2 Ways of Using Thermocouple to Measure Temperature in an Industrial Setting!

Optimized for Simplicity & Cost-Effectiveness

Optimized for Accuracy & Flexibility

Using Thermocouple to Measure Temperature

Practically Putting Thermocouples to Measure Temperature

Thermocouples are widely used temperature sensors due to their simplicity, durability, and wide temperature range capabilities. They consist of two dissimilar metal wires that generate a voltage proportional to the temperature difference between their measuring and reference junctions. This voltage can be measured and converted into temperature readings, making thermocouples a valuable tool in various industries, including manufacturing, automotive, aerospace, and scientific research. 

Using Thermocouple to Measure Temperature: 2 Different Means of Measurement

Let us explore two different means of using thermocouple to measure temperature: one optimized for simplicity and another optimized for accuracy & flexibility.

#1: Optimized for Simplicity & Cost-Effectiveness

When it comes to simple temperature measurements, thermocouples offer a straightforward & cost-effective solution. The setup typically involves a thermocouple probe, extension wires, and a temperature indicator or data acquisition system. Here’s a step-by-step guide to practically implementing this measurement solution while using thermocouple to measure temperature:

  • Select the appropriate thermocouple type: Thermocouples are available in various types, including Type K, Type J, Type T, and Type E, each with different temperature ranges and sensitivities. Choose the thermocouple type that suits your specific application requirements.
  • Prepare the thermocouple probe: The thermocouple probe is the part of the sensor that comes into direct contact with the object or medium being measured. Ensure that the probe is clean and free from any contaminants that could affect the temperature reading.
  • Connect the extension wires: Extension wires are used to connect the thermocouple probe to the temperature indicator or data acquisition system. Use extension wires made from the same thermocouple materials to maintain accuracy. Keep the wire length as short as possible to minimize signal degradation.
  • Reference junction compensation: The reference junction is the point where the thermocouple wires connect to the temperature indicator or data acquisition system. Since the reference junction is typically at a different temperature than the measurement point, it is crucial to compensate for this difference. This can be achieved by using a reference junction compensation method, such as a built-in cold junction compensator or an external reference junction temperature sensor.
  • Calibration and accuracy verification: To ensure accurate temperature measurements, it is essential to calibrate the thermocouple system periodically. This involves comparing the readings from the thermocouple with a known temperature reference source. Calibration can be performed using certified temperature standards or calibration equipment.

#2: Optimized for Accuracy & Flexibility

While the first measurement solution provides simplicity & cost-effectiveness, certain applications require higher accuracy & greater flexibility in temperature measurements. Here’s a more advanced approach for optimizing accuracy & flexibility while using thermocouple to measure temperature:

  • Use a thermocouple data logger: A thermocouple data logger is a device that combines the functions of a temperature indicator and a data acquisition system. It allows for continuous temperature monitoring and logging over extended periods. Look for a data logger that supports the specific thermocouple type and temperature range you require.
  • Implement multiple thermocouples: By employing multiple thermocouples, you can monitor temperature variations at different points simultaneously. This technique is particularly useful in applications where temperature gradients or spatial variations need to be analysed.
  • Consider thermocouple amplifiers: Thermocouple amplifiers amplify the small voltage signals generated by thermocouples, reducing noise, and improving measurement accuracy. These amplifiers can be integrated into the data acquisition system or used as standalone modules.
  • Implement cold junction compensation techniques: Compensating for the temperature difference between the reference junction and the measurement point is crucial for accuracy. Utilize advanced cold junction compensation techniques such as isothermal blocks, thermoelectric coolers, or active compensation circuits to achieve highly accurate temperature measurements.
  • Perform system validation: Regular system validation is vital to ensure accuracy & reliability. Validate the thermocouple measurement system by comparing its readings with other calibrated temperature sensors or traceable temperature references.

Using Thermocouple to Measure Temperature

So, using thermocouple to measure temperature has great industrial relevance as thermocouples provide a versatile & practical means of measuring temperature in a wide range of applications. By following the guidelines mentioned above, you can implement thermocouple-based temperature measurement solutions optimized for simplicity, accuracy, and flexibility. Whether you require a straightforward temperature reading or advanced monitoring capabilities, thermocouples offer a reliable and cost-effective solution. Always remember to consult the thermocouple manufacturer’s guidelines and best practices for your specific application to maximize accuracy and performance. Heatcon Sensors would be the best company to procure thermocouples for moving forward with your requirement.  

 

 

There Is Great Use of Thermocouples in Everyday Life for Temperature Measurement

What are Thermocouples?

Great Use of Thermocouples in Everyday Life in Temperature Measurement

Potential Issues with Thermocouples

Troubleshooting Thermocouple Issues

How to Test a Used Thermocouple Using System Tests?

Thermocouple: An Economical & Accurate Means to Measure Temperature 

Temperature measurement is crucial in various industries and applications, ranging from industrial processes to scientific research. Among the different temperature measurement devices available, thermocouples stand out as a reliable and cost-effective solution. 

What are Thermocouples?

Thermocouples are temperature sensors that generate a voltage proportional to the temperature difference between their two junctions. They are made of two dissimilar metal wires, joined together at one end, known as the hot or measurement junction, while the other end remains unconnected, forming the reference or cold junction. When there is a temperature gradient between the hot and cold junctions, a thermoelectric effect is produced, resulting in the generation of a small voltage.

Great Use of Thermocouples in Everyday Life in Temperature Measurement

Here’s the detail about the great use of Thermocouples in everyday life for different temperature measurement requirements. 

  • Wide Temperature Range: Thermocouples can measure temperatures from extremely low (cryogenic) to extremely high (up to 2,300°C or higher) ranges. This versatility makes them suitable for various industrial applications and scientific research.
  • Quick Response Time: Thermocouples offer a rapid response to temperature changes, making them ideal for dynamic processes that require real-time temperature monitoring and control.
  • Robustness: Thermocouples are highly durable and can withstand harsh environments, including high pressures, corrosive atmospheres, and mechanical vibrations. This robustness makes them suitable for challenging industrial settings.
  • Cost-Effective: Thermocouples are relatively inexpensive compared to other temperature measurement devices, such as resistance temperature detectors (RTDs) or thermistors. This cost-effectiveness makes them a popular choice, especially in applications requiring multiple temperature sensors.

Fundamentals of Thermocouples

  • Seebeck Effect: The Seebeck effect is the underlying principle behind the functioning of thermocouples. It states that when two dissimilar metals are connected and exposed to a temperature gradient, a voltage is generated across the junctions, which happens to be in direct proportion to the difference in the temperatures.
  • Thermoelectric Circuit: A thermocouple forms a thermoelectric circuit consisting of two dissimilar metal wires. The metals used and their combinations determine the thermocouple type, such as Type K, Type J, or Type T. Each type has specific temperature ranges and characteristics.

Potential Issues with Thermocouples

While thermocouples are reliable, a few problems can arise, some of which are given underneath:

  • Damage to Parts: Sheaths, protection tubes, & also thermowells, could possibly tend to fail owing to the damage done by corrosion or due to any mechanical damages.
  • Temperature Issues: The processes could possibly go over temperature, which can then expose thermoelements to temperatures higher than the anticipated limits.
  • Measurement Inaccuracies: Environmental factors, such as electromagnetic interference or poor electrical connections, can cause measurement inaccuracies. Calibration drift over time is also a concern.
  • Cold Junction Compensation: The reference or cold junction must be maintained at a known temperature to ensure accurate measurements. Failure to compensate for the cold junction temperature can lead to errors.
  • Thermocouple Breaks: Physical damage to the thermocouple wires or junctions can cause open circuits and result in incorrect temperature readings.
  • Human Errors: Human errors could also be the causative factors. Controls might be set incorrectly; connections might be made imperfectly, & actions might be inappropriate for the operating conditions could possibly be inadvertently applied. Instrument pooling along with training & accountability are common ways to combat such mistakes.

 

Troubleshooting Thermocouple Issues

  • Check Connections: Ensure that the thermocouple connections are secure and free from corrosion or loose contacts.
  • Calibrate Regularly: Periodic calibration against a known temperature source helps identify and correct any calibration drift or inaccuracies.
  • Cold Junction Compensation: Use a cold junction compensator, such as a thermocouple reference table or a dedicated temperature transmitter, to accurately compensate for the cold junction temperature.

Testing a Used Thermocouple

  • Visual Inspection: Examine the thermocouple for physical damage, such as broken wires, loose connections, or signs of wear and tear.
  • System Tests: Connect the thermocouple to a known temperature source and compare the displayed temperature with the reference value. 

How to Test a Used Thermocouple Using System Tests?

Testing a used thermocouple using system tests involves verifying its functionality and accuracy within a temperature measurement system. Here are the steps to perform a system test:

  • Gather Required Equipment: You will need the following equipment for testing:
    • Known Temperature Source: This can be a calibrated reference thermometer or a temperature chamber with a known temperature.
    • Portable Temperature Indicator: This happens to be quite a useful tool for troubleshooting thermocouple systems. It can work with 2 or more varied types of thermocouples, and some offer an “output” feature that produces an electrical output for simulating the thermocouple operating at a certain temperature(s).
    • Thermocouple Reference Tables: Obtain reference tables specific to the thermocouple type you are testing.
  • Prepare the Setup
    • Connect the used thermocouple to the temperature measurement system or a signal conditioner that converts the thermocouple voltage to a measurable millivolt signal.
    • Do ensure that all of the connections are well-secure & thoroughly tight.
  • Test Procedure
    • Set up the known temperature source to a specific temperature within the thermocouple’s range.
    • Connect the positive (hot) junction of the thermocouple to the known temperature source and the negative (cold) junction to the reference temperature or ambient temperature.
    • Use the tester to measure the voltage generated by the thermocouple. 
    • Compare the measured voltage with the expected millivolt value from the thermocouple reference tables for the given temperature. Consider the polarity and correct any signs accordingly.
    • Calculate the temperature reading using the reference tables if the measured voltage matches the expected value. Ensure that the calculated temperature aligns with the known temperature source.
  • Evaluate the Results
    • If the measured voltage and calculated temperature closely match the expected values within an acceptable tolerance, the thermocouple is functioning correctly.
    • If there are significant deviations from the expected values, it indicates potential issues with the thermocouple. Further troubleshooting or calibration may be necessary.

Procure the Best Quality Thermocouples from Heatcon

So, there is quite a good amount of use of thermocouples in everyday life. Testing a used thermocouple using system tests helps ensure its accuracy and reliability in temperature measurements. If any discrepancies or abnormalities are identified, it is advisable to consult the manufacturer or a qualified technician for further inspection and maintenance. You can be sure of getting the best service if you procure them from Heatcon Sensors, a company whose team is going to assist you very well!

 

 

Let Us Explore the Use of Thermocouples in Space

Principles of Operation

Thermocouples in Space

Applications of Thermocouples in Space

Contact Heatcon for Procuring Thermocouples

 

Spacecraft are marvels of engineering, designed to endure extreme conditions while exploring the cosmos. To ensure the safety and efficiency of these vehicles, precise monitoring of temperatures is essential. One of the primary tools employed for this purpose is the thermocouple. Let us explore the use of thermocouples in space, their principles of operation, and their vital role in space exploration.

Understanding Thermocouples

Thermocouples are temperature sensors that generate electrical voltage proportional to the temperature difference between their junctions. They rely on the Seebeck effect, where two dissimilar metals joined together at their ends produce a measurable voltage when exposed to temperature variations. This voltage can be measured and used to accurately determine the temperature.

Principles of Operation

Thermocouples in space are typically composed of two different metal wires, known as thermoelements. Common thermocouple types used in space missions include Type K, Type J, and Type T. These thermoelements are connected at one end to form the measurement junction and extend to the termination junction, which is maintained at a known reference temperature. The temperature difference between the measurement junction and the termination junction generates a voltage that is read by instruments on board the spacecraft.

Thermocouples in Space

Managing temperature is critical in the space segment, and thermocouples in space happen to be the essential tools in this field. Such thermocouples have been designed in such a way that they are used for systems on board satellites as well as space probes. Applications tend to include temperature control of the chemical propulsion catalyst bed and the temperature of particular ISS science test programs. These are even suited for using in the skin measurements for re-entry & special rakes for gas flow measurement in the launch vehicles. Such thermocouples have been usually installed in spacecraft engines for regulating the system temperature as well as for recording & monitoring system temperature behaviour. Thermocouple wires are available in several different diameters, that too with alternative outer sheaths depending upon the range of temperatures.

Applications of Thermocouples in Space

  • Temperature Monitoring: Thermocouples play a vital role in measuring temperatures within various components of a spacecraft. They can be employed in critical systems such as propulsion, power generation, life support, and electronics. Monitoring temperature variations helps engineers and mission controllers ensure the spacecraft operates within safe and optimal temperature ranges, preventing damage to sensitive equipment.
  • Thermal Protection: Spacecraft experience extreme temperature fluctuations depending on their location, such as the intense heat during atmospheric re-entry or the extreme cold in deep space. Thermocouples aid in monitoring and controlling the thermal protection systems, such as heat shields and thermal blankets, to ensure they adequately shield the spacecraft from these harsh environments.
  • Engine Performance: Monitoring the temperature of rocket engines is crucial for their efficient operation. Thermocouples placed near the combustion chambers and nozzles provide real-time temperature data, allowing engineers to optimize engine performance, detect anomalies, and avoid overheating or underperformance.
  • Solar Panel Efficiency: Solar panels are the primary source of power for most spacecraft. Thermocouples in space can be used to monitor the temperature of these panels, enabling engineers to assess their efficiency and performance. This information helps optimize power generation and maintain the panels within their operational temperature range.
  • Heat Dissipation: Thermocouples in space assist in monitoring the dissipation of heat from various components, ensuring that excess heat generated during spacecraft operations is managed effectively. This information aids in designing efficient cooling systems, preventing overheating, and ensuring long-term reliability.

Contact Heatcon for Procuring Thermocouples

Thermocouples in space are indispensable tools for temperature monitoring in spacecraft. Their ability to accurately measure temperature variations in extreme environments ensures the safety, efficiency, and longevity of space missions. By employing thermocouples in critical systems, engineers & mission controllers can effectively manage temperature-related challenges and ensure the success of space exploration endeavours. As technology advances, thermocouples will continue to play a crucial role in pushing the boundaries of human knowledge and exploration beyond Earth. If you are looking to procure such thermocouples, then Heatcon can be your ideal go-to destination!

 

 

Understanding the Use of Thermocouples and the Automotive Industry

Disk Temperature & Brake Block Measurement

Measurement of Racing Cars’ Disk Brake Callipers

Measuring Exhaust Gas Temperature

Measuring Temperature on the Simulated Exhaust

Thermographic Pyrometry & Infrared Pyrometry 

Oven Temperature’s Profiling System

Optimization of Air Conditioning 

Temperature Measurement, Relative Humidity Measurement, & Measuring Dew Point

 

Common Automotive Testing

Multi-location measurement of temperatures is quite usual in the process of automotive testing. For the measurement of thermocouples in the brakes, the wire bundle of the thermocouple could speedily attain a stage wherein the diameter starts impacting the structural integrity.

Disk Temperature & Brake Block Measurement

Temperature of the disk surface directly tends to affect the braking performance, & thus, temperature measuring systems tend to be significant in developing effective braking systems and for continuously monitoring the final product. The measuring systems have to record extremely variable temperature ranges occurring on the brake discs & pads. Usually, thermocouples tend to be fixed in the brake disk(s) & within the brake pad(s), as well as collector rings that tend to be integrated inside the circuit. Optical measuring systems like pyrometers, thermal cameras, & thermal scanners tend to be also utilised in the process of brake testing. The surface pressure distribution inside the brake pad(s) could even be revealed with the help of thermocouple system(s).

Measurement of Racing Cars’ Disk Brake Callipers

Temperature extremes could possibly change the brakes’ crystal structuring of the disk surface & also lead to crack the damage done to the surface. The deflection of the brake disk considerably affects the comfort of the brakes as the driver feels, because it’s transported into the steering-wheel as well as the brake system. Likewise, the friction(µ) coefficient of the alterations while the temperatures change lead to brake torque variations (also called as fading). Therefore, sound knowledge of the temperature gradient inside the brake disk as well as the brake pad is crucial.

Measuring Exhaust Gas Temperature

Turbocharger happens to be the significant element of the modern engine. It has superior rotational speed & comes in various shapes as well as sizes, and therefore, turbo chargers now happen to be complex subsystems in themselves. This is crucial for shielding the turbo from extreme temperatures during its service life because it’s generally exposed to supreme temperature exhaust stream. The temperature sensor with a speedy response happens to be a vital component of the control loop.

Measuring Temperature on the Simulated Exhaust

In automotive testing, manufacturers are required to test all the elements to their limits which they may encounter during the shelf life of any automobile. A large number of polymer elements tend to be found inside the modern automobile vehicles & they need to be subjected to several tests including the heat stress testing in case of they are being in close proximity to any heat source. For example, the bumper happens to be situated next to the engine’s exhaust gas system, wherein, the temperatures can attain quite extreme highs. So, the material of the bumper needs to be tested to ensure that it does not affect the increased temperature adversely of the exhaust, which may lead to polymer’s thermal degradation or even a fire (in a worst-case-scenario). In such state-of-the-art testing processes, the exhaust system tends to be subjected to simulated heat from a custom-made electrical heater, therefore escaping the utilization of the car engine.

Thermographic Pyrometry & Infrared Pyrometry 

The utilisation of infrared pyrometry & thermographic pyrometry for analysing heat distribution in the engines of the cars tends to be highly convenient for temperature measurements (that are non-contact) to test automotive engines and during any common inspection application.

Oven Temperature’s Profiling System

Automotive painting & automotive coating depends largely on the significant controlling of the temperatures so that it obtains the best paint finish in the material’s curing operation.

Optimization of Air Conditioning 

Air conditioning is quite significant inside the modern vehicles; there’re efficiency needs for satisfying, and also regulations by the government.

Temperature Measurement, Relative Humidity Measurement, & Measuring Dew Point

Environment control is of quite high significance for guaranteeing the greatest level of material quality & best performance during the engine tests for the automotive industry.

Heatcon Sensors Provides the Best Range of Products

If you are looking for thermocouples and the automotive industry is what you are dealing with, then the best spot for you is Heatcon Sensors.

 

 

A Comprehensive Guide on the Use of Thermocouple in Power Generation

Thermocouple In Power Generation

Use of Thermocouples in Power Generation

Temperature Sensors for the Solar Industry

Temperature Sensors for Waste-to-Energy

 

Temperature monitoring plays a critical role in various industries, including power generation, solar energy, and waste-to-energy. Accurate temperature measurement ensures safe and efficient operations, enabling proactive maintenance and optimizing energy production. 

Key Advantages of Thermocouples

  • Wide temperature range
  • Quick response time
  • Robust & durable
  • Accuracy & linearity
  • Cost-effectiveness

Thermocouple In Power Generation

Let us delve into the use of thermocouple in power generation

  • Resistance Temperature Detectors (RTDs): RTDs are widely used in power plants due to their high accuracy and stability. They consist of a wire wound around a ceramic or glass core. RTDs offer excellent linearity and can withstand high temperatures, making them suitable for monitoring critical equipment such as turbines, generators, and transformers.
  • Thermocouples: Thermocouples are temperature sensors based on the Seebeck effect, where a voltage is generated across the junction of two dissimilar metals. They are rugged, cost-effective, and can operate across a wide temperature range. In power generation, thermocouples are commonly used for temperature measurements in exhaust gas systems, boilers, and steam lines.

Use of Thermocouples in Power Generation

Thermocouples are particularly well-suited for power generation applications due to their ability to withstand extreme temperatures and harsh environments. They are used in various areas, including the ones given below:

  • Exhaust Gas Temperature Monitoring: Thermocouples measure the temperature of exhaust gases, enabling efficient combustion control and monitoring of emissions. They provide valuable data for optimizing fuel-air ratios, ensuring clean and efficient energy generation.
  • Boiler Temperature Monitoring: Thermocouples placed within boilers help regulate temperature, preventing overheating or insufficient heating. This ensures safe and efficient steam generation, which is crucial for power plant operations.
  • Steam Turbine Monitoring: Power plant thermocouples monitor steam temperature at various stages of the turbine, helping operators optimize efficiency and prevent damage due to overheating.

Temperature Sensors for the Solar Industry

  • Solar Radiation Sensors: These sensors measure the intensity of solar radiation to assess the amount of energy available for solar panels. They help optimize panel placement and maximize energy production.
  • Photovoltaic (PV) Module Temperature Sensors: PV module temperature sensors monitor the temperature of solar panels, ensuring they operate within optimal temperature ranges. Excessive heat can reduce panel efficiency, while low temperatures can affect performance. Monitoring helps identify and rectify issues promptly.

Temperature Sensors for Waste-to-Energy

A couple of waste treatment processes being utilised for converting waste to energy, including gasification & pyrolysis. Fuel sources for waste-to-energy plants are renewable woody biomass, fertilizers, and household waste.

