Multi thermocouple design helps bring new product to market for scientific equipment manufacturer

Contents

1. Background to Project
2. Customer Pain Points
3. Temperature Measurement Challenges
4. Thermocouple Sensor Solution
5. Results and Conclusions

Background to Project

TC were approached by an engineering company working on behalf of a large Scientific Company who have been trading for 40 years and provide scientific apparatus worldwide. A new design of one of their products required multiple thermocouples per unit and it came with some unique challenges.

Customer Pain Points

Our customer had little knowledge of thermocouples and approached us due to our years' of experience in manufacturing thermocouples and custom-built to meet our clients' application needs. Initially, we were approached with the idea of using Platinum Resistance Thermometers, but after further investigation, Pt100's were considered not suitable on this occasion.

Learn more about the difference between thermocouples and Platinum Resistance Thermometers here. They were unsure on the correct approach and what type of sensor would suit this scientific unit.

Temperature Measurement Challenges

Introducing this new product to the market posed several challenges for our customer, particularly in introducing thermocouples as the primary temperature measurement source. The application required precise monitoring at a consistent temperature range of 80–85°C.

Key constraints included extremely limited space within the unit, necessitating sensors that could bend around a tight coil while maintaining their structural integrity. Additionally, the sensors needed to have rapid response times, reliable performance, and provide accurate readings under these demanding conditions.

Another critical factor was mitigating potential noise interference from nearby electrical components, which could compromise the accuracy of the temperature measurements.

Thermocouple Sensor Solution

After in-depth conversations, tests, and analysis of the scientific unit, we offered the following solution:

Sensor Type – Mineral insulated type T thermocouple with a 1.5mm diameter stainless steel sheath terminating in a small custom sized pot seal with Teflon insulated extension cable.

Why this sensor? – Type T thermocouples were chosen for their exceptional accuracy at low temperatures, with a tolerance of ±0.5°C. The mineral insulated construction provided the necessary rigidity while allowing the sensor to be shaped to fit the application's requirements.

Given the significant bending involved, we selected a 1.5 mm diameter sheath, which gave a good balance between flexibility and durability. Additionally, a small pot seal and Teflon insulated cable were incorporated at the probe's rear. This design not only prevents moisture ingress but also ensures the cable can endure exposure to areas with potentially higher temperatures.

Results and Conclusions

After going through proof of concept, testing, and approval, this project was a tremendous success. Our client has sold over 300 units of their product globally, benefiting from a reliable and cost-effective temperature measurement solution. This collaboration has led to further projects, enabling innovations in other industries.

Further Reading

Learn more about Type T thermocouples
Explore the unique benefits and technical specifications of Type T thermocouples.

See our range of thermocouples for demanding applications
Discover designs of thermocouples for use in diverse and challenging environments.

Why calibrate thermocouples in a UKAS Accredited Laboratory?
Understand the significance of calibration in achieving precise measurements.