There are a number of sensors, such as RTDs and thermocouples, which are used for thermal control and temperature measurement all over industries. Keeping a certain temperature range is important for different processes because of the sensitivity of the materials utilised or the normal working of the process. These sensors may be employed as independent probes or can be added to a current system.
While sensors are created to withstand and sense very high temperatures, a wider variety also offers very precise output with tight tolerances. The thermocouple sensors are widely used as they fulfil most of these criteria. This post discusses these sensors as a perfect solution for temperature management in industrial activities.
Thermocouple Sensors: What Are They and How Do They Work?
Thermocouples, like other temperature sensors, assess temperature and sense thermal variations. They are composed of two dissimilar metals that are connected at two junctions, recognised as the cold and hot junctions. As the temperature all over them changes, a prospective difference or voltage is generated. This voltage is directly related to the temperature. As the temperature rises, the voltage also increases. Because of this relationship, these sensors can identify variations in voltage and associate them with temperature. Their design differs based on the system requirements; for example, some might be wired, and some may require joints or connectors. Here, the right selection of metals is important as they will directly impact the readings. These options should be tailored to your application needs, the precision level of accuracy you need, and many other factors.
What Are Different Types of Thermocouple Sensors?
Based on the metals used to manufacture the thermocouple wires, their capacity, and temperature calibration, they can be classified into different types. Here are a few pointers regarding the types and related details:
- Types J, E, N, K, and T refer to the usage of base metals.
- C, R, and S types are related to the use of noble metals.
- The calibration is based on the kind of metal used, and it is set as per the needed temperature range, in addition to the outer environmental dimensions.
- Wires with a thicker diameter can effectively use the ideal temperature range.
Advantages of Using Thermocouple Sensors
There are several benefits of using these sensors in your application.
- Initially, they provide precise output for most procedures and can measure a wide variety of activities.
- They are cost-efficient and easy to use, specifically as probes.
- They are powerful yet flexible and can be simply customised.
- They find uses in some of the most complicated and mission-critical uses like heating systems, gas turbines, electric furnaces, diesel engines, and a lot more.
- They can be manufactured as surface mount temperature sensors, which provide accurate output as the sensor is in close touch with the surface of the object, requiring temperature control.
- It is perfect for surfaces of all kinds, in spite of shape, rigidity, or size.
Quick Tips for Selecting the Best Thermocouple Sensor
Here are some factors to consider:
1. Check Operating Temperature
The range of operating temperature is the complete ambient temperature range over which it generates a linear output. This range will determine which metal combination of thermocouple you need for your application. The more the temperature range, the more it will increase your budget.
2. Consider Response Time
There are three types of response time such as Exposed, Grounded, and Ungrounded. An exposed type gives the quickest response time; yet, if the probe will be uncovered to corrosive gases or increased pressure, then an exposed type must not be utilised.
An ungrounded type gives a slow response time, but it is the best option if your application needs a thermocouple to be electronically segregated and protected by its sheath.
3. Precision
Precision is very significant for any instrument. It shows how close the measured value is to the real temperature value. This is also called tolerance or error.
4. Abrasion, Chemical or Vibration Resistance
The material of the sheath must be chemical-proof when employed in corrosive surroundings.
Final Words
If you are planning to integrate thermocouples into your system or employ them as autonomous probes, you must identify the kind that best suits your use. You can get in touch with known and authorised thermocouple sensor manufacturers and suppliers, but make sure they completely know your needs and provide the required customisations. Tempsens provides a variety of thermal probes, as well as incorporated systems for process-related temperature tracking. These systems are applicable to different industries and can be personalised to meet your particular requirements.