  • Gas Temperature Sensors: Waste-to-energy plants often use temperature sensors to monitor the temperature of flue gases and combustion chambers. This data enables efficient waste incineration, improves energy recovery, and ensures compliance with environmental regulations.
  • Waste Temperature Sensors: These sensors monitor the temperature of waste streams, helping operators maintain optimal operating conditions. Monitoring waste temperatures ensures efficient energy extraction while minimizing harmful emissions.

Procure Temperature Sensors from Heatcon 

Temperature sensors are indispensable in power generation, the solar industry, and waste-to-energy applications. From the use of thermocouple in power generation as power plant thermocouples to solar radiation sensors and waste temperature sensors, each type serves a specific purpose in optimizing energy production, enhancing safety, and improving environmental performance. By leveraging accurate temperature measurements, these industries can achieve higher efficiency, reliability, and sustainable operations. For procuring the same, you can always knock at the quality product gallery of Heatcon Sensors.

 

 

Know in Detail about Thermocouples and Use in the Defence Sector

Applications of Thermocouples in the Defence Sector

Sensors Play a Crucial Role in the Defence Sector

Various Defence Equipment Utilizes Sensors for Diverse Purposes

Difficulties for Temperature Sensors in Defence Applications

Thermocouples and Use in the Defence Sector

Temperature measurement is a critical aspect of various industries, including the defence sector, where precise monitoring and control are essential. In these high-stakes environments, accuracy, reliability, and durability are paramount. One technology that has proven its worth time and again is the thermocouple. Let us explore the fundamentals of thermocouples and use in the defence sector.

Applications of Thermocouples in the Defence Sector

Following are the applications of thermocouples and use in defence sector:

  • Aircraft Engines: In military aircraft, thermocouples play a crucial role in monitoring engine performance and preventing overheating. They measure temperatures in various engine components such as turbine blades, exhaust systems, and combustion chambers, helping to optimize engine efficiency and detect potential failures.
  • Missile Systems: Thermocouples are used in missile systems for temperature monitoring during launch, flight, and propulsion. They ensure that critical components, such as rocket motors and guidance systems, remain within safe temperature limits, enhancing the reliability and performance of the missiles.
  • Armoured Vehicles: Thermocouples are employed in armoured vehicles to monitor engine temperature, gearbox performance, and exhaust systems. They enable the detection of abnormal temperature levels, preventing engine damage and ensuring optimal operation under challenging conditions.
  • Naval Applications: Thermocouples are utilized in naval vessels for various purposes, including monitoring the temperature of engines, propulsion systems, and critical machinery. They help ensure reliable operation and prevent catastrophic failures in demanding maritime environments.
  • Ammunition Handling: Thermocouples play a vital role in the defence sector’s ammunition handling processes. They help monitor and control the temperature of storage facilities, ensuring that ammunition remains within safe limits to prevent accidental detonations.

Sensors Play a Crucial Role in the Defence Sector

All machines being utilised in the defence segment go through numerous extremes, including high vibrations, high temperatures, strong impacts, as well as high accelerations. Temperature sensors tend to be cost-efficient in ensuring machine reliability. Sensor technology is a way of achieving super-efficient military operations that are done by measuring high temperatures, including hot spots in internal combustion & turbine engines. RTDs or Resistance-Temperature-Detectors have been designed for operating in extreme temperatures as low as -40 F & as high as 300 F as they tend to give much accurate, stable, as well as reliable sensor data. They work by combining the resistance of the cell with the core’s temperature. They range from 2-wire to 4-wire RTDs, and these are quite reliable.

Military vehicle internal systems are always exposed to harsh temperatures, dirty environments as well as high shocks & vibration loads, yet they need maximum performance for lengthy periods with minimal maintenance. These temperature sensors are rugged in nature & provide fast temperature measurement solutions, making them suitable for extreme temperatures, RFI, EMI & vibrations. TA sustainability goes a long way, because the working environment of the Ministry-of-Defence is not the one where the team gets access to services like recurrent repairs.  Thermocouples are also useful for protection as they are quick temperature sensitive solutions. Processes being worked in protection need pressure control, vibration control as well as temperature control. Sensor data is useful to know the elements of a machine so that it can be controlled to avoid disasters and to ensure a longer shelf life of the machine.

Various Defence Equipment Utilizes Sensors for Diverse Purposes

Temperature sensors of aerospace & defence sectors have been utilized in various critical systems, like motion control & liquid cooling. Although most of these could possibly harm the utilization of temperature sensors in defence, still most of their machines require the use of sensors. The examples are military vehicles, marines, aircraft, & space vehicles etc. Heavy military vehicles have been seen to be evolved into sophisticated & highly durable vehicles, which operate in all sorts of extremes and all types of terrain conditions. Their internal systems tend to be exposed to tough environments, extremes, dirty environments, high shocks & vibration loads, but they still need long-term peak performance that too with little maintenance. 

Difficulties for Temperature Sensors in Defence Applications

Some of these challenges include the following:

  • Overheating Prevention: Temperature sensors help monitor and control the temperature of critical components in defence equipment, such as engines, aircraft avionics, and weapon systems. They ensure that temperature limits are not exceeded, preventing overheating, component degradation, and potential failures.
  • Thermal Management: Defence systems generate substantial heat, and temperature sensors assist in thermal management by monitoring heat dissipation, airflow, and cooling mechanisms. This helps maintain optimal operating conditions and prevents damage due to excessive heat build-up.
  • Cold Weather Operations: Temperature sensors are crucial in extreme cold weather conditions. They monitor equipment and systems to prevent issues like freezing, icing, and decreased performance, ensuring reliable operation in Arctic environments.
  • Equipment Performance Optimization: Temperature sensors are used to monitor and optimize the performance of defence equipment. By tracking temperature variations, adjustments can be made to maximize efficiency, minimize energy consumption, and enhance overall operational effectiveness.

There Are No Better Thermocouples Than the Ones with Heatcon Sensors!

So, we have talked about Thermocouples and use in the defence sector. In conclusion, thermocouples have become indispensable tools in the defence sector due to their exceptional temperature measurement capabilities and robustness in challenging environments. As technology advances, thermocouples will evolve further, ensuring the safety and efficiency of critical systems in the defence sector for years to come. You can procure the same from Heatcon’s wonder range!

 

 

Choosing between RTD or Thermocouple for an Industrial Application

When to Use an RTD Sensor?

Advantages of RTD Sensors

Disadvantages of RTD sensors

Thermocouples

When to Use a Thermocouple Sensor?

Advantages of Thermocouples

Disadvantages of Thermocouples

RTD or Thermocouple

 

Temperature measurement is an important aspect of process control and industrial applications. RTD (Resistance Temperature Detectors) and Thermocouples are two types of temperature sensors commonly used in various industries. Both these types of sensors can possibly provide accurate temperature measurements, but the selection between RTD or Thermocouple depends on various factors such as accuracy, temperature range, cost, and application requirements. RTD and Thermocouple sensors work on different principles of operation, which results in differences in their accuracy, response time, and range of temperature measurement.

RTDs

RTD sensors are made of one metal (that is typically platinum/nickel/copper) with a known temperature-resistance relationship. The resistance of the metal changes as temperature changes, and this change in resistance is measured by an external circuit to determine the temperature. RTD sensors provide high accuracy (typically ±0.1°C), and their temperature range can be from -200°C to 850°C, depending on the type of metal used. 

When to Use an RTD Sensor?

RTD sensors are ideal for applications that require high accuracy and stability over a wide range of temperatures. They are commonly used in applications such as food processing, pharmaceuticals, and aerospace industries. RTDs are also suitable for applications where a high degree of repeatability and reliability is required, and where long-term stability is significant.

Advantages of RTD Sensors

  • High accuracy: They provide a high level of accuracy, typically ±0.1°C.
  • Stability: RTDs have excellent long-term stability and repeatability, making them suitable for applications that require high accuracy over long periods of time.
  • Linear response: Such sensors have a linear response to changes in temperature, making them easier to calibrate and more accurate over a wide range of temperatures.
  • Low drift: RTDs have a low drift, meaning that the accuracy of the sensor does not change significantly over time.
  • Wide temperature range: They can measure temperatures from -200°C to 850°C, depending on the type of metal used.

Disadvantages of RTD sensors

  • Cost: RTDs are generally more expensive than thermocouples.
  • Slow response time: These sensors have a slower response time than thermocouples, making them unsuitable for applications that require fast response times.
  • Fragility: Such sensors are more fragile than thermocouples and can be easily damaged if mishandled.

Thermocouples

Unlike RTDs, Thermocouples are made of two different metals (typically chromel & alumel) that produce a voltage when exposed to a temperature difference. The magnitude of the voltage is directly proportional to the temperature difference between the two ends of the thermocouple. Thermocouples are less accurate than RTD sensors, with an accuracy typically ranging from ±1 to ±10°C. However, they have a wider temperature range of -200°C to 2300°C.

When to Use a Thermocouple Sensor?

Thermocouples are suitable for applications that require a wide range of temperature measurement and fast response times. They are commonly used in applications such as HVAC systems, industrial furnaces, and laboratory experiments. Thermocouples are also suitable for applications where the sensors need to be small and where a low cost is essential.

Advantages of Thermocouples

  • Wide temperature range: They can measure temperatures from -200°C to 2300°C, making them suitable for a wide range of applications.
  • Fast response time: Thermocouples have a fast response time, making them suitable for applications that require fast temperature measurement.
  • Cost: They are generally less expensive than RTD sensors.
  • Durability: These are more durable than RTD sensors and can withstand rough handling and harsh environments.

Disadvantages of Thermocouples

  • Lower accuracy: The accuracy of thermocouples is generally lower than that of RTDs, typically ranging from ±1 to ±10°C, depending on the type of thermocouple.
  • Non-linearity: The output voltage of thermocouples is not linearly proportional to temperature, which can make calibration and accurate measurement difficult, especially at lower temperatures.
  • Drift: The output of thermocouples can drift over time, which can affect their accuracy and require frequent recalibration.
  • Limited lifespan: The lifespan of thermocouples is generally shorter than that of RTDs due to their construction and the effects of aging.
  • Signal interference: The output of thermocouples can be affected by electromagnetic interference from nearby electrical equipment or wiring, which can affect the accuracy of measurements.

RTD or Thermocouple

While selecting between RTD or Thermocouple during the lookout for an appropriate temperature sensor depends on various factors such as the accuracy required, temperature range, response time, and cost. Both RTDs and thermocouples have their advantages and disadvantages, and it is important to consider these factors when selecting the appropriate sensor for a particular application. 

Come to Heatcon for Procuring the Best Range of Such Products 

If you are looking for an RTD or Thermocouple, Heatcon can be the best place for you to make such a selection for the appropriate sensor for a specific industrial application.

 

 

Factors That Direct the Cost of Temperature Sensors

Cost of Temperature Sensors

Factors Directing the Cost of Temperature Sensors

Heatcon Can be Your Go-To Destination for Procuring the Most Ideal Temperature Sensor(s)

Temperature Sensors

Temperature sensors are electronic devices that measure and monitor the temperature of various objects and environments. They play a vital role in a variety of industries, including HVAC, food processing, automotive, healthcare, and aerospace. 

Cost of Temperature Sensors 

Buyers’ biggest concern seems to be the price front, as most of them assume that all types of temperature sensors cost the same, which is not the case! This is because all industrial applications of temperature sensors are not the same, so all temperature sensors cannot be created as equal, therefore their prices tend to vary. The prices of RTDs & thermocouples are largely determined by different factors, like the applications for which they might be used for as well as the temperatures at which they will be operating. For example, the temperature sensors which measure the air temperature in a particular room would vary from the one that is utilised for measuring 1400 degree Celsius in an industrial heat treatment process. It all means that getting the right tool for the job is important!

Factors Directing the Cost of Temperature Sensors

The cost of temperature sensors can vary greatly, depending on several factors, as explained below:

  • Market Application: One of the most significant factors driving the cost of temperature sensors is the market application. Sensors used in high-end applications such as aerospace and medical equipment have higher accuracy, precision, and reliability requirements, which drives up the cost. Sensors used in less critical applications, such as household appliances or automotive engines, may have lower accuracy and precision requirements, resulting in lowering the costs.
  • Temperature Measuring Range: Temperature sensors are designed to measure temperatures within specific ranges. The wider the temperature measurement range, the more complex the sensor construction needs to be, which increases the cost. For example, a sensor designed to measure temperatures from -40°C to 125°C will be more expensive than a sensor that measures temperatures from 0°C to 50°C.
  • Hazardous Locations: Sensors used in hazardous locations, such as petrochemical plants, must meet specific safety requirements. They need to be explosion-proof, intrinsically safe, or have other protective measures to prevent accidents. This additional safety equipment adds to the overall cost of the sensor.
  • Construction of the Sensors: The cost of temperature sensors also depends on the sensor’s construction. Some sensors are designed to be small & lightweight, while others are intended to be durable and withstand harsh environments. The type of materials used to construct the sensor, such as stainless steel or plastics, can also affect the cost.
  • Options & Accessories: The cost of temperature sensors can vary based on the additional options and accessories that come with them. For example, sensors with wireless connectivity, calibration certificates, or custom-designed probe configurations can be more expensive than basic models.

Heatcon Can be Your Go-To Destination for Procuring the Most Ideal Temperature Sensor(s)

Overall, the cost of temperature sensors depends on several factors, including market applications, temperature measurement range, hazardous location approvals, sensor construction, and options and accessories. It is always essential to consider these factors when selecting a temperature sensor to ensure you get the most suitable sensor for your application while also staying within your budget. You can reach out to Heatcon Sensors for procuring the best products in this regard.

 

 

Here’s a Quick Guide to Use a Thermocouple!

About Thermocouple Sensors

Types of Thermocouples

Other Categorizations of Thermocouples

Selecting the Right Thermocouple

Guide to Use a Thermocouple

Here’s a quick guide to use a thermocouple. First and foremost, it is important to know what a thermocouple is and for what application you need it! By knowing the application, you can start using the thermocouple in the correct way. 

About Thermocouple Sensors

Thermocouple sensors are the tools utilised for measuring temperatures; they use 2 different types of metal wires. These are connected at 1 of the ends & are connected to the thermocouple’s thermometer at the other. The thermocouple sensor along with the thermometer allows us to send signals to each other; and, if configured correctly, can provide accurate temperature measurement(s). The temperature range is quite wide and can reach up to 1250 degree Celsius. This surely depends on what sort of thermocouple being used, some do not even reach that particular range & some could also detect boiling temperatures below -200 degree Celsius. Thermocouple sensors are useful in instant temperature detection. They’re even known for versatility as they’re quite commonly used in many applications. They’re even available in various types of models. It’s also quite significant to understand that each model type has its own basic structure and how the devices work. You need to choose the right type of thermocouple sensor that is most suitable for your application.

Types of Thermocouples 

  1. Beaded Wire Thermocouple: This happens to be one of the simplest forms of thermocouples. This has 2 thermocouple wires that are connected through a welded bead. That’s the reason why it’s called a wire-thermocouple. Though the thermocouple’s welded bead tends to be exposed, still it’s limited to only a few applications. Do not use this beaded thermocouple in a liquid environment or immerse it in liquid, as it can corrode/oxidize the thermocouple’s compound. Making use of metal surfaces can sometimes be difficult. Often, metal surfaces used in ground power systems have a non-direct connection with the power system, which can affect thermocouple’s measurements. In other words, such thermocouples are ideal for gas temperature measurement. The reason being their smaller size and faster response time.  
  2. Thermocouple Sensor: These work by placing a thermocouple wire inside a metal tube. This tube is known as the sheath. The probe sheath is constructed out of standard stainless steel & Inconel®, which supports higher temperatures than stainless steel. However, stainless steel is generally preferred over Inconel due to its broader chemical compatibility. If very high temperatures are involved, other exotic shell materials are even available. The only thing different is the tip of the thermocouple probe. 
  3. Surface Probe: The most difficult part of thermocouples is the measurement of a solid surface. Most temperature sensors cannot perform this task. So, to get an accurate measurement, the entire measuring area must be connected to the surface. Rigid sensors & rigid surfaces are difficult to work with. Such types of thermocouples are ideal for surface measurement because they can even be built into a rotary mechanism.

How Does It Work?

When 2 conductors are made of different metals, with 1 of the ends connected, & when heated, a constant current flows in the thermoelectric circuit. Now, if the said circuit somehow gets broken towards the middle of it, then the open-circuit-voltage (which is the Seebeck-voltage) happens to be a function of the junction’s temperature & lies among the 2 metal compounds. So, this means that when the junction of two metals is heated or cooled, a voltage is created that can be inversely correlated with temperature. The measurement works like this. 

Other Categorizations of Thermocouples 

There are several characteristics as well as different varieties of thermocouples, each of these types tend to have different characteristics. They are also having different combinations of metals and/or calibration(s). The most common are “base-metal-thermocouples.” The most common types are N, T, E, E J & K. In addition, there’re also high temperature calibrations, also known as “Noble-Metal-Thermocouples,” which happen to be types R, S, C and GB. Various sorts of thermocouples have distinct calibration ranges as well as varied metal combinations/alloys. Each of these fittings tend to have different temperatures as well as environment. The max temperature can vary depending on the wire diameter used in the thermocouple. Even though the calibration tends to determine the temperature-range, the max-temp range is limited as well. This is due to the diameter of the thermocouple wire. The finer the thermocouple wire, the lower the chance of reaching the entire temperature evenly. A K-type thermocouple is known as a general-thermocouple.

Selecting the Right Thermocouple

There are 3 different styles in toto, which are ungrounded, grounded, & exposed. 

  1. The grounded end of the thermocouple contacts the enclosure wall, which when in place, provides a faster response time, and is most sensitive to electrical ground loops. 
  2. For an ungrounded connection, the thermocouples are separated from the sheath’s walls by insulating layers. 
  3. The thermocouple’s end extends outside the enclosure wall with an open junction. These open junction thermocouples are best suited for measuring air. 

Buy Thermocouples from Heatcon Sensors

Choose the right thermocouple by understanding the guide to use a thermocouple provided above; else call Heatcon for making the right choice in this regard!

 

 

Underlining the Practical Application of Thermocouples

Practical Application of Thermocouples

Buy the Best Range of Thermocouples from Heatcon Sensors

 

Thermocouples are widely used in various industries to measure temperature accurately and reliably. A thermocouple is a device that measures temperature based on the voltage generated by the temperature difference between two different metals or alloys. The most common practical application of thermocouples in the industry includes their use in food applications, extruders, low-temperature processes, furnaces, and molten metals.

Practical Application of Thermocouples

  • Thermocouples in Food Applications: The food industry widely uses thermocouples for food safety, product quality, and process control. Thermocouples are used to monitor and control the temperature of food products during cooking, processing, and storage. Thermocouples can be placed in ovens, fryers, grills, and other cooking equipment to ensure that the food reaches the correct temperature and stays at that temperature for the correct duration to kill bacteria and ensure safety. They are also used in refrigeration units to ensure that food is stored at the correct temperature to prevent spoilage and maintain product quality.
  • Thermocouples Are Used in Extruders: Thermocouples are commonly used in extruders to measure the temperature of the molten plastic or rubber during the manufacturing process. Extruders are used to create various plastic and rubber products such as tubing, seals, and gaskets. Accurate temperature control is critical to achieving the desired product quality and consistency. Thermocouples are used to monitor and control the temperature of the extrusion barrel and the extruded product to ensure that the temperature is consistent throughout the process.
  • Thermocouples Used for Low-Temperature Processes: Thermocouples are also used in low-temperature processes such as cryogenic cooling and refrigeration. In these applications, thermocouples are used to measure the extremely low temperatures of the refrigerant and ensure that the system is functioning correctly. They are also used in laboratory and medical applications, such as in freezers and refrigerators, to monitor the temperature and ensure that samples and medications are stored at the correct temperature.
  • Thermocouples Are Utilized in Furnaces: Thermocouples are commonly used in industrial furnaces to measure and control the temperature of the furnace. Furnaces are used in various industries such as steel, glass, and ceramics manufacturing, where high-temperature processes are required. Thermocouples are used to monitor and control the temperature of the furnace to ensure that it remains within the desired temperature range and to prevent overheating and damage to the furnace.
  • Use of Thermocouples for Molten Metals: Thermocouples are also used in the metal industry to measure the temperature of molten metal during the manufacturing process. Accurate temperature control is critical to achieving the desired product quality and consistency in the production of metal products such as casting and forging. Thermocouples are used to monitor and control the temperature of the molten metal to ensure that it remains within the desired temperature range and to prevent overheating and damage to the furnace.

Buy the Best Range of Thermocouples from Heatcon Sensors

In conclusion, thermocouples are widely used in various industries to measure temperature accurately and reliably. Accurate temperature control is critical to achieving the desired product quality and consistency in these applications, and thermocouples are a reliable and cost-effective solution for temperature measurement and control. You can buy the best range of thermocouples from the industry-leader, Heatcon.

