulty, due to the lack of variation vice versa if the second thermocouple 206b remains at a fixed reading of 60°C for an extended duration while the first thermocouple 206a fluctuates between 58°C and 62°C, the processing unit 210 recognizes the second thermocouple 206b as faulty, due to the lack of variation. The predefined duration over which the static condition is monitored typically ranges between 30 seconds to 2 minutes, depending on the operational parameters and heating chamber 204 dynamics.
[0033] The processing unit 210 flags a thermocouple failure when the processing unit 210 detects the complete absence of temperature data from either thermocouple 206. This condition may indicate a disconnection, wiring issue, or a complete sensor breakdown. For instance, if no data is received from the second thermocouple 206b while the first thermocouple 206a continues to transmit values normally and if no data is received from the first thermocouple 206a while the second thermocouple 206b continues to transmit values normally, the processing unit 210 interprets this as a critical fault and flag thermocouple failure.
[0034] The processing unit 210 is configured to identify the thermocouple 206 failure based on the above comparison. Upon identifying any one or more of these failure conditions, the processing unit 210 sends a signal to the control unit 208 to generate an alert signal to notify the operator. (For example, the processing unit 210 generates an alert signal to notify an operator upon detection of the thermocouple 206 failure). The alert signal may involve generating a visual or audible alert to inform the operator, logging the failure for maintenance tracking, and optionally executing safety mechanisms such as halting the extrusion process or shifting to a fail-safe mode, thereby ensuring equipment protection and maintaining product quality.
[0035] Further, the processing unit 210 is configured to disable or shut down a heating element of the respective heating chamber 204 upon detecting a thermocouple 206 malfunction.
[0036] Fig. 4 illustrates a flowchart of a method 400 for detecting failure of one or more thermocouples 206 of the extruder, in accordance with an embodiment of the present disclosure. The method 400 enhances the accuracy, reliability, and safety of the extrusion process by enabling early detection of abnormal thermal conditions of the extruder. The method 400 is executed by a processing unit 210, which is communicatively coupled to a plurality of thermocouples 206, a control unit 208, and a display unit 212. The thermocouples 206 include a first thermocouple 206a and a second thermocouple 206b provided in each heating chamber 204 of the barrel 202.
[0037] At step 402, the first 206a and the second thermocouples 206b continuously monitor the real-time temperature of the heating chamber 204.
[0038] At step 404, the processing unit 210 continuously receives real-time temperature data from the first thermocouple 206a and the second thermocouple 206b associated with the heating chamber 204. The temperature readings from the first thermocouple 206a and the second thermocouple 206b are evaluated as explained above.
[0039] At step 406, the processing unit 210 compares the received monitored temperature data to determine whether a deviation between the readings exceeds a predefined allowable deviation range. The comparison includes evaluating the difference between the two thermocouple 206 readings to detect any deviation between the temperature readings of both thermocouples 206, as explained above.
[0040] At step 408, the processing unit 210 compares the temperature reading of the thermocouples 206 to determine whether the deviation exceeds a predefined allowable deviation range. If the deviation is present, the processing unit 210 flags thermocouple failure, as explained above.
[0041] At step 410, the processing unit 210 compares each thermocouple’s 206 temperature reading individually against a preconfigured upper and lower threshold temperature value in the associated heating chamber 204, as explained above.
[0042] At step 412, based on the comparison results, the processing unit 210 identifies failure of the thermocouple 206 based on the comparison in steps 406, 408, and 410, as explained above.
[0043] At step 414, upon detection of a thermocouple failure or anomaly, the control unit 208 generates an alert signal. This alert is communicated to the operator via the display unit 212 or through an integrated alarm system. The alert enables prompt operator intervention to take corrective actions, such as halting the extrusion process, initiating maintenance protocols, or switching to a backup control mode.
[0044] The present disclosure offers several significant advantages over conventional thermocouple failure detection systems used in extruders. The thermocouple failure detection system incorporates at least two thermocouples within each heating chamber. Cross-verification of data from the first and second thermocouples enables early detection of thermocouple malfunctions, wiring faults, or disconnections, issues that might otherwise go unnoticed in a single-sensor configuration. This proactive approach helps prevent overheating or underheating conditions, thereby protecting the extruder from potential damage and extending its operational lifespan. Furthermore, the system enhances safety by generating alerts or initiating automatic shutdown procedures upon detection of abnormal conditions, thereby minimizing risks to both equipment and personnel. The continuous, real-time monitoring also allows for immediate feedback and rapid operator response, reducing production downtime and ensuring consistent product quality. Overall, the invention significantly improves operational efficiency, product consistency, and safety in the extrusion process.