 

 

Talking of the Application of Thermocouple in Industry

Contact Heatcon to Procure High-Quality Thermocouples

Thermocouples are temperature sensors that are widely used in various industrial applications due to their reliable performance and versatility. They are made of two different metals or alloys that produce a voltage when heated, which is proportional to the temperature being measured. This voltage is used to determine the temperature of the material or environment being monitored. 

Application of Thermocouple in Industry

Let’s explore four industrial applications for thermocouples:

  1. In the Food & Beverage Industry: In the food and beverage industry, thermocouples are used to monitor and control the temperature of various processes, including pasteurization, sterilization, cooking, and cooling. They are also used to monitor the temperature of food storage facilities, such as refrigerators and freezers. In addition, thermocouples are used to monitor the temperature of food during transportation to ensure that it stays within safe temperature limits. By using thermocouples in these applications, food and beverage companies can ensure that their products are safe to consume and meet regulatory requirements.
  2. In Metallurgy: In metallurgy, thermocouples are used to monitor the temperature of furnaces, ovens, and other heat treatment equipment. They are also used to monitor the temperature of molten metal and alloys during casting and forging processes. By monitoring the temperature of these processes, metallurgists can ensure that the material is processed correctly and that it meets the desired specifications.
  3. In Plastic Manufacturing: In plastic manufacturing, thermocouples are used to monitor the temperature of the extruder barrel and die, as well as the temperature of the plastic melt. The temperature of the plastic melt is critical to the quality of the final product, as it affects the viscosity and flow properties of the plastic. By using thermocouples to monitor the temperature, plastic manufacturers can ensure that their products meet the desired quality and performance specifications.
  4. In Pharmaceutical Manufacturing: In pharmaceutical manufacturing, thermocouples are used to monitor the temperature of various processes, including drying, sterilization, and lyophilization (freeze-drying). They are also used to monitor the temperature of storage facilities, such as refrigerators and freezers, to ensure that pharmaceutical products are stored within safe temperature limits. By using thermocouples in these applications, pharmaceutical companies can ensure that their products are safe, effective, and meet regulatory requirements.

Contact Heatcon to Procure High-Quality Thermocouples

In conclusion, thermocouples are essential sensors in many industrial applications, including the food & beverage industry, metallurgy, plastic manufacturing, and pharmaceutical manufacturing. By using thermocouples to monitor temperature, companies can ensure that their products meet the desired specifications and regulatory requirements, as well as ensure safety and quality. You can contact Heatcon Sensors to procure the best-quality thermocouples.

 

 

About the Use of Thermocouples in Washer Disinfectors

Other Medical Applications of Thermocouples

Thermocouples are temperature sensors that work by measuring the voltage difference between two wires made of different metals. When the temperature changes, the voltage produced by the wires also changes, allowing the thermocouple to measure the temperature accurately.

Thermocouples Are Commonly Utilised in Washer Disinfectors

Thermocouples are commonly used in washer disinfectors for heat treatment. These devices are used to measure the temperature of the water or steam used in the washer disinfector, which is critical in ensuring that the instruments being sterilized are exposed to the correct temperature for the correct amount of time. In a washer disinfector, thermocouples are typically installed in the chamber where the instruments are placed, as well as in the water or steam supply lines. This allows for real-time monitoring of the temperature of the water or steam as it is circulated through the chamber, ensuring that the proper temperature is maintained throughout the entire cycle of sterilization.

The thermocouples used in washer disinfectors are typically designed to withstand high temperatures and are constructed from materials such as platinum, tungsten, or nickel alloys. They are also designed to be resistant to corrosion and contamination, ensuring that they provide accurate readings even after prolonged use. Overall, the use of thermocouples in washer disinfectors is an essential part of the sterilization process, ensuring that the instruments being sterilized are safe for use in medical settings.

Other Medical Applications of Thermocouples 

Thermocouples have several medical applications beyond their use in washer disinfectors. Some of these applications include:

  • Temperature monitoring in medical devices: Thermocouples can be used to measure the temperature of medical devices, such as incubators, sterilizers, and anesthesia machines. This ensures that the devices are operating within safe temperature ranges and can help prevent overheating or underheating.
  • Body temperature monitoring: Thermocouples can be used to measure body temperature, which is an important indicator of health. This can be done by inserting a thermocouple probe into the ear or by placing a thermocouple sensor on the skin.
  • Catheter temperature monitoring: In some medical procedures, such as cardiac catheterization, thermocouples can be used to measure the temperature of the catheter. This can help guide the procedure and ensure that the catheter is placed correctly.
  • Tissue temperature monitoring: During surgery, thermocouples can be used to measure the temperature of the tissue surrounding the surgical site. This can help prevent tissue damage from overheating or underheating.
  • Cryosurgery: In cryosurgery, thermocouples can be used to monitor the temperature of tissue during freezing. This ensures that the tissue is frozen to the correct temperature and can help prevent damage to surrounding tissue.

Get Best-Quality Thermocouples & Other Such Products from Heatcon

Overall, thermocouples have a variety of medical applications, including temperature monitoring in medical devices and body temperature monitoring etc. Their accuracy & reliability make them a valuable tool in many medical procedures. You can procure best-quality products including Thermocouple from Heatcon Sensors.

About the Use of Thermocouples in CTU’s and TCU’s

Thermocouples Are Used in CTU’s and TCU’s

Other Medical Uses of Thermocouples

Get 1st-Rate Thermocouples and Other Such Products from Heatcon Sensors

 

A thermocouple is a type of temperature sensor that measures temperature by detecting changes in voltage across two different metals. The two metals are typically joined together at the sensing end of the thermocouple, and when exposed to heat, a voltage is generated that is proportional to the temperature difference between the sensing end and the reference end.

Thermocouples Are Used in CTU’s and TCU’s

Thermocouples are commonly used in CTUs (Coolant Temperature Units) and TCUs (Temperature Control Units) for temperature sensing and control. These devices are used to maintain a stable temperature in industrial equipment, such as injection moulding machines, extruders, and other machinery that requires temperature control. In CTUs and TCUs, thermocouples are typically used to measure the temperature of the coolant or fluid in the system. The thermocouple is usually located at the inlet or outlet of the cooling system, or directly in the fluid stream. The thermocouple then sends a signal to the control unit, which can then adjust the temperature of the coolant as needed to maintain a stable temperature. Thermocouples are popular in CTUs and TCUs because they are relatively inexpensive, durable, and accurate. They can also operate in a wide range of temperatures, making them suitable for use in a variety of industrial applications. Additionally, they are easy to install and require minimal maintenance. Overall, the use of thermocouples in CTUs and TCUs is a reliable and cost-effective way to maintain temperature control in industrial processes.

Other Medical Uses of Thermocouples 

Thermocouples are also used in various medical applications, including temperature sensing and control in medical devices and equipment. Some of the other medical uses of thermocouples are:

  • Body temperature measurement: Thermocouples are commonly used to measure body temperature. They are often used in disposable temperature probes for single-use or multi-use applications.
  • Catheter temperature sensing: Thermocouples can be incorporated into catheters to monitor temperature changes in the body. This is particularly useful in procedures such as cardiac ablation, where the temperature of the catheter tip is critical for successful treatment.
  • Surgical instrument temperature monitoring: Thermocouples can be attached to surgical instruments to monitor their temperature during surgery. This is important to ensure that the instruments do not overheat, which can damage surrounding tissue.
  • In vitro fertilization (IVF): Thermocouples are used to monitor the temperature of IVF incubators, which are used to culture embryos.
  • Hyperthermia treatment: Thermocouples are used to monitor the temperature of the tissue during hyperthermia treatment, which is used to treat cancer by heating the tumour cells to a temperature that causes them to die.

Get 1st-Rate Thermocouples and Other Such Products from Heatcon Sensors

Overall, thermocouples are valuable tools in medical applications where precise temperature monitoring is required. They are used in a wide range of medical devices and equipment to ensure that temperatures remain within safe and effective ranges. You can get first-rate products from Heatcon.

 

 

About the Use of Thermocouples in Cold Storages

More on the Use of Thermocouples in Warehouses

Other Medical Uses of Thermocouples

Procure Avant-Garde Thermocouples from Heatcon Sensors

Thermocouples are temperature sensors that are commonly used in a variety of industries, including warehousing. In warehouses, thermocouples are used to monitor the temperature of goods and products being stored to ensure that they are kept within the appropriate temperature range.

Thermocouples Are Used in Warehouses

One common use of thermocouples in warehouses is for monitoring the temperature of perishable goods such as food and pharmaceuticals. These products need to be stored at specific temperatures to ensure their safety and quality. A thermocouple can be placed in a storage area or inside a shipping container to monitor the temperature and alert warehouse personnel if the temperature falls outside of the safe range. Thermocouples are also useful for monitoring the temperature of equipment and machinery in warehouses. Overheating of machinery can cause breakdowns and safety hazards, so monitoring the temperature of critical components can help prevent accidents and prolong the lifespan of equipment.

More on the Use of Thermocouples in Warehouses

In warehouses, thermocouples are commonly used to monitor the temperature of goods and products being stored. Many products, such as perishable food items and pharmaceuticals, need to be stored at specific temperatures to maintain their quality and safety. Deviations from the appropriate temperature range can lead to spoilage, degradation, or even harmful bacterial growth. Thermocouples are typically placed in strategic locations throughout a warehouse to monitor the temperature of the surrounding air or specific areas of interest, such as refrigerated storage units or shipping containers. The temperature data is transmitted to a monitoring system, where it can be tracked and analysed in real-time. Warehouse personnel can use this data to quickly identify and address any temperature fluctuations or anomalies.

If the temperature falls outside of the acceptable range, an alert can be sent to a designated employee, allowing them to take immediate action to remedy the situation. For example, if the temperature of a refrigerated storage unit drops below the appropriate range, an employee may be able to adjust the thermostat or take other measures to bring the temperature back within the acceptable range before any products are damaged. In addition to monitoring the temperature of products, thermocouples can also be used to monitor the temperature of equipment and machinery in a warehouse. Overheating of machinery can cause breakdowns and safety hazards, so monitoring the temperature of critical components can help prevent accidents and prolong the lifespan of equipment. Overall, thermocouples are an important tool for ensuring that warehouses are able to maintain the appropriate temperature conditions for their products and equipment.

Other Medical Uses of Thermocouples 

In addition to their use in warehouses, thermocouples have a variety of medical applications. For example, thermocouples can be used to measure body temperature in a clinical setting, as well as to monitor the temperature of medical equipment such as incubators and refrigerators. They can also be used in research settings to monitor the temperature of lab equipment and experiments. 

Procure Avant-Garde Thermocouples from Heatcon Sensors

Use of thermocouples is indeed a versatile and reliable temperature sensing technology used in a wide range of medical applications. Heatcon Sensors manufactures and sells these thermocouples. When procuring thermocouples, it is important to consider the specific application and temperature range required, as well as the accuracy and reliability of the thermocouple. It is also important to ensure that the thermocouple is compatible with the equipment and instrumentation being used to measure and record the temperature. In addition to procuring thermocouples, it may also be helpful to consult with a temperature sensing expert to ensure that the thermocouple is being used and installed correctly, and to troubleshoot any issues that may arise.

 

 

Thermocouples Medical Applications

Thermocouples Medical Applications

Steam Sterilization Using Thermocouple Devices in the Medical Sector

More about Steam Sterilization Using Thermocouples

Heatcon Provides Customizable Thermocouple Devices That Are Used in Medical Industry

Thermocouples Medical Applications

There are a host of Thermocouples Medical Applications, some of which are as follows:

  • Steam Sterilization
  • Laboratories
  • Et0 Sterilization
  • Environmental Test Chamber
  • H202 Sterilization
  • Ovens
  • Stability Chambers
  • Warehouses
  • CTU’s & TCU’s
  • Washer Disinfectors

Steam Sterilization Using Thermocouple Devices in the Medical Sector

Thermocouples are temperature sensors that are commonly used in medical applications, including steam sterilization (autoclave) in the healthcare sector. The use of thermocouples in sterilization processes ensures that medical instruments and equipment are free of microorganisms, preventing infections and diseases in patients. Thermocouples work based on the principle of the Seebeck effect, which states that when two dissimilar metals are joined together, a voltage is generated that is proportional to the temperature difference between the two junctions. By measuring this voltage, the temperature of the system can be determined.

In steam sterilization, the autoclave is a chamber that is heated to high temperatures and pressures to kill microorganisms on medical equipment. The temperature and pressure inside the autoclave must be monitored and controlled to ensure that the sterilization process is effective. Thermocouples are commonly used to measure the temperature inside the autoclave during the sterilization process. The thermocouple is placed inside the chamber and connected to a data logger or temperature controller that displays and records the temperature. By monitoring the temperature with thermocouples, healthcare professionals can ensure that the sterilization process is effective and that the medical equipment is safe to use.

More about Steam Sterilization Using Thermocouples

Steam sterilization is a reliable and efficient way of disinfecting medical instruments, equipment and materials. Thermocouple devices are useful for monitoring what is going on inside the sterilization process, ensuring that it is executed correctly. Thermocouples are composed of two different metals, with each metal having a different electrical voltage. The difference between them produces a measurable electrical current that can be used to detect temperature changes. In steam sterilization, thermocouples are used to measure the temperature and pressure of the steam, as well as the time it takes for the sterilization process to be completed. This ensures that medical tools and materials are completely sterilized.

Thermocouple devices have become more popular in the medical sector due to their reliability, accuracy and affordability. They are small and durable, so they can be placed in tight areas where space is limited. They are also easy to install and maintain, making them an ideal choice for medical professionals. Steam sterilization is an effective way to protect patients and medical staff from infection and contamination. Using thermocouple devices can make the process even more reliable while helping to ensure that medical instruments, equipment and materials are completely sterilized.

Heatcon Provides Customizable Thermocouple Devices That Are Used in Medical Industry 

Thermocouple devices are becoming increasingly popular in the medical sector for steam sterilization. These devices offer a safer and more reliable way to ensure that medical instruments and devices are properly sterilized, helping to reduce the spread of infectious diseases. Thermocouples measure the temperature during the sterilization process and can be used to ensure that the correct temperatures are being achieved. They also provide an accurate and consistent readout, making them ideal for medical applications. With their compact and lightweight design, thermocouples can be easily installed in any medical environment. By using steam sterilization with thermocouples, medical professionals can ensure that their instruments are being sterilized correctly and efficiently.

In addition to steam sterilization, thermocouples are also used in other medical applications, including monitoring the temperature of blood during transfusions, monitoring the temperature of vaccines during transportation and storage, and measuring the temperature of medical gases. Overall, the use of thermocouples in medical applications is critical for ensuring the safety and effectiveness of medical equipment and procedures. You can procure these thermocouple devices from the industry leader, Heatcon Sensors. Heatcon is a prominent heating devices manufacturer for all types of industries and industrial processes requiring heating technology. Heatcon engineers are capable of determining the exact requirements of the processes and provide custom solutions after studying the needs of the same.

Thermocouples are one of the most widely used temperature measurement devices in medical applications. Their use in medical laboratories is particularly important, as they are capable of accurately measuring temperature in different environments. The thermocouple is composed of two wires of different materials, which join together to form a junction that generates a voltage when heated. This voltage can then be used to measure the temperature at the junction, and from there, it can be used to measure the temperature of the environment. Thermocouples are also commonly used to measure the temperature of liquids and gases in laboratories. They can be used to provide accurate readings for chemical processes, as well as to ensure safety in many situations. Due to their accuracy and reliability, thermocouples are an invaluable tool in medical laboratories. Thermocouples are commonly used in medical laboratories for temperature measurements due to their accuracy, reliability, and durability. Here are some of the medical applications of thermocouples in laboratories:

  • Incubators: Thermocouples are often used to monitor and control the temperature in incubators used for culturing cells or microorganisms. The accuracy of thermocouples helps maintain optimal conditions for the growth of cells or microorganisms, which is crucial for research and diagnostic purposes.
  • Autoclaves: Thermocouples are used to measure the temperature inside autoclaves, which are used to sterilize laboratory equipment and medical instruments. Accurate temperature measurement is necessary to ensure that the equipment and instruments are properly sterilized.
  • Cryogenic freezers: Thermocouples are used to monitor the temperature of samples stored in cryogenic freezers. These freezers are used for long-term storage of biological samples such as cells, tissues, and fluids. The accuracy of thermocouples helps maintain the desired temperature, which is crucial for preserving the integrity of the samples.
  • Blood banks: Thermocouples are used to monitor the temperature of blood storage units. The accuracy of thermocouples helps ensure that blood products are stored at the proper temperature to maintain their potency.

More about the Use of Thermocouples in Laboratories

Thermocouples have a wide variety of medical applications, ranging from diagnostics and monitoring to research and treatment. One of the most common uses for thermocouples is in laboratories for measuring the temperature of a variety of materials. They are widely used in the medical industry for the accurate measurement and monitoring of temperatures for processes such as aseptic preparation, incubation, cell culture, and sterilization. Due to their accuracy and compact size, thermocouples are also widely used in medical equipment such as anaesthesia monitors, ventilators, and defibrillators. Additionally, thermocouples can be used to measure human body temperature, helping to identify health abnormalities such as fever or hypothermia. Furthermore, thermocouples can be used to measure the temperature of liquids and gases in medical processes such as dialysis and infusion. The wide range of medical applications for thermocouples demonstrate their versatility and importance in the medical industry.

Heatcon Sensors Happens to Provide Custom-Made Thermocouples Utilised in Laboratories 

Overall, thermocouples play a critical role in temperature measurement and control in medical laboratories, ensuring the accuracy and reliability of experimental and diagnostic procedures. You can procure high-quality thermocouples from the industry leader itself, i.e., Heatcon Sensors.

Thermocouples are temperature sensors that rely on the principle of thermoelectricity, which involves the generation of a voltage at the junction of two dissimilar metals when the temperature at the junction changes. They are commonly used in a wide range of industries, including medical applications. Thermocouples are one of the most popular temperature sensors used in medical applications. They provide accurate temperature measurements and are particularly effective for monitoring during sterilization processes. One of the most common medical applications for thermocouples is for monitoring Ethylene Oxide (EtO) sterilization. During this process, medical devices such as implants, equipment, and instruments are exposed to the gas in order to kill any living microorganisms. 

Thermocouples Medical Applications Include EtO Sterilization

One common use of thermocouples in the medical field is for temperature monitoring during sterilization processes, including ethylene oxide (EtO) sterilization. Ethylene oxide is a gas that is commonly used for sterilization of medical equipment and supplies that cannot withstand high temperatures or moisture. During the sterilization process, the temperature inside the sterilization chamber needs to be carefully monitored to ensure that it reaches and maintains the desired temperature to effectively kill any microorganisms present. Thermocouples are an effective way to do this as they can provide accurate temperature measurements in real-time. 

More on EtO Sterilization Using Thermocouples

Thermocouples are widely used in many medical applications, including the monitoring of EtO sterilization. EtO sterilization is a process in which ethylene oxide is used to kill microorganisms on medical devices. Thermocouples are used to monitor the temperature of the system, as well as the amount of EtO present, to ensure that all of the bacteria and other microorganisms are destroyed. They also help to ensure that the process is safe, efficient, and effective. The use of thermocouples in this process ensures that the medical equipment is properly sterilized and that it is safe for use on patients. Thermocouples are used to accurately monitor the temperature of the sterilization process, ensuring that the sterilization is effective. They can also be used to track the rate of temperature increase, which is important for achieving optimal sterilization results. The small size of the thermocouples makes them ideal for monitoring EtO sterilization. They can be easily installed in the equipment and provide accurate readings without disrupting the sterilization process. Additionally, thermocouples are very reliable and require minimal maintenance. Thermocouples are a valuable addition to medical facilities, ensuring the safe and effective sterilization of medical devices. They can provide accurate readings and are well suited for monitoring EtO sterilization processes.

Other Medical Applications of Thermocouples

Thermocouples are also used in medical research and clinical applications, such as in studies of thermoregulation in humans and animals, and in the monitoring of patients’ body temperatures in critical care settings.

Heatcon Sensors Happens to Provide Custom-Made Thermocouples 

Overall, thermocouples are a versatile and reliable tool for temperature monitoring in a range of medical applications, including sterilization processes using EtO. You can procure best-suited thermocouples from the industry’s leading provider, Heatcon.

In medical applications, thermocouples are commonly used to measure temperature in a variety of settings. For example, they can be used in incubators to measure the temperature of new-born babies to monitor temperature and humidity in incubators to keep new-borns safe, or in surgical instruments to ensure they remain within a certain temperature range during use. They can also be used in research settings to measure body temperature in animals, or to monitor the temperature of equipment during experiments. Thermocouples can also be used to monitor temperature in operating rooms to ensure a sterile environment for the patient. Additionally, thermocouples can be used to measure the temperature of pharmaceutical drugs to ensure they are stored in optimal conditions. In one of the medical applications, Thermocouples are used in Environmental Test Chambers to monitor and control an array of factors such as temperature, humidity, and pressure.

Medical Applications of Thermocouples Include Their Utilization in Environmental Test Chambers

Thermocouples are a type of temperature sensor commonly used in these chambers. Thermocouples are used to monitor and analyze various properties of the chamber such as temperature uniformity and rate of change. Thermocouples have a wide range of medical applications, including their utilization in the environmental test chambers. In these environmental test chambers, thermocouples are used to monitor temperature and humidity levels. These chambers simulate various environmental conditions, such as temperature and humidity, to test the durability and performance of products. Thermocouples are critical for maintaining precise and accurate temperature measurements in these environments, which is essential for ensuring that products are safe and reliable. Thermocouples are responsible for providing highly accurate temperature measurements. This makes them an integral part of environmental test chambers, ensuring that parameters are not exceeded and that the tests are reliable. 

More on Environmental Test Chambers and the Use of Thermocouples There

Environmental Test Chambers are special testing equipment enclosures used to simulate various environments for a variety of uses like for conducting environmental tests & measurements. They are often used to test products and materials for a range of parameters, and to evaluate the performance of electronic systems under different conditions. These chambers are capable of simulating a variety of environmental conditions including temperature, humidity, pressure, and vibration. Overall, Environmental Test Chambers provide a safe and reliable way to test and monitor different environmental conditions. Thermocouples are commonly used inside these chambers to measure and monitor temperature for testing purposes. Thermocouples provide an ideal way to accurately monitor and measure the temperature in these chambers. 

Heatcon Provides Thermocouples That Are Tailor-Made

Overall, thermocouples are highly versatile instruments that have a wide range of applications in various industries, including the medical and environmental testing fields. The main use of Environmental Test Chambers in medical applications is to test and measure the effects of harsh environments, such as extreme temperatures, on medical devices. Thermocouples help to measure the temperature of the environment within the chamber and to detect any fluctuations or changes that could harm the device, or the user. Through this, medical equipment can be tested in a real-world environment, which may be too dangerous for humans to enter. In conclusion, Environmental Test Chambers and thermocouples are essential components in a range of medical applications, from testing and monitoring environments in which medical devices are to be used, to providing accurate temperature measurements. The use of these technologies ensures that medical devices perform within safe and reliable parameters, for the benefit of all. You can easily procure the thermocouples that are best suited for your specific needs from the industry’s leader itself, that’s Heatcon Sensors.

Thermocouples are temperature sensors that work on the principle of the Seebeck effect, which states that a voltage is generated when two dissimilar metals are joined at their ends and a temperature gradient exists between them. This voltage happens to be in proportion to the difference in temperature between 2 junctions of the 2 different metals.

Medical Applications of Thermocouples Include H2O2 Sterilization

One of the medical applications of thermocouples is in the sterilization of medical instruments and equipment using hydrogen peroxide (H2O2) gas. H2O2 sterilization is a low-temperature sterilization process that is effective in killing a wide range of microorganisms, including bacteria, viruses, and spores. The process involves exposing the equipment to a high concentration of H2O2 gas for a specified period, typically 2-4 hours. Thermocouples are used to monitor the temperature during the H2O2 sterilization process. The temperature inside the sterilization chamber needs to be maintained at a certain level for the H2O2 gas to be effective in killing the microorganisms. If the temperature is too low, the sterilization process will not be effective, and if the temperature is too high, it can damage the equipment being sterilized. A thermocouple is inserted into the sterilization chamber, and the temperature is monitored continuously throughout the sterilization process. The thermocouple is connected to a data logger, which records the temperature data. The data logger can then be used to generate a temperature profile of the sterilization process, which can be used to ensure that the process has been effective. 

Other Medical Applications of Thermocouples 

In addition to monitoring the temperature during the H2O2 sterilization process, thermocouples are also used in other medical applications, such as monitoring body temperature, monitoring the temperature of organs during transplant surgery, and monitoring the temperature of refrigerated drugs and vaccines. Overall, the use of thermocouples in medical applications is essential for ensuring the safety and effectiveness of medical treatments and procedures.

Heatcon Sensors Is a Company That Provides Tailor-Made Thermocouples 

You can comfortably get high-quality thermocouples best suited for your specific requirements from Heatcon Sensors. Heatcon Sensors is a company that specializes in providing customized thermocouples for various industries and applications. Heatcon designs and manufactures thermocouples according to the specific needs and requirements of their clients. They can also provide different constructions, such as grounded, ungrounded, exposed, and protected, to suit different applications. Heatcon Sensors uses high-quality materials and advanced manufacturing techniques to ensure that their thermocouples are accurate, reliable, and long-lasting. They also offer a variety of accessories, such as connectors, extension wires, and protection tubes, to complement their thermocouples and provide a complete temperature measurement solution. Overall, Heatcon Sensors is a company that is dedicated to providing tailor-made thermocouples that meet the specific needs and requirements of their clients. They have extensive expertise in the field of temperature measurement and can provide solutions for a wide range of industries and applications.

Thermocouples are commonly used in a variety of medical applications, particularly in temperature measurement and control. They are often used in medical devices such as incubators, sterilizers, and refrigerators to ensure that the internal temperature is maintained within a specific range to support safe and effective medical practices. One common use of thermocouples in medical applications is in the measurement of body temperature. Thermocouples can be used to measure the temperature of a patient’s body by inserting a small probe into the ear or under the tongue. This measurement can provide valuable information about a patient’s health and can help medical professionals to diagnose and treat illnesses.

Thermocouples Are Used in Industrial Ovens

While thermocouples are not commonly used in ovens in medical applications, they are widely used in industrial ovens and furnaces for temperature measurement and control. Thermocouples can provide accurate and reliable temperature data in high-temperature environments, making them an essential tool for many industrial processes.

Thermocouples are commonly used in industrial ovens for temperature measurement and control. Industrial ovens are used in a wide range of industries, including food processing, chemical manufacturing, and materials testing, and require precise temperature control to ensure that products are cooked or processed correctly. Thermocouples can be used to measure the temperature inside the oven and provide feedback to the temperature control system, which can adjust the temperature as needed to maintain the desired temperature profile. This temperature control helps to ensure consistent quality and product safety.

There are many different types of thermocouples available for industrial oven applications, each with its own unique characteristics and temperature range. The type of thermocouple selected will depend on the specific requirements of the application, such as temperature range, accuracy, and response time. In addition to temperature measurement, thermocouples can also be used for safety applications, such as over-temperature protection. In these cases, the thermocouple is used to monitor the temperature inside the oven and activate an alarm or shut off the oven if the temperature exceeds a safe limit. Overall, thermocouples are an essential component of industrial ovens and play a critical role in ensuring product quality and safety.

Other Medical Applications of Thermocouples 

Another medical application of thermocouples is in the measurement of temperature during surgical procedures. During surgery, it is essential to monitor the patient’s body temperature to ensure that they do not become too cold or too hot, which can cause complications. Thermocouples can be used to monitor the patient’s temperature and provide real-time feedback to the surgical team. Thermocouples can also be used in the calibration and testing of medical equipment, such as autoclaves and sterilizers. These devices rely on precise temperature control to ensure that medical instruments and equipment are properly sterilized before use. Thermocouples can be used to measure the temperature inside these devices and ensure that they are operating correctly.

Choosing an Ideal Thermocouple

Some companies that provide tailor-made thermocouples may also offer installation, maintenance, and calibration services to ensure that the thermocouples are working correctly and providing accurate temperature measurements. These services can be particularly important for critical applications where accuracy and reliability are essential. It is always important to choose a reputable and experienced thermocouple supplier to ensure that you get the best product and service. When selecting a supplier, consider factors such as the company’s experience, reputation, and track record, as well as their ability to provide customized solutions to meet your specific needs.

Heatcon Sensors Is a Company That Provides Tailor-Made Thermocouples 

You can comfortably get high-quality thermocouples best suited for your specific requirements from Heatcon Sensors. Heatcon Sensors specializes in providing customized thermocouples for various industries and applications. Tailor-made thermocouples made here can be designed to meet specific requirements such as temperature range, accuracy, response time, and durability. These customized thermocouples can be used in a variety of industries, including aerospace, automotive, energy, and medical.

A thermocouple is a type of temperature sensor that measures temperature based on the voltage generated when two different metals are connected at two different temperatures. In a stability chamber, thermocouples are placed at various points inside the chamber to measure the temperature and provide accurate readings. The thermocouples are connected to a data acquisition system, which records the temperature data over time.

Thermocouples Are Used in Stability Chambers

Thermocouples are commonly used in stability chambers to measure and monitor the temperature inside the chamber. Stability chambers are used to test the stability of pharmaceutical products, medical devices, and other sensitive materials under controlled environmental conditions, and temperature is a critical parameter in this process. Thermocouples are preferred in stability chambers because they are accurate, reliable, and able to withstand a wide range of temperatures. They can be used to measure temperatures ranging from -200°C to +1800°C, making them suitable for a wide range of applications. In addition, thermocouples are relatively inexpensive, easy to install, and require minimal maintenance. They are also compatible with most data acquisition systems and can be easily integrated into the monitoring and control systems used in stability chambers. Overall, the use of thermocouples in stability chambers is critical to ensuring that the environmental conditions are maintained within specified limits, which is essential for the proper testing and evaluation of sensitive materials.

Some Other Medical Applications of Thermocouples 

Thermocouples are widely used in the medical industry due to their accuracy, durability, and ability to withstand extreme temperatures. Here are some other medical applications of thermocouples:

  • Patient temperature monitoring: Thermocouples are used to measure body temperature in patients. They can be inserted into the ear canal, rectum, or other areas to provide accurate temperature readings.
  • Surgical instruments: Thermocouples are used in surgical instruments to monitor the temperature during procedures such as cauterization or tissue ablation. They ensure that the instruments are at the correct temperature and prevent tissue damage.
  • MRI imaging: Magnetic resonance imaging (MRI) machines use thermocouples to monitor the temperature of the patient during the scan. The thermocouples ensure that the patient does not overheat and that the MRI machine is working properly.
  • Laboratory equipment: Thermocouples are used in laboratory equipment such as incubators, refrigerators, and freezers to monitor and control the temperature. They ensure that the samples being tested are kept at the correct temperature and prevent spoilage.
  • Blood warming: In some medical procedures, it is necessary to warm blood before it is transfused into a patient. Thermocouples can be used to monitor the temperature of the blood as it is warmed, ensuring that it is at the correct temperature before being transfused. 

Heatcon Provides Efficient Thermocouples 

Overall, thermocouples are a versatile and important tool in the medical industry, helping to ensure accurate temperature monitoring and control in a wide range of applications. You can procure avant-garde thermocouples ideally suited for your specific industrial requirement(s) from Heatcon that specializes in providing tailor-made thermocouples for different industries as well as various applications.

Air Temperature Indicator in Aircraft

Air Temperature Indicator in Aircraft

Non-Electrical Temperature Sensors

Air Temperature Indicator in Aircraft

The temperatures of many objects should be known prior to the flight for the correct operation of an aircraft. Such equipment acts as the air temperature indicator in aircraft! These aircraft temperature measuring equipment include the intake air, engine oil, free air, carburetor mixture, engine’s cylinder heads, heater duct as well as turbine engine exhaust  temperature. These happen to be all the things that require proper monitoring of temperatures. Several other temperature measurements should be known as well. Various thermometers are being utilized for collecting & displaying temperature data. 

Non-Electrical Temperature Sensors 

The physical properties of many of the materials alter when they are exposed to any alterations in the temperatures. These alterations tend to be continuous, for example, the expansion/contraction of solids, liquids, & gasses. The coefficient of such an expansion happening with various materials tends to be different, and is individual for every such material. 

  • Many people are quite familiar with the liquefied mercury thermometer most of us use at home. As mercury increases in temperature, it expands and goes up along a narrow channel with a scale that can be utilized for reading the temperature associated with that expansion. Such mercury thermometers are of no use at all in the aviation industry.
  • Bimetallic thermometers, on the other hand, are quite useful in the aviation field. The element used for sensing the temperature measurement of such bimetallic thermometers is made of 2 different metal strips that are glued together. Every metal tends to expand as well as contract at different rates as the changes in temperature happen. 1 of the ends of this bimetallic strip tends to be fixed, while the other end is twisted. A pointer is attached to the threaded end, which is inserted into the body of the instrument. When the bimetallic strip gets heated, the 2 metals tend to expand. Because they have different expansion rates, and are connected to each other; the coiled end will try to loosen if one metal expands faster than the other. This leads to a movement in the pointer over the instrument dial. As the temperature tends to drop, the metals tend to contract at different rates; this tightens the coil & helps in the movement of the pointer in the opposite direction.
  • Direct-range bimetallic temperature gauges have been in use much frequently in light aircraft for measuring free air temperatures or the outside air temperatures (OAT). In such an application, the collection probe is inserted through the aircraft’s windshield for exposing it to atmospheric air. The end that is coiled on the gauge head’s bimetallic strip is just inside the windshield where the pilot can read it.
  • The bourdon tube too is utilized for direct reading non-electrical temperature gauges for simple & light aircraft. Bourdon tube gauge’s dial face with temperature scale tends to be the indicator of the temperature. Such an operation is based on the uniform expansion of the steam that has been generated by the volatile liquid present in a closed space. Such pressure from the vapor varies with temperature directly. By filling a sensing bulb with this type of volatile liquid and then connecting it to a Bourdon tube, it helps in acting as an indicator of the rise & fall of the vapor pressure owing to the changes happening in the temperature. Calibrating the handle in degrees (Fahrenheit/Celsius) instead of psi gives a reading of the temperature. In this type of meter, a sensor bulb tends to be placed in the region where the temperature is being measured. A lengthy capillary tube tends to connect the bulb to a Bourdon tube in the instrument’s housing. The capillary tube’s much narrower diameter ensures that the evaporating liquid is light and it also remains mainly in the sensor bulb. Sometimes oil temperature is also measured like this.

Utilizing electricity to measure different temperatures is quite prevalent in the aviation industry. Different ranges of temperature tend to be measured in a more suitable way by one or the other sort of the system. Below mentioned are some measuring systems as well as indication systems that are largely seen in various sorts of aircraft. 

Electrical-Resistance Thermometers

The main parts of electrical-resistance thermometers happen to be the indicator instrument, the element (or the bulb) that is temperature-sensitive & the connecting wires along with the plug connectors. Such type of a thermometer is largely used in various types of aircraft for measuring carburetor air, oil, free-air temperature etc. These are utilized for measuring low & medium temperatures between -70 degree Celsius and 150 degree Celsius. 

The electrical resistance of most metals alters when the temperatures of those metals tend to change. A resistance thermometer works on this principle. Normally, the electrical resistance of metals tends to augment with increasing temperatures. Different metal alloys tend to have high temperature-tolerance coefficient, which means that their resistance differs significantly with temperatures. This property makes them highly suitable to be used in devices used for sensing temperatures. The metal resistors are in contact with the liquid or the area where the temperatures are to be measured. This is wired to a device in the cockpit detector. Optionally, the instrument dial tends to be calibrated in degrees Celsius or degrees Fahrenheit instead of ohms. As the measured temperature tends to change, the metal resistance also changes, and the indicator shows the exact extent to which the change is happening.

A common electrical-resistance thermometer appears to be like any other such thermometer. For use in multi-engine aircraft, these detectors are available in 2 different forms. Most such indicators themselves compensate for cabin temperatures. A thermally-sensitive resistor is designed to have its own resistance for every temperature value within its operating range. The temp-sensitive resistive element happens to be the length or coil made of nickel or manganese wire or any other such suitable insulating material alloy. The resistor tends to be protected by a sealed metal tube that is connected to a hexagonal head. The 2 ends of the coil are soldered or welded to a socket designed to accept the plugs of the plug connector. 

Such indicators include the resistance measuring devices. They sometimes use a modified form of the Wheatstone Bridge circuit that works on the principle of balancing 1 unknown resistance with other such known resistances. 3 resistance values ​​of the same are connected in a bridge circuit that is diamond-shaped. One resistor, whose value is unknown, also happens to be one part of the circuit. The unknown resistance shows the temperature bulb’s resistance of the electric-resistance thermometer system. A galvanometer is fixed at 2 points in the circuit. 

If the temperature makes the resistance of the bulb the same as the other resistances, there’s no potential difference between the 2 points in the circuit. So, no current will flow in the galvanometer’s leg of the circuit. As the temperature of the bulb changes, so does its resistance, and the bridge tends to become imbalanced, leading to the current to flow through the galvanometer in 1 direction or the other. The pointer of a galvanometer is basically the pointer of a gauge. The time of it moving against that dial-face that is calibrated in degrees, the temperature is shown. Many such pointers are equipped with a zero adjustment screw on the front of the instrument. This adjusts the tension of the pointer reset spring when the bridge is at the balancing point (this happens to be that position where the bridge circuit tends to balance & no current flows through that meter).

One more method to determine the temperatures using electrical-resistance thermometers is to do it by utilizing a ratiometer. In the Wheatstone bridge detectors, there are failures due to fluctuations in the mains voltage. The ratiometers tend to be more stable, & they can provide much larger accuracy. As suggested by their name, ratiometer electrical-resistance thermometers help in measuring the ratio of current. 

The sensor part of the resistance bulb of such types of thermometers is primarily similar to the one explained above. The circuit consists of a variable resistance as well as a fixed resistance to give the reading. This consists of 2 power supplies; each having a coil that is mounted on one of the sides of that pointer mounted in the field of a large-sized permanent magnet. The changing current passing through the coils leads to varied fields reacting with the much larger permanent magnet’s field. Such an interaction turns the cursor against a dial that has been calibrated in degrees Fahrenheit/Celsius, providing the indication of the temperature being measured. 

The ends of the magnetic poles of such types of permanent magnets tend to be closer at the topmost point than at the bottom-point. It leads to the flux’s magnetic field lines among the poles to concentrate at the tip. When the 2 coils release their own magnetic field, the one that is stronger tends to interact & deflect down into the weaker one, which happens to be the less concentrated part of the permanent field of the magnet; however, the field of the weaker coils moves up into the more concentrated large magnet’s flux field. This leads to a sort of balancing effect, which alters but tends to remain balanced as the coil field becomes strengthened and varies with the temperatures & currents that are flowing in the coils. 

For instance, if the temp-bulb’s resistance is the same as the value of the fixed resistance (R), then the same values of current will flow through the coils. The torque(s) thus produced by the magnetic fields by each coil tends to be the same & cancels out any motion in the larger field. The pointer is in the vertical position. As the temperature of the bulb augments, so does its resistance. This leads to the current through one of the coils in the circuit-branch to augment. This leads to a stronger magnetic field being produced in one coil than in the other one. As a result, the torque on one of the coils increases, and it is pulled down to the weak point of the higher magnetic field. Simultaneously, lesser current flows through the resistance of the sensor bulb and the second coil, causing that coil to form a weaker magnetic field, which is pulled up into the stronger flux region of the permanent magnet’s magnetic field. The pointer halts turning when the fields tend to reach a new equilibrium point, which is directly related to the resistance of the sensing bulb. This would be the opposite if the temperature of the thermosensitive bulb were to drop. 

Ratiometer’s temperature measurement systems are being utilized for measuring outside air, engine oil, carburetor air as well as other temperatures in many of such types of aircrafts. These happen to be particularly useful for measuring temperature conditions wherein accuracy is more significant or where there are large fluctuations in the supply voltages.

Thermocouples happen to be the circuits or connections between 2 metals that are unlike. The metals meet at 2 different junctions. If 1 of these junctions gets heated to a higher degree temperature than the other junction, an electromotive force is generated inside the circuit. Such voltage tends to be directly linked to the temperature. Thus, the temperature can be determined by measuring the magnitude of this force. A voltmeter tends to be placed on the cooler of the 2 thermocouple junctions. This would be calibrated in Celsius/Fahrenheit (as required). As the high-temp junction (or also called the hot junction) becomes hotter, the electromotive force thus generated becomes greater & the temperature reading on the meter becomes greater!

A thermocouple is utilized for measuring high temperatures. 2 most common applications of this are measuring the cylinder-head-temperatures (CHT) in the reciprocating engines, and second is the measuring of the exhaust-gas-temperatures (EGT) in the turbine engine. The wires of the thermocouples tend to be made from several metals as per the max temperature they are being exposed. Iron & constantan/copper & constantan happen to be the most commonly used ones for measuring CHT. Chromel & alumel tend to be utilized in turbine EGT thermocouples. 

The amount of voltage generated while heating different metals tends to be measured in the units of millivolts. So, the wires of thermocouples are formed in such a way that they give a certain amount of resistance (that is usually very low) in the thermocouple circuit. Their materials, lengths or cross-section sizes could not be changed without compensating for the resulting change in the total resistance. Any wire connecting back to the voltmeter should be designed from the similar metal as that of the thermocouple’s part wherein it has been connected. For instance, a copper wire tends to be connected to the copper part of the hot junction, & a constantan wire has been connected to the constantan segment. 