[0045] The scope of the invention is only limited by the appended patent claims. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. , Claims:We Claim
1. A system (200) for detecting failure of one or more thermocouples in an extruder, the system (200) comprising:
a. at least two thermocouples (206) disposed in a heating chamber (204) of a barrel (202) of the extruder, each thermocouple (206) configured to monitor a real-time temperature of the heating chamber (204);
b. a control unit (208) operatively coupled to the thermocouples (206), the control unit (208) comprising a processing unit (210) and a memory (211) configured to store one or more predefined parameters, including one or more temperature threshold values and allowable deviation ranges, wherein the processing unit (210) is configured to:
i. receive a real-time monitored temperature data from each of the thermocouple (206) associated with the heating chamber (204);
ii. compare the received temperature data of the thermocouples (206) with each other to determine whether a deviation is present between the two readings;
iii. compare whether the deviation exceeds a predefined allowable deviation range, if the deviation is present;
iv. compare each thermocouple’s (206) temperature reading individually against a preconfigured upper and lower threshold temperature value;
v. identify failure of a thermocouple (206) based on the comparison in steps ii-iv; and
vi. generate an alert signal to notify an operator upon detection of the thermocouple (206) failure.
2. The system (200) as claimed in claim 1, wherein the at least two thermocouples (206) include a first thermocouple (206a) and a second thermocouple (206b), the heating chamber (204) comprises a at least two hole (302) configured to accommodate the corresponding thermocouples (206) such that the bottom end of the thermocouples (206) is in contact with an interior of the heating chamber (204).
3. The system (200) as claimed in claim 2, wherein the first thermocouple (206a) resides in the first hole (302a) of the heating chamber (204), and the second thermocouple (206b) resides in the second hole (302b) of the heating chamber (204).
4. The system (200) as claimed in claim 1, wherein the top ends of each thermocouple (206) extend outwardly from the barrel (202) and are operatively coupled to the control unit (208) through a cable or wire.
5. The system (200) as claimed in claim 1, wherein the processing unit (210) is configured to flag the thermocouple failure when the deviation between the temperature readings of the first (206a) and the second thermocouples (206b) is present.
6. The system (200) as claimed in claim 1, wherein the processing unit (210) is configured to flag the thermocouple failure when any one of the thermocouple (206) temperature readings falls outside the preconfigured threshold range.
7. The system (200) as claimed in claim 1, wherein the processing unit (210) is configured to flag the thermocouple failure when one of the one thermocouple (206) shows a static or non-changing temperature over a monitoring period, while the other thermocouple (206) shows dynamic and expected variations .
8. The system (200) as claimed in claim 1, wherein the processing unit (210) is configured to flag the thermocouple failure when absence of temperature data from either thermocouple (206).
9. The system (200) as claimed in claim 1, wherein the memory (211) stores historical temperature data and temperature deviation trends for predictive or pattern-based anomaly detection.
10. The system (200) as claimed in claim 1, wherein the processing unit (210) is configured to disable or shut down a heating element of the respective heating chamber (204) upon detecting the thermocouples (206) malfunction.
11. The system (200) as claimed in claim 1, wherein the system (200) comprises a display unit (212) coupled to the control unit (208), the display unit (212) configured to display real-time temperature readings, diagnostic alerts, and fault messages to the operator.
12. The system (200) as claimed in claim 10, wherein the display unit (212) comprises a human-machine interface (HMI), touchscreen panel, or programmable logic controller (PLC)-based graphical interface.
13. The system (200) as claimed in claim 10, wherein the threshold values and allowable deviation ranges are user-configurable through a graphical user interface of the display unit (212).
14. A method (400) for detecting thermocouple failure in an extruder, the method (400) comprising:
a. monitoring, by a first thermocouple (206a) and a second thermocouple (206b), real-time temperature of a heating chamber (204);
b. receiving, by a processing unit (210) of a control unit (208), the monitored real-time temperature data associated with the heating chamber (204);
c. comparing, by the processing unit (210), the received temperature data of the thermocouples (206) with each other to determine whether a deviation is present between the two readings;
d. comparing, by the processing unit (210), whether the deviation exceeds a predefined allowable deviation range, if the deviation is present;
e. comparing, by the processing unit (210), each thermocouple’s (206) temperature reading individually against a preconfigured upper and lower threshold temperature value;
f. identifying, by the processing unit (210), failure of the thermocouple (206) based on the comparison in steps c-e; and
g. generating, by the control unit (208), an alert signal to notify an operator upon detection of the thermocouple failure.