The thermocouple’s hot junction has different shapes as per the application(s). The 2 most common ones happen to be the pack one and the bayonet one. In a gasket, 2 dissimilar metal rings tend to be pressed together for forming a gasket, which could be installed either under the spark plug or the cylinder that is retaining the nut. In the bayonet one, the metals are connected within a perforated protective casing. The bayonet type of the thermocouple fits into a hole or well inside the cylinder head. In turbine engines, these are installed in the turbine inlet/outlet, & then extend through the casing into the gas-stream. Note that the cylinder that runs hottest under most operating conditions is selected to mount the thermocouple to read the CHT. This cylinder’s location happens to vary for different engines. 

The thermocouple circuit’s cold junction happens to be inside of the instrument housing. As the electromotive force generated inside the circuit tends to vary according to the temperature difference between the hot & cold junctions, it is much needed to compensate for temperature changes in the cockpit of the detector mechanism that affect the cold junction. This is achieved by a bimetallic spring that has been connected to the detector mechanism. It basically works the same way as the bimetallic thermometer. With the wires disconnected from the detector, the cockpit temperature around the instrument panel could be read from the indicator dial. CHT’s number LED indicators also tend to be quite common in the modern type of the aircraft.

EGT happens to be a critical variable in the operations of turbine engines. Such EGT indicator systems tend to show the visual temperatures inside the cockpits of turbine’s exhaust gasses once they tend to leave that particular turbine unit. In some types of these turbine engines, the exhaust gas temperatures are measured at the inlet of the turbine unit. Such values are called the Turbine-Inlet-Temperature (i.e., TIT) detection systems. 

Certain types of thermocouples happen to be utilized for measuring this EGT/TIT. Such thermocouples tend to be placed at intervals circling round the circumference of that engine’s turbine case or the exhaust pipe. The small thermocouple voltages are usually increased & are utilized to drive the servo motor that moves the indicator pointer. Moving the digital drum pointer out of the cursor movement is quite a common phenomenon. The EGT indicator happens to be in a hermetically sealed device. The instrument scale tends to range from 0 degrees Celsius to 1200 degree Celsius, with a vernier scale in the upper right corner of the dial and a power failure warning flag in the lower part of the dial. 

The TIT display system visually displays the temperature of the gasses entering the turbine on the instrument panel. Multiple thermocouples could possibly be utilized with an intermediate TIT voltage. Inside the sensor are 2 thermocouples that contain 2 junctions, which happen to be electrically independent. One of these 2 thermocouples happens to be in parallel to send signals to the cockpit detector. Another set of parallel thermocouples provides signals for temperature to the engine monitoring system as well as the control system. Every such circuit happens to be electrically independent, thus ensuring the reliability of the two systems. 

The circuits for the other 3 engines happen to be quite identical to that system. The detector includes a bridge circuit, a switch, a 2-phased motor for the purpose of driving the indicator, and a feedback potentiometer. Also included is a voltage reference circuit, amplifier, shutdown indicator, power supply, & overheat warning light. The output of the amplifier activates the adjustable field of the 2-phase motor, which positions the detector master pointer & the digital detector. The motor even utilizes a feedback potentiometer for providing a buzzer signal in order to stop the drive motor at the time when the correct pointer position (relative to that of the temperature signal) is reached. The voltage-reference-circuit gives a precisely regulated reference voltage inside the bridge circuit for avoiding errors generated from fluctuations in the input voltage of the indicator’s supply of power. 

The warning light telling about over temperature tends to illuminate when TIT happens to reach the predetermined limit. An test switch (external) is ideally installed for the engines overheating warning lights to be tested simultaneously. While making use of such a test-switch, an over-temperature signal tends to get simulated inside every bridge circuit for detector temperature control. 

Digital cockpit instruments do not require the use of resistance-type indicators or the regulated servo-driven thermocouples for communicating temperature information to the pilot. The sensor’s resistance & the voltage values tend to be entered inside a suitable computer wherein they are adjusted, processed, monitored & printed on the cockpit panels. They are even sent to other computers that need temperature data to control & monitor various integrated systems.

Air temperature happens to be quite a significant parameter on which various types of performance monitoring as well as different control variables tend to depend. During the flight, the air temperature (static) is constantly changing, & accurate measurements are quite hard to get. Below Mach 0.2, a simple resistance-type/bimetallic temperature gauge could possibly give relatively correct readings for air temperature measurements. At higher speeds however, friction, air compressibility & boundary layer behaviors tend to create difficulty with correct temperature measurements. Total-air-temperature (i.e. TAT) happens to be the static air temperature added to any temperature increase due to the rapid movements of the aircraft in the air. The rise in the temperatures is called ram rise. TAT sensors are specifically designed for capturing such values accurately & sending signals for pilot detection and usage in different engine systems as well as aircraft systems. 

Simpler TAT systems tend to consist of the sensors as well as the detectors with in-built resistance-balancing circuits. The airflow through the sensor has been designed in such a way that air (at the exact temperature) tends to hit the platinum alloy resistive element. Sensors are designed in such a way that they help in detecting any changes in the temperatures versus the variations in the element resistance. When the pointer is placed in the bridge circuit, it moves in response to the imbalance caused by the variable resistance. 

More advanced systems tend to utilize the technology of signal correction as well as amplified signals that are sent to the servo motor for adjusting the cockpit indicators. Such systems consist of precisely regulated power supply as well as fault monitoring. These usually utilize digital drum-type readouts; however, they can also be sent to the LCD controllers for illuminating the LCD screens. Various LCD displays tend to be multi-functional, and they are also able to display static air temperatures & actual air speed. In a totally digital system, the correction signals tend to feed to the ADC. They can be properly processed there for cockpit displays or systems that need temperature data. 

The designs of the TAT sensors/probes are indicated by the possibility of ice formation in icy cool conditions. Sensors that are left unheated might stop working properly. Adding a heating element comprises accurate data collection. The heating of the sensors should not affect the sensor element’s resistance. 

During the design phase, special attention tends to be paid to the air flow as well as material conductivity. Some of the TAT sensors direct the airflow through the devices for influencing the ambient airflow so that it directly flows into the platinum sensors without additional energy from the sensor heaters.

Heatcon Sensors

For the best temperature indicator devices, you can connect with Heatcon Sensors; they happen to be the best in this domain!

 

Get to Know Cartridge Heater Working Principle

Cartridge Heater Working Principle

How Do Cartridge Heaters Operate?

Operating Temperatures of Cartridge Heaters

Uses of Cartridge Heaters

Temperature Controllers & Sensors for Cartridge Heaters

Cartridge Heater Working Principle

A cartridge heater is a device that is used to heat a large variety of materials and objects. It is an efficient, self-contained electrical heating element that works on a simple working principle. The heater consists of a tubular metal sheath with resistance wire wound around a ceramic core, with insulating material filling the spaces between the core and the sheath. It operates by allowing an electrical current to pass through the resistance wire, which in turn generates heat. This heat is then transferred to the working materials or objects.

How Do Cartridge Heaters Operate?

Cartridge heaters are an ideal solution for application requiring a concentrated heat source. They are designed for tight spaces, and are available in a variety of sizes, wattages, and voltages. Cartridge heater working principle is simple; the cartridge heats up when electric current is applied, and the heat dissipates into the surrounding environment. 

Operating Temperatures of Cartridge Heaters

The operating temperatures of a cartridge heater depend on the design, the type & wattage of the cartridge and the materials that it is made from, but usually they are designed in such a way that they can possibly withstand working temperatures of even up to 1400 degree Fahrenheit.

Uses of Cartridge Heaters

Cartridge heaters are used in a wide range of applications, including medical equipment, food processing, and chemical manufacturing. They are also used in the automotive and aerospace industries for sealing, soldering, and heat treating. Cartridge heaters are also used for many applications including shrink-fitting, plastic extrusion, and food processing.   Some of their most common uses include heat sealing and melting plastic materials, heating up molds for injection molding and forming, hot-air welding of plastics, and soldering of electronic components. Mentioned underneath are some of the typical examples of the specific applications of cartridge heaters:

  • Hot stamping
  • Heating gasses 
  • Heating liquids
  • Hot runner molds
  • Laminating press
  • Medical equipments
  • Semiconductors
  • Plastic moldings
  • Scientific equipments

Temperature Controllers & Sensors for Cartridge Heaters

To ensure safe operation, temperature controllers and sensors must be used to monitor the Cartridge Heater’s temperature. Also, for best results, it is important to use the right temperature controller and sensors when working with them. The temperature controller helps to ensure that the cartridge heater reaches the desired temperature, while the sensors monitor the temperature and provide feedback to the controller. With their ability to provide accurate, reliable, and cost-effective heating, cartridge heaters are an essential part of many industrial processes. By making use of the right temperature controller and sensors, they can help to ensure that your processes are operated at the optimal temperature and with the highest degree of safety and efficiency.

Heatcon Sensors 

If you are searching for the best range of products in this regard, then there’s a company which you can bank upon, and that is Heatcon Sensors; we are known to provide high-quality products that have high-end applications.

A Potent Cartridge Heaters Manufacturer

Application Areas

Specifications

Construction

Termination Options

Hot-Rod cartridge heater has been designed in such a way that it provides totally uniform heating as well as great heat transfer rates across the entire heating surface. With individually adjustable heating zones, different process requirements could possibly be achieved, including heating that is zone-specific as well as distributed power demand with precise & uniform temperature. Such a heater is built with as little space as possible between the sheath and heating element for keeping the internal temperature low, resulting in smaller heaters that operate at higher power.

Application Areas

  • Metal die molding 
  • Control over humidity 
  • Semiconductor room heating 
  • Semiconductor’s wire & die bonding
  • High-temp glass-forming equipment
  • Seal bars that are being utilized in the packing material 
  • Heating  (as per patient’s comfort) in medical equipment 
  • Frost protection & melting of equipments in cold climate or cold application

Specifications

  • Material of the Sheath: stainless steel, INCOLOY 
  • Operating Temp: Up to 760 degree Celsius 
  • Watt Density: Up to 400 W/in2 
  • Voltage: Up to 480V AC 
  • Tolerance of the Sheath’s Length: ±3%
  • Wattage Tolerance +5%, -10%
  • Resistance Tolerance: +10%, -5%
  • Termination Style
    • Swaged in the wires or leads
    • Pressed on wires
    • Right angle wires
    • Stainless steel braided 
    • Teflon Cable
    • Fiberglass Cables

Construction

  • High temp lead wires for temperatures ranging up to 550 degree Celsius 
  • High in efficiency ceramic caps slows down contamination, and also it is greatly suitable for applications, which are high in vibration. Deep holes inside the cap helps to prevent these leads from unfolding when bent. 
  • Nickel-chromium resistant lead or wire ensures longer service life, uniform twist and uniform heat distribution. 
  • Magnesium oxide filler that is high in purity is chosen for maximum dielectric strength as well as thermal conductivity; also it is quite compact for maximum transfer of heat. 
  • Stainless steel sheath or Inconel coating used for the purpose of oxidation & corrosion resistance in many different environments. 
  • Tig-welded end plate for preventing contamination due to dirt & absorption of moisture

Termination Options

  • Ceramic Beads: When the temperature at the heater outlet goes beyond 590 degree Celsius, the ceramic beads tend to protect the lead or wire until normal insulation could possibly be utilized. 
  • Flexible Copper Elbow SS Pipe: The right-angled flexible pipe or conduit could possibly be fixed with a copper elbow. Such methodology could also be utilized for connecting right-angled flexible pipe or conduit to the stock heaters. 
  • Crimped Wires: Crimped wires or leads are usually utilized when the temperatures at the end of the heaters exceed the maximum-allowed limit of the lead wire’s temperature. 
  • Right-Angled Cables: Right-angled cables or leads tend to be the most ideal ones for tight spaces. These leads or wires have been covered with silicone-impregnated fiberglass sleeves wherein they tend to exit the heater. 
  • Right-Angled SS Flexible Pipe: This provides similar advantages as those with stainless steel flexible conduits, however, with the right-angled arrangement tends to allow this to be utilized in tight confined spaces. 
  • Sleeve: Silicone rubber fiberglass sleeve & fiberglass sleeve.
  • Flexible SS Tube: The flexible tube or conduit tends to protect the wire from friction, but can’t bend as sharply as stainless steel’s braid. The flexible ducts are also recessed, offering a similar kind of benefit of not being pulled outside of the heater.

Heatcon Sensors 

If you are looking for a worthy Cartridge Heaters Manufacturer, then look no further than Heatcon, which happens to be a great company providing amazing products in this regard.

Let Us Look at the Detail about Pt100 Probe

What is a Pt100 probe?

Termination

Lead Wire

Element

Sheath

Temperature Rating

Types & Specifications

What is a Pt100 probe?

If you have been wondering what a Pt100 probe is, then you are not alone. The Pt100 probe is basically the assembly that consists of the RTD’s element, one sheath, one lead wire & also one terminal or one connection. The Pt100 happens to be a temperature sensor, which contains one resistor, which tends to change the resistance value when there are changes in the temperature. Such a type of probe is commonly used in temperature measurement and control, and it is important to understand how it works in order to get accurate readings. The Pt100 probe is used in a variety of applications including temperature measurement, process control, and thermal management. The Pt100 probe has a wide range of temperature ratings and can be used in both Cryogenic and High Temperature applications. The Pt100 probe can be terminated with a variety of lead wires and sheaths.

 

Termination

A Pt100 probe could be terminated inside a connection head, in the fast disconnect, in the terminal-block or also in the extension wire. The standard terminations are described on the product-related pages. Other styles of termination are available by special order. 

Lead Wire

Pt100 probes also have lead wires, which are used to connect the probe to a measuring device. The lead wires are usually made of copper or another conductive material. Lead styles & RTD cables of extension tend to be provided in 1 of the 4 configurations. Style two is the standard. Ensure selecting a configuration, which matches the instrumentation. Some probes are also available with different types of lead wires, depending on the application.

Element

A Pt100 probe consists of a Pt100 element, which is a resistive material that changes resistance with temperature. 

The standard RTD probe has been built from a 100 ohm European platinum curved element (á = 0.00385). 

Sheath

The element is encased in a sheath, which is typically made of stainless steel. The sheath protects the element from damage and also helps to ensure accurate readings. The sheath, the tube with a closed end, secures the element and also protects it against any moisture content & other environment for measurement. The sheath too gives protection as well as stability for the lead wires of transition of the sensitive element wires. The standard sheaths are 3 mm (1/8″) & 6 mm (1/4″) O.D. 304 tubes made of stainless steel material. 

Temperature Rating

Pt100 probes are available in a variety of temperature ratings, which determine the range of temperatures that the probe can accurately measure. “PR” Style of the RTD’s probe assemblies have been rated to be used in temperatures largely up to even 600 degree Celsius (1110 degree Fahrenheit). The style sensor of “PRTF” has been rated up to the range of 260 degree Celsius or 500 degree Celsius as per the design. The limitations for the temperatures might be placed upon the styles of termination because of the insulation used in the wire. The rating of maximum temperature has been made available by special order, and it can be 750 degree Celsius (1380 degree Fahrenheit). 

Heatcon Sensors

If you have been looking for accurate temperature readings, a Pt100 probe is a great option. This type of probe consists of a thin wire that is wrapped around a metal rod. The wire is then connected to a monitoring device. Pt100 probes are often used in industrial settings, as they are able to withstand high temperatures. They are also available in different sizes and with different lead wire and sheath options, so you can choose the best option for your needs. Keep in mind that the element and temperature rating of the Pt100 probe will affect its accuracy. When using a Pt100 probe, it is important to choose the right termination for the lead wires. This will ensure that the readings are accurate and that the probe is properly connected to the measuring device. For procuring the right type of products, you can come to Heatcon!

Describing the Equipments for Calibration Systems

Standard PRT

Secondary SPRTs

Master Thermocouples

Dry Block Calibrator

Coefficient of Uncertainty

The equipment that is needed for performing temperature sensors’ thermal calibration largely depends upon the desirable accuracy as well as easiness of usage. The larger is the precision needed, the more demanding is the procedure as well as the costs. The equipments for Calibration Systems is usually divided into 1 of the 3 groups.

  1. The general purpose system used to test temperature sensors in industrial plants generally provides an accuracy of 1.0 degree Celsius to 0.1 degree Celsius making use of the comparison techniques. 
  2. A secondary standard system used for high-quality comparisons as well as fixed-point measurement typically provides an accuracy of 0.1 degree Celsius and 0.01 degree Celsius. 
  3. The primary standardization system makes use of the highly advanced & precise equipment for achieving accuracy better than 0.001 degree Celsius. 

Typical equipments utilized for comparison calibration include the following: 

  • A standard PRT or the secondary PRT
  • Multiple temperature baths
  • System for data acquisition
  • Temperature Sensors

For low temperature calibration, Platinum resistance detectors are utilized as SPRT & RTD forms, which are quite stable as well as highly accurate. A noble-metal thermocouple, such as an R, S type, is utilized for high temperature calibration. Such sensors should have accuracy & repeatability. 

Standard PRT

SPRT or Standard-Platinum-Resistance-Thermometer happens to be a highly accurate standard that is currently available, but it is also quite an expensive one, & other such standards are the better acceptable alternatives as per the temperature ranges covered, desired accuracies, capability , or calibration lab preferences. 

Secondary SPRTs

These are much more usable & deal with less processing interferences. It is cheaper than SPRT. 

Master Thermocouples

These are utilized as reference sensors in the comparison calibration processes. These are placed together with the calibrated sensor in quite a stable temperature zone, and their values ​​are compared & errors are calculated. 

  • Temperature Reading Methods

These devices measure the power of sensors; they should be having higher resolution as well as fine accuracy. 

  • Secondary Temperature Sources

Dry Block Calibrator

This provides a highly convenient portable device for monitoring industrial sensors & typically achieves relatively fast heating and cooling. 

Stirred Liquid Bath

Such a bath provides an excellent thermal environment for probe immersion because there’s no air gap between probe & medium. 

Ice Baths

Such a bath consists of a mixture of melting shaved ice & water. 

Negative Baths

Negative Bath & Ice Bath are primarily utilized for RTD calibration, providing negative temperature for the application of lower temperature calibration. 

Fluidized Calibration Bath

Such a bath is a unique way to obtain precisely controlled temperatures

Coefficient of Uncertainty 

In the past, test device error or inaccuracy was usually a concern when the test device was used as a reference. The concept of uncertainty is now often used in the calibration of precision instruments, where high precision is required in the measurement. This concept is viewed based on several significant parameters. Today, calibration labs must calculate & add total/expanded uncertainty to all measurements while calibrating test instruments. This should be noted that “error” isn’t “uncertainty”.

Heatcon Sensors 

There’s a potent company providing high-quality products in this domain and that is Heatcon Sensors!

Let Us Discuss the Types of Thermal Calibration

Fixed Point Method of Thermal Calibration

Comparison Method of Thermal Calibration

Electrical Method of Thermal Calibration – Simulators & Sources

Types of Thermal Calibration

There happen to be chiefly 3 types of thermal calibration methods, which are as follows:

Fixed Point Method of Thermal Calibration

Fixed points happen to be the highly accurate devices, which are available to determine the temperature’s scale. The devices that are fixed-point in nature tend to utilize completely pure materials in sealed, inert environments; these tend to be generally delicate in nature, so, must be handled with utmost care. This method i.e. the fixed point method is basically an absolute methodology that is utilized for realizing the ITS-90 (which is the International-Temperature-Scale). The thermometer tends to be calibrated by measuring a series of temperature points that are fixed: for example melting or freezing point, triple point and vapor pressure point. This particular method consists in placing the thermometer in a cell with a fixed point, which provides an environment that is isothermal in nature. A fixed point cell is basically a flask that is almost filled completely with pure material & that is protected by a shell. The cell is placed in an apparatus, which provides fine temperature control as well as sufficient cell immersion for producing a uniform temperature in that particular measuring zone. The apparatus should have cooling that is fixed point & regulated heat. This can be a furnace; usually a vertical tube one with adequate insulation, or a liquid bath one. Multiple set points are selected. These must be as few as possible, which is consistent with creating a fine interpolation formula. Such methodology provides a very accurate calibration, and is being used only for the most high-quality thermometers. However, this is hard to implement due to the intricacy of the equipment, and the very many precautions needed to be taken for making fixed points successful. Fixed points are realized with the help of many pure substances. But, many don’t provide the necessary stability & reproducibility, and some others may also need an intricate procedure & special lab facilities.

 

Comparison Method of Thermal Calibration

In this type of method, usually the following are needed:

  1. A stable source for temperature 
  2. A calibrated master sensor
  3. A calibrated meter

 

The selectable calibration medium largely depends on the range of temperature as described below: 

  • For low temperature‘s calibration (that is usually below minus 180 degree Celsius) a copper block that is vacuum-jacketed. 
  • A controlled mixed liquid bath above minus ninety degree Celsius and up to 300 degree Celsius is the most common calibration method. Freon/alcohol could also be utilized from minus ninety degree Celsius, water at room temperature, oil up to 300 minus ninety degree Celsius. 
  • Salt-bath/liquid bath/dry-block can be used at temperatures up to 600 degree Celsius. 
  • Furnaces are more suitable for much higher temperatures. There are many models. Some have low thermal mass & fast response; while others may have high thermal mass & slow response.

 

For minimizing or reducing the temperature gradients in the bath/furnace, a metal equalizing block with thermowells is placed to receive both the standard as well as the thermometers, which are to be calibrated. This particular methodology makes it possible to cover a wide temperature range in a short time, point-by-point/continuously, & for calibrating several thermometers at the same time. However, the comparative method is less accurate than the fixed one.

Electrical Method of Thermal Calibration – Simulators & Sources

Indicators & controllers tend to be calibrated using injection signals that usually simulate thermocouples, thermistors or resistance thermometers. The simulators tend to give quite fast & comfortable methods to calibrate the instrument at several points.

Heatcon Sensors 

The best company, from which you can procure the best range of products happen to be Heatcon Sensors!

Thermocouple Extension Cable Insulation Type

Fiberglass Insulation

Ceramic Fiber Insulation

Alumina Fiber

Polymide Insulation

Mica

Asbestos

Thermoplastic Compounds – High Temperature Insulation

Fiberglass Insulation 

Such type of fiber-glass thermocouple extension cable insulation is basically utilized in high-temp applications with temperature ranging from -73 degree Celsius to 600 degree Celsius. This tends to have very good wear resistance, great dielectric characteristics, excellent fire & high-temp resistance. All these properties make this a vastly utilized one mainly in the industrial applications including glass plants, steel plants as well as aluminum plants. This is also made use of in the heat-treatment industry. 

Ceramic Fiber Insulation

This type of ceramic-fiber thermocouple extension cable insulation is having a higher range of temperature than that of the fiberglass discussed above. The operating temperature of this particular one is up to 800 degree Celsius. This has great fire & heat resistance characteristics. This is vastly made use of in various industrial applications such as in glass plants, steel plants as well as aluminum plants too. This one is also utilized in the heat-treatment industries, furnace research as well as in temperature sensors too. 

Alumina Fiber

This one has the highest temperature tolerance range up to even 1200 degree Celsius. This is also having great flame retardant as well as heat resistance characteristics. Continuous filament aluminum fiber has been adopted for use in the insulation of conductors as well as in the jacketing of cables, for the reason of it withstanding quite high temperature, thus maintaining crucial strength as well as flexibility even upto 1200 degree Celsius for long durations of time. These also have great chemical resistance. 

Polymide Insulation

Such types of polyimide tapes tend to be sturdy golden brown plastic films with great physical, chemical as well as electrical characteristics over a very wide temperature range. Such films do not tend to melt and they are also fire resistant because of having the highest flammability. The operating temperature of this type of insulation ranges from -267 degree Celsius to 310 degree Celsius. 

Mica

Having great fire & heat resistance characteristics, this flame retardant insulation type is typically used as a fire resistant intermediate tape. 

Asbestos

The primary reason for utilizing such asbestos insulation is its property of being fire & heat resistant. Among other reasons is its property of electrical insulation, acid resistance as well as good durability. The property of electrical insulation is also being used for protecting conductors from damaging conditions such as with exposure to moisture & chemicals, and even to fill up spaces wherever corona discharges are likely.

Heatcon Sensors

Heatcon Sensors is a company that houses the best range of products. So, whenever you are making such purchases, you can do so from the house of Heatcon!

 

 

Discussing about the Calibration of Sensors

Heatcon Sensors

Temperature is such a parameter that is oftentimes measured in business processes quite regularly. Various sorts of mechanical as well as electric thermometers tend to be utilized for experiencing & managing process temperature(s). Regular calibration of those thermometers is important to ensure a steady quality of the product(s) that are being manufactured, in addition to supplying regulatory compliance for a few industry verticals.

Calibration is a contrast among measurements – one in every acknowledged value or correctness made or set with 1 device & any other measurement done in the same manner as feasible with a 2nd device. The device with the acknowledged or assigned correctness is referred to as the standard. The 2nd device is the unit below check, testing instrument, or any of numerous different names for the device that is being calibrated.

Calibration of sensors is usually achieved for confirming the performance of an instrument/sensor. Calibration is the technique, which is utilized for making sure that an instrument/sensor keeps specification through the years & converting ambient conditions. Calibration of sensors is the technique that is utilized for preserving traceability of parameters almost about national/global benchmarked standards.

The technique of calibrations may be defined in as many ways as there are these methods. As per ISA’s (Automation, Instruments & Systems) dictionary, calibration may be described as – A test through which an acknowledged cost of measurement is carried out to transducers & corresponding output readings thus recorded below detailed conditions. The definition consists of the functionality to regulate the instrument at 0, and to set the favored span. The interpretation of this definition might say that the calibration is a contrast of measuring device in opposition to a standard instrument of better accuracy for detecting, correlating, regulating, rectifying & recording the accuracy of the instrument that is under comparison.

Heatcon Sensors

Having more than thirty years of expertise in the manufacturing of temperature sensors & heaters, Heatcon provides a greater level of accuracy, quality, as well as indomitable commitment to continuous customer support. Heatcon is a topnotch firm having great wealth of experienced & dedicated employees, who get on-going training in all segments of the business ensuring to provide the best level of service as well as product delivery to all the esteemed customers. Heatcon provides a host of different temperature measuring products to include thermocouple cables, general thermocouples, thermocouple connectors, mineral insulated thermocouples, and all sorts of different temperature sensors, as well as heaters. The products could be manufactured as per the specific requirements of the customers. We have an in-house calibration laboratory that is NABL-accredited. Heatcon happens to have the required resources as well as great expertise for providing worldwide advice on product(s) & equipment(s) to various companies across the world.

 

 

About the Inspection and Testing of the Sensors

Heatcon Sensors

Various tests are performed to ensure the quality of the sensor: 

  • Type Test: Such testing that is usually performed to demonstrate compliance with the specification is called a type test. The purpose of such a test is to show the general characteristics & design of a particular sensor sample. 
  • Routine Test: Such a test that is performed on each sensor according to the sampling plan is known as the routine test.

 

Important quality assurance tests are as follows: 

  • Inspection of Appearance & Construction: Visual inspection ensures conformance of thermocouple assembly to specification, drawing & materials. The finish of seams, joints, welds, name-plates/tagging-plates and other parts are visually inspected for any defects, dirt and roughness on the surface. If needed, welds and fittings can be subjected to a dye-penetration-test, hydrostatic pressure testing and even X-ray inspection. 
  • Dimensional Checks: Unless otherwise stated, dimensional checks are made according to the tables using a straight gauge, Vernier Caliper, and even gauges. 
  • Insulation Resistance Test: Such testing is usually performed with a super megohmmeter by applying a steep temperature gradient to the sensor assembly that has been immersed in a boiling water-bath for accelerating the condensation of residual moisture in the assembly. Such testing allows a very precise measurement of the assembly’s insulation resistance between the sheath and the terminal. 
  • Emf Calibration Tests: Such a test could be performed by two ways, one with the standard method with RTD or standard thermocouple, and second option is by the absolute method using fixed point standards in each unit or set at 3 points of the preset temperature as per the sensor type. 
  • Pressure Tests (Only for Elements That Are Sealed): The element would be tested in a hydraulic testing chamber where ice & water are in equilibrium, and they are electrically connected to a suitable indicator. The fluid pressure in the chamber should be increased to 35 kgf/cm, and then maintained for 15 mins. The element’s resistance or EMF must not deviate considerably enough from the equilibrium temperature that corresponds to the applied pressure, and when the element is later removed from that chamber, it must pass the accuracy test as well as the insulation resistance testing. 
  • Thermocouple Type Identification Test & Polarity Test: Either immersing the thermocouple in the boiling water bath above or applying hot air/flame heat to the hot-end/cold-end of the bead thermocouple to produce an EMF that allows a certain type of thermocouple to be plotted on Temperature vs. EMF-table. A DC circuit tester that is high in resolution tends to be utilized for identifying the thermocouple type & the polarity of the thermocouple’s terminal & its leg.
  • Others: Loop Resistance tests, pressure tests, X-ray tests, vibration tests, voltage withstand tests, helium leak tests, etc. could even be done if requested.

Heatcon Sensors

Heatcon happens to be that ultimate stop where you can find the best range of products in this regard.

Gain Adequate Know how about Furnace Monitoring System

Cement Kilns & Coolers

Power Utility Boilers

Steel

Glass 

 

Furnace Monitoring System – Introduction 

Such systems are necessary to see the internal conditions of any hot furnace. Conventionally speaking, this used to be done through peep holes inside the furnace, however with better protections and the advent of new-found technologies, to obtain this image, the control room provided a great benefit to the operators as well as plant management. Cameras for monitoring the furnaces are utilized in cement plants, steel plants, glass plants as well as power plants; to see in the boiler furnaces, rotary kilns, melting furnaces, clinker coolers, and etcetera. Such types of systems are flexible in nature and they are quite easy in installation on the furnace wall. They have a 68°horizontal & 50°vertical field of the view; providing a better overall picture. The conventional straight view lens tube is commonly utilized in most wall-mounted boilers. The offset angle-lens could be utilized in much smaller-sized tangentially-heated boilers that are corner-fired. 

Application Information 

Cement Kilns & Coolers 

To make the finest firing decision, the kiln user must have reliable information about the kiln. The camera of the furnace offers a view into the interior of the kiln directly in that of the control room. The camera of the furnace shows the flame, monitors its length, direction and any effect that it has on the feed. Better control helps in achieving the best conditions of operating for the flame and also improves efficiency of the fuel. The temperature of the flame could also be monitored while petroleum coke or burning coal; and this is done by observing the color changes or selecting a thermal camera. The camera selected for the coolers-section offers a view in the coolers, which is crucial for monitoring the condition of the cement clinker that is quite significant for the quality of the product.

Power Utility Boilers

Cameras have been utilized for decades for viewing the interiors of the boilers operating with coal & oil heating for facilitating start-up or shut down! There is a risk of an explosion inside the boiler if the fuel does not ignite as it should, so monitoring this process will help prevent this type of any unrequired reactions. Earlier, flame detectors had been utilized for assisting light-of, but this was not quite reliable as is needed. Black & white cameras had also been utilized for helping, but were often pulled when the boiler was under full load as such cameras rarely work well across the full dynamic ranges of these boilers. Now, with the help of certain new found systems, it’s now becoming increasingly possible to constantly monitor the various condition(s) of such furnaces. 

Steel 

The camera of the furnace gives a clear-cut view of steel-slab progress in batch or even continuous steel reheating of the furnace as well as the performance of the burner. The camera here is perfectly installed near the furnace exit, above the products on opposite sides. A collective view of the cameras gives a 360-degree view of this furnace. The camera is even quite useful if it is installed below the height of the slab traveling movement. This helps to see the scale accumulated under the steel. 

Glass 

The camera of the furnace offers a clear-cut view of the inside of the glass furnace. It controls the condition of the molten glass, the health of the refractory material and the activity inside the furnace. A thermal view is used in some of the specific cases wherein the need is of obtaining a thermal view of the furnace. With the help of data recording, it is possible to analyze the life of the refectory, etcetera. Such types of cameras are also being utilized in the applications of steel kilns to view the interior of those kilns & the burner flame. A furnace camera installed at the entrance of the rolling mill helps the users to monitor the slab from the plate to the rolling mill.

Heatcon Sensors 

For the best range of products, you can count upon Heatcon! So, for any such industrial need, you now know whom to contact!

Know It All about Thermowell Fitting Accessories

Metal Plugs & Socket Connections

Standard and Mini Thermocouple Connectors

 

Thermowell Fitting Accessories

Installation of the temperature sensor assemblies into a thermowell or straight inside a said process needs the utilization of a certain type of fitting that of brass/stainless-steel. This fitting tends to consist of some threaded connections, a bayonet cover (& adapters) along with a flange as well. The flange, which is somewhat adjustable, could simultaneously be utilized to assemble the sensors during the said process. The cap enables quick installation in suitable adapters, which are located inside that process; and such a technology has been used widely majorly in plastic machineries. Bushes & hexagon-plugs have been utilized while adjustments and/or removals in a much lesser significance. The selection of the fitting might be driven by the necessity for pressure integrity or also by the limitations of physical sizes. Such a compression-fitting as well as threaded brush could be supplied as well with the tapered threads for achieving a connection that is pressure-tight. 

  • Compression Fittings: The compression fittings, which are adjustable in nature, have been utilized straight over the probe for achieving the much-needed insertion length in that process, as well as for ensuring right protection of the probe(s) inside the thermowells. A compression fitting thus used to attach tubing (i.e. piping) usually has ferrules inside them. Compression fitting is thus quite popular as it does not need any kind of soldering, which makes them relatively quicker & easier to be used. 
  • Nipple Fittings: A nipple is made from the same flange family at both ends of the tube section. (Hybrid adapters are connectors with flanges of a different family on each end.) A straight nipple is made with the same-sized flange on both ends of a straight tubing-section. The reducer nipple has flanges of different sizes at both ends (that belong to the same family). 

 

3-piece unions must be utilized in dangerous places, in the junctions of pipes (conduits) & boxes or different appliances. The links consist of 3 independent pieces, which could possibly be screwed together by the rotation of the same pieces together among them. 

Terminations

Metal Plugs & Socket Connections

The connection between the thermocouple’s thermoelectric leads and the extension cables is made with uncompensated male & female connectors. The metal frame and housing of such connectors tend to ensure the continuity of protection or screening, & good temperature. 

Standard and Mini Thermocouple Connectors

The standard and mini connectors are perfect for connecting the sensors of a thermocouple along with the extension or compensation cable towards one another. The pins tend to be polarized for preventing any wrong connections and the connector body also tends to be marked with polarity. Such connectors are color coded as per the specific standards such as: IEC and ANSI etc.

 

 

Gain Information about Thermowell Special Coating

Thermowell Special Coating

Variety of Thermowell Special Coatings

Tests on Thermowell 

Thermowell Material Selection

 

Most industrial facilities rely on some form of temperature measurement in order to monitor and control processes. One of the most critical aspects of temperature measurement is the thermowell. A thermowell is a protective sleeve that houses the temperature sensor. It acts as a barrier between the process and the sensor, allowing the sensor to be removed or replaced without disrupting the process. The thermowell is basically the component that is used to protect sensors from high temperatures. In order to prevent damage to the sensor, a thermowell is often used. This tube-like component is inserted into the process stream. The sensor is placed inside the thermowell. The thermowell protects the sensor from the high temperatures of the process stream. The thermowell also allows the sensor to be removed from the process stream without interrupting the process. Thermowells are often subjected to harsh conditions, which can lead to corrosion and wear. In order to protect the thermowell and extend its lifespan, many facilities specify a special coating for their thermowells.

Thermowell Special Coating

Thermowells are often coated with a special coating to protect the sensor from the high temperatures of the process stream. The coating also allows the sensor to be removed from the process stream without interrupting the process. The coating is applied to the thermowell before the sensor is placed inside the thermowell. The coating is applied to the outside & inside of the thermowell, to the sensor, lead wires, electrical connections, solder joints, terminals, housing, base, cover, mounting bracket, support bracket, gasket, seals, o-rings, washers, screws, and nuts & bolts.

Variety of Thermowell Special Coatings

There are a variety of special coatings that can be applied to thermowells, depending on the specific needs of the application. Some common special coatings include:

  • Teflon
  • Tungsten
  • Boron Nitride
  • Zirconia 
  • Alumina
  • Stellite 

 

The type of special coating that is applied to a thermowell will depend on the specific needs of the application. In many cases, a combination of coatings may be used in order to achieve the desired results. If you are specifying a thermowell for a temperature measurement application, be sure to discuss your coating requirements with your supplier. They will be able to recommend the best coating for your particular application.

Tests on Thermowell 

Some Thermowell tests include the following:

  • Radiography
  • Material tests
  • Dimensional tests
  • Dye penetration tests
  • Hydrostatic pressure tests

Thermowell Material Selection 

The choice of material is the most significant aspect in the service life of a thermowell. Selection of the thermowell is entirely based on the application temperature & process environment.

  • Connection: This happens to be the installation factor
  • Insertion Length: This happens to be the accuracy factor
  • Bore Size: This happens to be the interchangeability factor
  • Tapered/Straight Well: This happens to be the factor for velocity rating 

PTC 19.3 Thermowell Standardization 

ASME (American-Society-of-Mechanical-Engineers) PTC (Performance-Test-Codes) have been made use of for determining the performances of particular, mechanical equipment that tend to be constructed for meeting some required criteria for performance as well as operability. 

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Thermowell Special Coating is a type of coating that is applied to thermowells in order to protect them from the environment and extend their life. There are many different types of thermowell special coatings available, each with its own set of benefits. Choosing the right coating for your thermowell is important in order to get the most out of it. Contact Heatcon for the best range of products in this domain.

 

 

Introduction to Thermocouple Extension Cable

More about Thermocouple Extension Cable

About the Costs

Insulation

Introduction to Thermocouple Extension Leads and Compensating Cable

It’s usually desired for connecting thermocouples’ probes as parts of some very long circuits to a remotely operated unit of reference and/or some measuring instruments further away from the sensor itself. However, the expense is generally avoided of high-quality thermocouples’ cables in the longer run. It can be fine if some cheaper cable is connected, but this has to be done without worrying too much that the connection temperature is known & taken well into consideration. When thermocouples are connected to instruments, it’s necessary to use a cable with the same EMF-output as that of the thermocouple; else spurious EMFs will occur at those junctions. The finest solution hence comes with the utilization of the same material as that of the thermocouple (extension-cable). A cost-effective option is to utilize compensating cables with alloys different from those of the thermocouples, which have the same power in a limited range of temperature.

More about Thermocouple Extension Cable 

Compensating & extension grades of wires tend to be provided in the bright-annealed form. To make this happen, the extra conductor’s thermoelectric properties mustn’t vary much from that of the thermocouples. Extension & compensating cable offers a highly-convenient & quite-economical solution; with its own advantages as well as disadvantages. The extension cable nominally utilizes a similar conductor as that of the thermocouples, so that it has similar thermal characteristics and no such problems appearing with the connection. The mismatching error appearing from high temperature of the connecting-box tends to be comparatively small.

About the Costs

Such cables tend to be less expensive than thermocouples’ wires, though not quite cheap; they tend to be produced in a form suitable for long-distance transport, usually as multi-core cable or flexible wiring. These are advisable for the highest level of accuracy. Compensating cables, alternatively, tend to be less accurate but less expensive even. They use quite a variety of relatively cheaper alloy conductors’ material. Therefore, combining these would harness the same power as a particular thermocouple, but the range of operating temperature must be limited to keep the mismatch error acceptably diminutive.

Insulation

Insulation is known as the layer of polymer, plastic, or high-temp compound applied directly over the conductor. Generally, various insulations are offered along with a vast temperature range from -260 degree Celsius to 1200 degree Celsius. Most insulating materials are also being utilized for sheathing. Insulating material is selected as per their mechanical, electrical, and high-temp properties. Sheath means the outer layer of polymer, plastic, or high-temp compound applied to the cables. The outermost sheath (or better known as the jacket) is intended for mechanical protection of the insulated cores and other cable’s components. 

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Get Complete Knowledge on Thermowell Tip Profile

Basic Thermowell Structure – Shank Construction

Flange Face Types

Thermowell Welding

WPS & PQR

 

Thermowell Tip Profile

  • Tapered: The outside diameter progressively reduces along the length of the immersion. This is utilized for various high-speed applications. 
  • Flat Tip: One end of this is having a flattened surface. This one is utilized for low-pressure applications or in places where the flow characteristics that are around the body aren’t that significant. 
  • Domed Tip: This type of protective cover has a hemispherical tip at the thermowell at one of the ends. This one is utilized in various high-pressure applications or in places where the flow characteristics, which are around it, are quite significant. 
  • Spherical Tip: For this, a special drill with 118ºC tip angle is utilized for thermowell’s production. The end is spherical i.e. in the shape of a ball, for achieving wall thickness as uniform as possible. 

Basic Thermowell Structure – Shank Construction

  • Q-Dimension: This happens to be the shank’s thickest segment on the hotter side of flange or process connection. This depends on the size of the bore & that of the process connection. 
  • Bore size: This is Thermowell’s inner diameter. This can also be referred to as the diameter of the cylindrical cavity inside the thermowell or protective tube. The standardized drilling dimensions are 6.5mm and 8.5mm. 
  • Immersion U-Length: Thermowell’s length or that of the protecting tube, which is under the flange, the mounting threads, the bushing, etcetera; extending into the area of the process. This length, ‘U,’ is actually measured from the process connection bottom to that of the Thermowell’s tip. 
  • Lagging Extension T-Length: Additionally to the standardized head lengths, the trailing extension length is required to allow access to the end of the trailing extension and allow the probe to reach through insulation/walls. 
  • Inside Mounting Thread: Thermowell’s inside thread shields to secure the junction temperature device & nipple extension for the assembly of a Thermowell. 

Flange Face Types

  • Raised-Face or RF: This is the most commonly used flange type, and this one can be easily identified. This is called an RF or the raised surface as the sealing surfaces are raised above the surface of the bolt circle. 
  • Ring-Type Joint or RTJ: Its flanges have grooves, which are cut into the surface that seal with steel rings. 
  • Flat Face or FF: This one has a sealing surface that is in the similar plane as the surface of the bolt circle. 

Thermowell Welding 

Welding is actually the process in which 2 metals are joined by heating them to a suitable temperature. This can be made with or without pressure, and with or without any filling. The 2 main types are as under:

  • Full Penetration – This particular type of weld provides a fully-welded interface between 2 parts & is usually the sturdiest joint. 
  • Partial Penetration – This particular type of weld consists of an interface that is partially welded with a filler metal placed on the surface of the 2 metals.

WPS & PQR 

WPS stands for Welding-Procedure-Specification. It is actually a document, which tends to describe the process of welding and how it should be done in production. These are advisable for all sorts of welding operations as well as the many application codes & standards tend to make them kind of mandatory.  WPQR or PQR is shortened to Procedure-Qualification-Record. This is something that supports the WPS. This is actually a test-weld that has been made & tested (quite rigorously) for ensuring a good weld with the procedure.

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Know All about Thermowells and Their Types

Types of Thermowells as per Their Connection to Process

Types of Thermowells as per Their Production Method

 

Thermocouples, RTDs, and other temperature sensors are essential for many industrial and commercial applications. However, these sensors can be damaged by exposure to high temperatures. This is where thermowells come in. These are designed to protect temperature sensors from the high temperatures of the process. They are made of materials that can withstand the temperatures of the process, such as stainless steel or ceramic. It also provide a convenient way to remove and replace sensors without disturbing the process. Those are an essential part of many industrial and commercial applications. They protect temperature sensors from the high temperatures of the process, and provide a convenient way to remove and replace sensors.

Types of Thermowells as per Their Connection to Process

There are many different types of thermowells, depending on the application.

  • Threaded Thermowells have threads at one of the ends & they are screwed in the process. These threads could be of parallel/tapered types. Threaded thermowells are easy to install & remove, and they’re relatively inexpensive. They can be used with a variety of different thread sizes. However, they’re not as sturdy & durable as other types of thermowells; so they’re not suitable for high-pressure applications; and can also be damaged if not installed correctly.
  • Socket-weld Thermowells are welded into the weldalets & one weld is welded straight in the process. Those are more expensive than threaded thermowells, but they’re much more sturdy & durable. They’re also better suited for high-pressure applications. They’re also easier to install correctly, which reduces the risk of damage. However, they can only be used with certain types of socket weld fittings.
  • Flanged Thermowells have flange collars that are connected to mating flanges. Though they are a bit expensive, still Flanged welded thermowells are quite strong, and they’re also the most durable ones. They’re generally only used in high-pressure applications where threaded or socket weld thermowells wouldn’t be suitable. They can be used with a variety of different flange sizes, and are easy to install correctly. However, they’re not as widely available as other types of thermowells.

Types of Thermowells as per Their Production Method

Thermowells are used in a variety of industries to protect temperature sensors from the environment. They are also classified according to their production method.

  • Fabricated thermowells are made from a variety of materials, including stainless steel, Inconel, and Hastelloy. They are typically custom-made to fit the specific application. 
  • Bar-stock thermowells are made from a solid piece of metal that is machined to the desired shape. 
  • Van-stone thermowells are made by welding a metal sleeve to a pipe.

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Protection Tubes Explained in Detail

Features of a Protection Tube

Metallic/Non-Metallic Sheath or Protection

Ceramic Sheaths with Thermocouple Elements 

Types of Protection Tubes

 

Protection Tubes

Thermowell, Fittings, and Terminations are all important components of a protection tube assembly. A protection tube, also called a thermowell, is a hollow sleeve that is used to protect temperature sensing elements, like thermocouples and RTDs, from the process environment. Thermowell is available in a variety of materials, like stainless steel that can withstand high temperatures and corrosive environments. Fittings are used to connect the protection tube to the process. Common fittings include weld-in fittings, threaded fittings, and sweat fittings. Terminations are used to seal the end of the protection tube and protect the sensor from the process environment. When selecting a protection tube assembly, it is important to consider the type of process environment, the temperature range, the pressure range, and the corrosion resistance required.

Features of a Protection Tube

Thermowell fittings and terminations are an essential part of any process system. They provide a means of protecting expensive instrumentation from the hostile environment of the process. A well-designed protection tube will have a number of features that make it an ideal choice for use in a process application. These features include:

  • A smooth interior surface that is free of sharp edges or burrs. This is important to prevent damage to the instrumentation that is being protected.
  • A thick wall that is resistant to corrosion and can withstand the pressures and temperatures of the process.
  • A robust connection to the process piping that will not leak or fail under pressure.
  • A flared end that allows for easy installation of the instrumentation.

Metallic/Non-Metallic Sheath or Protection 

A metal tube, mostly stainless steel, tends to have some mechanical advantages plus an increased thermal conductivity; these are usually immune to any thermal shock(s). The metal protective sheath can possibly be utilized at temperatures up to 1150 degree Celsius. Ceramic is better when more purity is needed for the sensors or products to not contaminate at high temperatures.

Ceramic Sheaths with Thermocouple Elements 

The basic use range of the ceramic sheath is at 1000 – 1800 degree Celsius. These could be in direct contact with the medium one or could also be utilized as gas-tight inner sheaths for separating the thermocouples from actual metal protective tubes. These must be installed in a hanging position above the temperature of 1200 degree Celsius for avoiding any distortion or breakage owing to bending stress. Even any hairline crack could possibly cause contamination of the thermocouples, leading to drifts or damages. Thickness of the wall of the material is also significant; where a thin-walled tube is better than a thicker wall. Cracks often occur when they are subjected to too rapid temperature alterations when quickly removed from hot furnaces.

Types of Protection Tubes

  1. Metallic 
  2. Non-Metallic 

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When selecting a protection tube for your application, it is important to consult with a knowledgeable supplier who can help you choose the best option for your specific needs. Contact Heatcon right away! So, if you are looking for high quality protection tubes, thermowell, fittings and terminations, look no further than our company. We offer a wide range of products that are designed to meet the highest standards of quality and safety. Our products are also available in a variety of sizes and configurations to meet your specific needs. Contact us today to learn more about our products and how we can help you protect your investment.

 

 

Information about Industrial RTD Probes

Probe Assemblies

Flexible Resistance Thermometers

Resistance Thermometer for Special Purposes

Applications of Resistance Thermometers

Advantages of Platinum Resistance Thermometers

Limitations of Platinum Resistance Thermometers

 

Industrial RTD Probes

Encapsulated probe is basically a resistance thermometer’s standard configuration usually for industrial process control as well as protection of the machinery. Most of such probe cases tend to be of stainless steel or Inconel for withstanding extreme temperature, though other material provides better benefits in the mid-range. Standard diameter of the probe ranges from 0.125. to 0.250. Small sized probes tend to react faster when they are inserted directly, however large sized probes fit much tightly into the standard protective covers. The length-range of a probe tends to vary between some inches to even 10 feet or even more than that. 

Probe Assemblies

A wide range of mounting parts as well as accessories tends to assist in the installation of sensors. The choice is largely based upon the nature of the detected carrier and the cost needs. Direct probe immersion needs a threaded connection that can be fitted well or welded to the probe. 

Flexible Resistance Thermometers

The encased probe is not very suitable for detecting flat surfaces. Unlike the junctions in thermocouples that could be soldered straight to metal surfaces, RTDs provide some mass; & heat loss to the surrounding air, which can tend to affect the reading. Small-sized flattened elements like thin films could also be mounted to the surfaces, but sensitive elements as well as wire connections tend to make the process installation much more difficult. 

Resistance Thermometer for Special Purposes

A resistance thermometer tends to adapt easily to most models of process control & thermal equipment. The users can specify axial lead enclosures for the mounting of the circuit boards, flat packages in order to clamp to the surface(s), mini enclosures for embedment in metal blocks, and any fittings & sheaths that can all be produced by a machine shop. Additionally, windings of the wires could possibly be configured for detecting larger regions. 

Applications of Resistance Thermometers

In general, resistance thermometer offers the maximum number of benefits over other types of thermometers in the following situations: 

  • High standardization is desirable 
  • Sensing of area, instead of point, betters control 
  • Accuracy should be extending over a vast range of temperature
  • Accuracy & stability being the most important application goals  

Advantages of Platinum Resistance Thermometers

  • Lesser drift 
  • Higher accuracy 
  • Wide range of applications 
  • Suitability for specific and precise applications  

Limitations of Platinum Resistance Thermometers

  • A resistance thermometer in industrial application is rarely used above 600 degree Celsius. At a temperature above 660 degree Celsius, it tends to become highly difficult to avoid contamination of the platinum with the metal shell of the thermometer. Therefore, standard lab thermometers replace the metal sheath with a glass construction. At a very low temp, say somewhere around -270 degree Celsius (i.e. 3K) or even lower than this, the reason being quite a lesser no. of photons, the resistance is principally measured by the impurities as well as boundary diffusion; and therefore, essentially temperature independent. Resultantly, RTD sensitivity is largely zero, so it is not quite useful. 
  • Compared to a thermistor, platinum resistance thermometer is less sensitive to minute temperature alterations & has a much slower reaction time. But a thermistor has a much smaller range of temperature as well as stability.

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Potential Sources of Error in RTD

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Sources of Error in RTD

RTD’s i.e. the Resistance-thermometer-systems are prone to 3 major sorts of errors:  one is the tolerances built into the thermometers inherently, second is with the gradients between the thermometer & the measuring medium, and third type of errors in the path between the sensor & the display/control device. Some error sources are purely electronic; while others can be due to the mechanical designing of the thermometers. 

  • Conformity or Interchangeability: Interchangeability or conformity defines the amount of resistance by which the thermometer is allowed deviation from the standard curve.
  • Sensitivity: The change in resistance per degree temperature change is actually the function of the base resistance as well as TCR (which is the Temperature-Coefficient-of-Resistance). 
  • Insulation Resistance: If the sensing element & the leads are not insulated fully from the housing, a bypass effect happens, wherein, the housing tends to become a parallel resistance that tends to lower the apparent values. 
  • Self-Heating: The resistance thermometers are the passive resistance sensors; they need a measured current for producing beneficial signals. As this particular measuring-current tends to heat up the cell wire above the actual ambient temperature, errors are bound to occur if excess heat is not being dissipated. 
  • Time Constant: The time constant is actually the indicator of the sensitivity or responsiveness of the resistance thermometers to any temperature changes. The rate of these responses is dependent over the thermometer’s mass as well as the rate at which heat is being transferred from the outermost surface towards that of the sensing element. A faster time constant decreases the chances of errors in the system subject to quick changes in the temperature. 
  • Repeatability: The amount of agreement between 2 consecutive readings of any thermometer happens to be its repeatability. Loss of this repeatability may lead to temporary or permanent changes happening in the element’s resistance characteristics & they can eventually lead to exposing the thermometer to temperatures which are at some specified range endpoints or above them. 
  • Stability: Being stable is a long deviation of the readings of the thermometer. A normal specification limits such deviations to only 0.1 degree Celsius per year in nominal mode. Usual services that stay well within the temperature range tend to result in very less drift. Drift is actually the consequence of the element’s material; platinum happens to be the most stable one; encapsulating those materials that can contaminate the element; as well as the mechanical stress which is there on the element due to the expansion of coils or some other supporting structure. 
  • Shock & Vibration: Mechanical shock as well as vibration tend to alter the reading of any such thermometer or can also lead to total failure. In reality, stability as well as durability is somewhat unique. Designed for maximum stability, the lab thermometers contain unsupported elements that are too sensitive for use in industrial applications. The elements of most such industrial RTDs are supported completely by the bobbin or some other packaging material, so that they can withstand even the most extreme environments quite well. 
  • Packaging & Heat Transfer: Sheaths & other such structures neighboring resistance elements must be maximizing the transfer of heat from any detected environment, and must be minimizing the transfer of heat from any environment that can change the reading, & thus provide the elements with the required protection.

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Let’s Delve Deeper into the Concept of Mineral Insulated RTD

Metal Sheathed RTD

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Mineral Insulated RTD

Mineral-insulated (M.I.) resistance thermometers are usually equipped with platinum measuring resistors (i.e. Pt100 Ω) according to DIN IEC 751. The inner conductors (Cu) have been embedded in densely packed inert mineral powder (i.e. MgO) which measures that the resistor has been connected to the internal conductors; and it is also surrounded & embedded in a metal shell, thus forming an assembly that is hermetically-sealed. Constantan & nickel inner conductor(s) are also sometimes utilized. Cover is a useful protection in most of the circumstances. These are used in places where a quick response, lesser space and/or vibration resistance is required. These could be equipped with a fixed cable or a special connector that allows quick installation or replacement. Such Mineral Insulated RTD temperature sensors usually have flexible, thin-walled mineral-insulated stainless steel cables with low-resistance copper wires that have been braided in compressed heat-resistant magnesium oxide. The temp-probe is well-connected to internal wiring and placed in a stainless steel case. Thermowell & mineral-insulated cable have been welded together. Proper heat transfer between the housing & the temp-probe enables a short response time & high measurement accuracy. Anti-vibration (vibration-resistant) design ensures long service life. Temperature measurement of hard-to-reach measuring points is possible; thanks to a flexible cable with mineral insulation. The smallest bending radius is five times the outside diameter.

Metal Sheathed RTD

  • Consists of thin-walled & flexible stainless steel mineral-insulated cable. 
  • The cable consists of low-resistance inner wires, which are made from compressed refractory magnesium oxide. 
  • Temperature sensor being well-connected to internal wires & installed in the protective tube. 
  • The protective tube & sheath cable have been hermetically connected. 
  • Proper heat transfer in the protective tube & the temperature sensor enables quick response time & high measurement accuracy. 
  • Flexible sensor tubes enable measuring of temperature in hard-to-reach places. 
  • These are being utilized in heavy measuring applications with high vibration and in all measuring positions where flexibility & exchange ease have been required. 
  • Applications can be seen in power plants, chemical plants, engines, and mechanical engineering & construction facilities along with some usual industrial applications.

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With more than thirty years of experience in manufacturing temperature sensors & heaters, Heatcon provides high-quality, precision and an unsurpassed commitment to customer support. Ours is a world-renowned firm with vast experience of our employees, who are provided with continuous training in all areas of the businesses so that they can continue providing excellent service as well as product support to all our esteemed clients.

 

 

Gaining Knowledge about RTD Wire Configuration

Two Wire RTD

Three Wire RTD

Four Wire RTD

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RTD Wire Configuration

RTD is available in 3 different types of wire configurations. The choice of such lead wire configuration is entirely dependent on the expected accuracy as well as on the instrumentation that is being utilized for measurement purpose.

Two Wire RTD

Of the 2 wires, the RTD has the simplest circuit configuration. 1 of the wires is attached to each of the sides of the element. The measurement can be made with any device that has been equipped for measuring resistance, which includes the basic VOMs (i.e. the volt-ohmmeters). This is the least accurate method of measuring temperature because the resistance of the lead wire is in serial conjugation with the sensing element. The lead wire is at a temperature different from the sensing element, and is also having varied resistance & temperature characteristics. More the length of the wire, the bigger is its effect over the measurement.

Three Wire RTD

Three-wire RTDs happen to be the most popular configurations for use in industrial applications. Three wires can be used to minimize the effect of wire resistance. Making use of this way, the 2 wires leading to the sensor are on adjacent branches. Each leg of the bridge has a lead resistor, so the impedance cancels as long as the two lead resistors are exactly the same. This type of configuration allows up to 600 meters of cable. When utilized in the correct fashion, the three-wire configuration removes any series resistance, which allows accurate measurement of the sensor element. Two wires are connected to one side of the sensor element and one wire to the other side. The resistance of L1 & L3 must be very close as much as possible; which will cause the resistance of the wire to decrease. The color code for a three-wire RTD is 2 red and 1 white.

Four Wire RTD

Four-wire RTDs are the most accurate ways of RTD measurement. They are mostly used in labs & are rarely seen in any kind of industrial applications. The 4-wire resistance thermometer configuration augments the accuracy as well as the reliability of the measured resistance: the resistance error is zero due to the resistance of the lead wire. Four-wire RTD circuits eliminate the effects of mismatched resistors in the wires. Constant current passes through L1 & L4, L2 & L3 measure the voltage drop across the RTD elements. Four-wire RTDs are mostly color-coded as 2 red and 2 white wires. 

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Let’s Discuss the Different Types of RTDs

Other RTDs Types

Standards of RTD

RTD Construction

 

Types of RTDs

The Platinum-RTDs are generally offered in 2 different categories; 1st is the ‘Class A’ & the other is ‘Class B.’ 

  • Class A: This one is presumed to be high in accuracy, and also, this one has ±0.06 ohms ice-point-tolerance. 
  • Class B: This one is known to have standard accuracy, and also, this one has ±0.12 ohm ice-point-tolerance. This type B is used popularly in most of the industry verticals.

Other RTDs Types

  • PRT or the Platinum-Resistance-Temperature Sensor: These provide awesome accuracy over a vast range of temperature (ranging from -200°C to even up to 850°C). 
  • Other options for resistance value: The RTD elements are even provided with resistances of 200 Ω, 500 Ω and 1000 Ω at zero degrees Celsius. These RTD types are commonly called PT200, PT 500 & PT 1000 respectively. 
  • SPRT or the Standard-Platinum-RTD: ITS-90 (1990 International-Temperature-Scale that is utilized as a global practical scale for temperatures in the laboratories of national metrology such as NIST & NPL etc.) consists of several fixed reference points as well as various interpolation devices, which are made use of for determining the scale amongst the points.

Standards of RTD

Platinum RTDs have basically 2 standards

  1. European standard (this is also called the DIN/IEC standard) 
  2. American standard

RTD Construction

RTD elements almost permanently need insulated conductors. At a temperature below about 250 degree Celsius, the PVC, silicon rubber or the PTFE-insulator are majorly made use of. Fiberglass or ceramic is used over it. The measuring point, & largely most wires, needs a housing/sleeve protection, which is usually made from metal alloys, which are chemically inert to this process that is under monitoring. 

  • Platinum Thin Film: RTD’s thin film style is perhaps the most known model due to its rugged design & less price. For making a thin film element, a small ceramic chip is covered with a very thin (0.0001″) platinum film & then a resistive path is cut or chemically etched into the platinum film. After that, the element is covered with quite a thin glass layer for protecting it from harmful chemicals as well as gases. 
  • Internal Coil Wire Wound: This type is usually made of platinum wire. A very small platinum wire (0.02 mm) is twisted & after that slipped into a small 2-hole ceramic insulator. After that, big extension wires are welded to the platinum wire ends & cemented in. Some of the manufacturers fill the insulating holes with ceramic powder after the coils are installed. This prevents the coils from moving & shorting against one another. The one end, which is right opposite the extension wires, is also coated with ceramic cement. 
  • External Wound Element: An external wound element of RTD is formed by winding the sensor element wire around the central mandrill that is generally formed from ceramic. After that, this coil or winding is covered with glass/other material for insulating so as to protect & secure the winding. These wires are then welded to the extension cords & after that secured to the frame with ceramic epoxy/cement.

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All You Need to Know about the RTD Sensor

RTD

RTD Materials

Temperature Rating

 

Introduction 

Sir Williams Siemens, in the year 1871, was probably the 1st to introduce temperature measurement using the resistance/temperature characteristics of various materials and largely laid the foundation for modern resistance thermometry. The resistance of the material is given by the given formula:

R = (ρ × L)/A

In this:

  • R is for Resistance (measured in ohms)
  • ρ stands for Resistivity (measured in ohm/cm)
  • L is for Length (measured in cm)
  • A stands for Cross-sectional area (measured in cm )

History 

Sir William Siemens proposed using platinum metal as an element inside the resistance thermometers. Platinum is particularly suitable for this very purpose because it has the ability to withstand high-temperature while still maintaining great stability. As a precious noble metal, it has very limited susceptibility to any sort of contamination. The classic RTD design i.e. the design of the resistance-temperature-detector with platinum was given by C.H. Meyers in the year 1932. Another lab standard replaced Meyers’ design. This was the birdcage element, which was proposed by Evans & Burns. Resistance changes with time & temperature due to voltages were minimized, and the birdcage became the ultimate lab standard. However, due to the unsupported construction & subsequent susceptibility to any kind of vibration, this configuration proved to be very delicate for industrial environments. There were then the partially supported versions of RTD that offered a compromise between the birdcage’s approach & the sealed helix. One of these approaches makes use of a platinum helix threaded via a ceramic cylinder & secured with a glass alloy. These devices maintain great stability in moderate vibration applications.

RTD

RTD resistance & temperature characteristics are stable, repeatable, and have an almost linear positive temperature coefficient from 200°C-800°C. Such characteristics make an RTD the de facto industry standard. The temperature is calculated by measuring the resistance & then utilizing the RTD.s .R vs T. characteristics for extrapolating the temperature. Superior sensitivity & superior stability of such devices compared to thermocouples provide them significant pluses in the low & medium temperatures. Additionally, resistive devices generally simplify control & readout electronics. Resistance thermometers might be known as the RTD or the PRT (i.e. the platinum-resistance-thermometer), or the SPRT (i.e. the standard-platinum-resistance-thermometer). Chemical stability as well as availability in the purest form, and greatly reproducible electrical characteristics has made platinum the chosen metal for RTD, made from either the IEC/DIN grade platinum or from the reference-grade one. The difference is in metal’s purity. The IEC/DIN standard one is pure platinum, which is contaminated intentionally with some other platinum.

RTD Materials

Some common RTD materials are copper, platinum, nickel, Balco (which is basically an alloy made of seventy percent of nickel & thirty percent of iron). The benefit of all these metals is that they could be produced in very high purity and are therefore available with very reproducible temperature/resistance properties. Such metals can even be drawn into the fine diameter wires needed in resistance thermometry.

Temperature Rating

The max temp rating of an RTD is based on 2 main factors. The 1st is the elemental material. Platinum RTD could be utilized up to 650degree Celsius (i.e. 1202 degree F). The temperature rating of other materials is much lower and varies from one material to another. The 2nd factor that determines the temperature rating is the probe construction. All of these different styles use construction aspects that make them ideal for use in all of these styles. No single style fits all types.

 

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Explicating the Characteristics of Thermocouples

Reaction Times of Thermocouples

Measurement of the Surface Temperature

Characteristics of Thermocouples

  • Temperature Reading Tolerances: Tolerance refers to the max allowable value that is gathered by subtracting the temp-reading or hot junction temperature from the standard –temp converted from the applicable EMF temperature table.  
  • Max Operating Temperature: The operating temp limit refers to the upper temp, at which, the thermocouples could be utilized constantly in the air. The max limit refers to the upper-temp, at which, the thermocouples could be utilized temporarily for short time duration due to the inevitable conditions. There are thermocouple charts, which should be used for guidance only, & should not be used for full guarantee. The most vital factors affecting the service life of thermocouples are as under: 
    • Temperature: The service life of thermocouples diminishes by approximately fifty percent whenever there is a temperature raise by 50 degree Celsius. 
    • Diameter: When the wire’s diameter is doubled, it augments the service life by two to three times. 
    • Thermal-cycling: When a thermocouple is thermally cycled above room temperature to 500 degree Celsius, its service life is reduced by approximately fifty percent in comparison to the thermocouples that are continually operated at the same temperature. 
    • Protection: When a thermocouple is covered with a protective sheath & placed in ceramic insulator(s), its service life is amplified greatly. 
  • Reaction Times of Thermocouples: The reaction times of thermocouples are largely described as the time, which is required for the thermal voltage (i.e. the output) reaching 63 percent of the maximum range for the step-change temperature. This depends on different factors, which include the dimensions of the thermocouple, its design & construction, the tip configuration, as well as the nature of that medium wherein the sensors are located. If the thermocouples are immersed in environments with higher heat capacities, wherein, heat transfers are fast, then the most effective reactive time would be practically the same to that of the thermocouples themselves (which is the internal reaction time). But, if the thermal properties of that medium are poor (for example, in static air), then the reaction time would be hundred times higher.
  • The Length of Immersion: The assemblies of thermocouple are state-of-the-art ‘tip’ sensing devices, that are suitable for both surface as well as immersion applications, as per their designs. But, the immersion type should be utilized with care for avoiding any process-induced stress conduction errors that can lead to higher or lower values. A thumb rule is to soak in an environment at least four times of the outer diameter of the sheath; quantitative data is not applicable, but care must be taken to get logical results. 
  • Measurement of the Surface Temperature: Though the assemblies of thermocouples are mainly tip-sensing devices, still using shielding tubes makes surface detection impractical. Physically though, the probe doesn’t fit the surface & vapor conduction causes reading errors. If thermocouples have to be utilized in a reliable way for surface sensing, then they should either be exposed or welded junctions, with very low thermal mass, or placed in a design that allows for actual surface contact while attached to some surface. The thermocouples could be attached to the surfaces in a number of ways, like an adhesive pad, washer & stud, ferrous magnet, & pipe clips.

Contact Heatcon Sensors for the best range of products!

Mineral Insulated Thermocouple Is One of the Types of Thermocouple Designs

Mineral Insulated Thermocouple

Advantages of M.I. Thermocouples

M.I. Thermocouples Tip Models

Non M.I. Thermocouple

 

Types of Thermocouple Designs 

2 main types of thermocouple designs are largely used M.I. thermocouple design i.e. mineral insulated thermocouple & the non M.I. thermocouple design. 

Mineral Insulated Thermocouple

This is a thermocouple design which is a magnesium-oxide insulated one, also known as the MgO thermocouple. Such types of thermocouples are mainly utilized in multiple processes & lab applications. Available in all types of thermocouple elements, in many diameter ranges and many types of materials, they are inherently durable and flexible, and their quite high temperature rating makes them a standard selection for many temperature measurement applications. Many looked-for features make them an ideal selection for general as well as special use. An MgO sensor is constructed by setting the element(s) in the sheath of suitable material as well as size, thus insulating those elements from themselves and the sheath with loosely-filled/breakable magnesium-oxide powder/insulators, and after that pulling down /drawing the filled sheath to the final diminished size. The result of the swaging procedure produces the element(s) with largely-impacted MgO insulation, & also gives raised dielectric strength insulation among the elements themselves as well as their sheath. An M.I. thermocouple consists of thermocouple wire, which is embedded in tightly-packed refractory oxide powder insulation, all of these enclosed in a seamlessly drawn metal sheath (that is mostly of stainless steel). 

Advantages of M.I. Thermocouples

  • Small size & great flexibility; this allows temperature measurement in places with poor accessibility 
  • Nice mechanical strength 
  • Protection of the wires of the thermos-element against any corrosion or oxidation or even contamination
  • Rapid thermal reaction

M.I. Thermocouples Tip Models 

M.I. Thermocouple’s junction tip could be of 3 main types. This tip can either be isolated type or grounded type or even of the reduced type. 

  • Insulated Tip: The insulated hot-end junction is best-suited for many applications, specifically when low EMF reception is mandatory. The high insulation resistance is increased by the maximum density of ultra-pure MgO powder insulation 
  • Grounded Tip: Bonded/grounded junction provides quite a speedier temperature reaction than the other insulated types. This is not advisable for multipoint instrumentation. 
  • Reduced Tip: The reduced tip junction is best-suited for applications wherein low mass & very speedy reaction time is needed and high mechanical strength is required. Such a tip can be supplied for thermocouples from 1.0 to 6.0 mm in diameter. 

Non M.I. Thermocouple

In such a thermocouple, the wires are either insulated ones with ceramic beads/after ceramic insulation, that is covered with metal jacket (mainly of stainless steel) & some type of termination (such as an extension, connector end, or plug). In such a sort of design, the leads or wires of the thermocouple are shielded from the measurement medium when protection is provided. The material of the sheath largely depends on the medium of measurement; mostly stainless steel is utilized. Depending on the corrosive environment, selection of the sheath is altered. This design doesn’t offer flexibility, and is not available in small sizes. This one does not have very good mechanical strength. In such types of thermocouples, the construction sheath could be ceramic or even metal depending on the fit. All types of open, earthed and unearthed junctions are created in the construction of both M.I. thermocouples & non-M.I. thermocouples, alike.

 

You can contact Heatcon Sensors for the best range of products.

 

 

Let Us Know the Thermocouple Types

Base Metal Thermocouple Types

Noble Metal Thermocouple Types

Refractory Metal Thermocouple Types

 

Thermocouple Types

Several combinations of different materials are used for producing acceptable thermocouples, out of which, each has its own specific application-spectrum. But, the value of interchangeability as well as mass production economics leads to standardization, and a number of specific types are now readily available and cover most of the temperature as well as environmental applications.

Base Metal Thermocouple Types

These consist of some of the most common, and cost-efficient metals including copper, iron & nickel. The type E, type J, type K, type N, and type T belong to this group and they happen to be the most common ones.

  • E Type– This has a positive chromel leg (which is ninety percent of nickel and ten percent of chromium) and a negative constantan leg (which is five percent of nickel and 55 percent of copper) 
  • Type J – This has an iron-positive-leg & a Konstantin-negative-leg. 
  • K Type – This has a chromel positive leg (which is ninety percent of nickel and ten percent of chromium) and an Alumel negative leg (which is 95 percent of nickel and five percent of aluminum, silicon & manganese). 
  • Type N – This has a positive leg of Nicrosil (i.e. 74.1 percent nickel – 14.4 percent chromium – 1.4 percent silicon.0.1 percent magnesium) and a negative leg of Nisil (which is 95.6 percent of nickel to 4.4 percent of silicon). 
  • T-type – This has a positive leg of copper and a negative leg of constantan.

Noble Metal Thermocouple Types

They are made from wire made from precious metals such as Platinum & Rhodium. These can be utilized for oxidizing or for inert applications, & should be utilized with a ceramic protective tube outside of the thermocouple element. Such types of sensors are generally delicate and shouldn’t be utilized for applications that reduce or contain metal vapors. 

  • R Type – This is made with a positive leg of platinum or 13 percent rhodium & pure platinum negative-leg. Type R has the temperature ranging from 0°C to 1450°C (32°F – 2642°F) 
  • S Type – This is made from a positive leg of platinum or ten percent rhodium & a pure negative-leg of platinum. Type S has the temperature ranging from is 0°C to 1450°C (32°F to 2642°F) 
  • B Type – This is made from a positive leg of platinum or 30 percent rhodium.

Refractory Metal Thermocouple Types

They are made of wire made from the exotic metals tungsten 17 and rhenium. Such metals are a bit on the expensive side, hard to make, and wires made from such metals are quite brittle. So, such types of thermocouples are designed for use in vacuum ovens at very high temperatures and should not be used above 300°C in the presence of oxygen. Several different alloy combinations have been used in the past, but there is currently only one commonly used. 

  • C Type – This has a tungsten positive leg or five percent rhenium positive leg & a tungsten 26 percent rhenium negative leg. The temperature ranges from 0°C to 2320°C (32°F  to 4208°F). 
  • G Type – They are known technically as this – WM26Re. They have a combination of alloy with a positive lead of tungsten (W) and a negative lead of tungsten + 26 percent rhenium (W-26% Re). The max operating temp. of this is 0°C to 2320°C. 
  • D-Type – This is even called W3ReM25Re technically. It has a combination of alloy with a positive lead of tungsten plus 3 percent rhenium (W-3% Re) and a negative lead of tungsten plus 25 percent rhenium (W56% Re). The max operating temperature range is 0°C to 2320°C.

Heatcon Sensors

Are you looking for a reliable and trustworthy heat sensor company? If so, consider Heatcon Sensors, the leading provider of high quality heat sensors and temperature controllers. The company has been in business for many years and has a reputation for providing quality products and excellent customer service. We offer a wide range of heat sensors and temperature controllers to meet your needs. Whether you need a simple heat sensor for your home or a more complex temperature controller for your industrial application, we have the products you need. Our products are backed by a team of experienced engineers, who are available to answer your questions and provide support. If you are looking for a quality heat sensor or temperature controller, consider Heatcon Sensors.

 

 

How Does a Thermocouple Work?

Seebeck Effect

Cold Junction Compensation

Measuring Junctions

Hot Junction Formation Method

 

Thermocouples happen to be the pairs of different metallic wires, which are connected at 1 of the ends, and that produce a net thermoelectric-voltage in the open pair as per the difference in the temperatures between those ends. The junction that has been brought into this very procedure, wherein the temperatures are measured, is known as the ‘HOT Junction. The second junction that is present at the end-point of the thermocouple’s material and that is always present near some gauges is known as the ‘COLD Junction.’

Seebeck Effect

In the year 1821, a physicist from Germany, whose name was Seebeck, discovered this thermoelectric effect, which happens to be the basis of today’s thermocouple technology. Seebeck had discovered that electric current flows into the closed circuits between 2 different metals when their 2 junctions happen to be at varying temperatures. The resulting thermoelectric-voltage that is generated will be depending upon the metals, which are being used, & the temperature relationship in these junctions. If both the 2 junctions have similar temperatures, then the voltage thus generated across each junction cancels each other out and there would be no movement of the current in the circuit. At different temperatures, different voltages develop at each junction & current will flow in this circuit. Therefore, the thermocouple can measure only the difference in temperatures between 2 junctions.

Cold Junction Compensation

A practical industrial/laboratory thermocouple has only one (measurement) junction; and the reference here is, at all times, the final temperature. The possible gauges or measures are as follows:- 

  • Accurately measures final temperature and compensates as per it while calculating the measured values. 
  • Locates the terminals in the thermally-controlled case. 
  • Don’t terminate in copper cable, instead use the compensating/actual thermocouple wire for extending the sensor termination to the connected instrumentation

Measuring Junctions

In general, 3 alternative tip-configurations are mostly offered, as mentioned underneath: 

  • Exposed (Measurement) Junction. This is advised for the temperature measurement of flow or static non-corrosive gas where the highest sensitivity & fastest response is needed. 
  • Insulated Junction: These are best suited for corrosive substances, though the thermal reaction is sluggish. In some of these applications where multiple thermocouples have been connected to relevant instrumentation, insulation might be needed in the measurement of circuits for preventing any false signals. If this has not been specified, then it is the default one. 
  • Earthed Junction: These are also suitable for corrosive & high-pressure applications. These provide a quicker response than insulated ones & also offer protection that exposed ones do not.

Hot Junction Formation Method

A proper hot junction method must be used to achieve good electrical contact in the wires of a thermocouple. For Chromal/Alumal as well as some other such combinations in high-temp applications, welding is the one & only way of obtaining a proper joint.

  • Tig welding: GTAW or Gas-tungsten-arc-welding, also called TIG or tungsten-inert-gas welding, is the sort of arc-welding, which makes use of a non-consumable tungsten electrode for producing the weld. The welding area tends to be safeguarded from atmospheric contamination by a shielding gas. 
  • Laser Beam Welding: LBW or Laser-Beam-Welding is a technique of welding, which is mainly made use of for joining more than one metal with a laser. This beam gives a concentrated heat source, which allows narrow & deep welds, and high-welding-rates. Laser-Beam-Welding happens to be a versatile way that can weld stainless steels, carbon steels, HSLA steels, aluminum & titanium. The welding speed is in the right ratio to the amount of input power, but it is also dependent upon the type & thickness of the processed pieces.

About Heatcon Sensors 

If you’re looking for a reliable and accurate heat sensor, look no further than Heatcon. We offer a wide range of heat sensors that are perfect for a variety of applications. Whether you need a sensor for research or industrial use, we have a sensor that will meet your needs.

 

 

All about Temperature Measurement

Contact Method 

Non-Contact Method

Temperature measurement is very crucial in a wide range of industrial applications, so continuous temperature measurement is highly significant. Temperature can be measured with various sorts of sensors; which all work according to a similar principle of temperature output as per the changes whatsoever caused by their physical properties. According to the type of application, this can be divided into the following parts. 

Contact Method 

This particular method is used when the body and the sensor remain in contact with each other. 3 different thermometers are used in the contact method, as follows:

  1. Expansion thermometers: They use bimetallic devices that have 2 different materials. So, these devices have strips of 2 metals, bonded together. When heated, one side expands more than the other, so the resulting expansion is converted into a temperature reading by a mechanical connection to a pointer. The advantage is that they are portable and do not require a power source. And the disadvantage of these types of instruments is that they are not as accurate as other devices and cannot be used for direct control or recording. 
  2. Filling system thermometers: They are filled with any substitute. They generally fall into 2 main categories: mercury type and organic liquid. Because mercury is considered an environmental hazard, regulations apply to the transportation of equipment containing mercury. Today, there are filled system thermometers that use gas instead of liquids. The advantage of such devices is that they do not require electricity, do not present an explosion hazard, and are stable even after repeated cycling. And the disadvantage of these types of devices is that they do not produce data that can be easily stored or transmitted, and they do not make point or point measurements. 
  3. Electric thermometers: As its name proposes, this type of instrument detects temperature through electrical quantities (like the voltage, & resistance, etc.). So, we can say that this won’t be controlling indicator thermometers, for instance, mercury in glassware. In most industrial & laboratory processes, the measuring point is usually far from the indicator or control device. This may be due to necessity (like in an adverse environment) or convenience (as in centralized data collection). Devices that convert temperature into another signal, usually electrical quantities, are necessary. The most common devices in this type of thermometer are as follows:
  • Thermocouples : They consist primarily of a thermocouple & a suitable two-wire extension lead, working based on a junction in the process, creating a small voltage that increases with temperature. It is done on a relatively stable & repeatable basis. 
  • Resistance thermometers : This makes use of a precision resistor whose resistance value (ohms) increases with temperature. The RTD had a positive temperature coefficient. Such sort of variation(s) is quite stable & indeed repeatable. 
  • Thermistors (the similarity is that they all require) : This is a semiconductor used as a temperature sensor. It is made from a mixture of metal oxides pressed into a bead, disc, or other shapes. The pearl is heated under pressure at a high temperature and then encapsulated in epoxy or glass. Beads can be very small, in some cases less than 1 mm. 

Non-Contact Method 

This method is used if the body and the sensor are not allowed to contact each other. The most common non-contact thermometers are the easy-to-be-operated infrared sensor & pyrometer, which is now the most common non-contact temperature measuring instrument in industrial applications! 

Heatcon Sensors

If you’re looking for accurate temperature measurement, you can’t go wrong with Heatcon Sensors. These sensors use the latest in heat-sensing technology to provide reliable readings. Whether you’re measuring the temperature of a room, an object, or even the air, Heatcon sensors are up to the task.

Importance of Thermocouple Metals In Determining Their Accuracy, Temperature Sensitivity, & Stability!

Considerations for Choosing The Right Type of Thermocouple For Your Industry!

Noble Metal Thermocouples & Their Types!

Most Commonly Used Base Metal Thermocouples!

Heatcon Sensors – The Manufacturer of All Types of High-Quality Thermocouples For Every Industry!

Thermocouples are one of the most important tools that determines the accuracy of temperature measurement. The thermocouple metals used to create the sensing junction have a major impact on the accuracy, temperature sensitivity, and stability of the temperature sensing device. In this blog post, we’ll take a look at the importance of thermocouple metals in determining the accuracy of temperature measurement.

Considerations for Choosing The Right Type of Thermocouple For Your Industry!

Thermocouples are made up of two dissimilar metals which typically meet at a particular junction. This meeting point or the junction between the two metals creates a voltage that is proportional to the temperature difference between the two junctions. The most common thermocouple metals are copper and nickel that are widely used in various industries. Copper has a high thermal conductivity and a low melting point, making it ideal for use in thermocouples. Nickel has a lower thermal conductivity than copper, but a higher melting point. This property of nickel makes it ideal for use in high temperature applications.

  • The accuracy of a thermocouple is determined by the material of the two metals used. Different metals have different coefficients of expansion. This means that they will expand at different rates when exposed to heat. The amount of expansion is directly proportional to the temperature change. The most accurate thermocouples are made with pure metals, such as copper and nickel. Thermocouples made with impure metals, such as stainless steel, are less accurate.
  • The temperature sensitivity of a thermocouple is determined by the material of the two metals used. The most sensitive thermocouples are made with metals that have a high thermal conductivity, such as copper. Thermocouples made with metals that have a low thermal conductivity, such as nickel, are less sensitive.
  • Thermocouples made with different metals can be more stable and less sensitive to temperature changes. For example, thermocouples made with constantan and chromel are often used in high-temperature applications. These metals have a lower thermal conductivity, which means they are less accurate at measuring temperature changes. However, they are much more stable and less sensitive to changes in the surrounding environment.
  • The stability of a thermocouple is determined by the material of the two metals used. The most stable thermocouples are made with metals that have a high melting point.

Noble Metal Thermocouples & Their Types!

Industries working at extreme temperatures prefer using noble metal thermocouples because of their stability at higher temperatures and extreme environments, even though these are least sensitive. There are three main types of thermocouples: type B, type R, and type S.

  • Type B thermocouples are made of boron and iron. They have a low thermal conductivity, which makes them ideal for use in high-temperature applications. They are also very resistant to oxidation and corrosion.
  • Type R thermocouples are made of platinum and rhodium. They have a higher accuracy than type B thermocouples and are often used in precision temperature measurement applications.
  • Type S thermocouples are made of silicon and silicon-germanium. They have the highest accuracy of all the thermocouple types and are often used in critical temperature measurement applications.

Most Commonly Used Base Metal Thermocouples!

Thermocouples are also classified according to the base metals used in their construction. These base metal thermocouples are most widely used in industries because of their high sensitivity to temperature changes. The most common types are Type E, Type J, Type K, and Type T.

  • Type E thermocouples are made with chromel and constantan. They are the most accurate type of thermocouple and are used in many industrial applications.
  • Type J thermocouples are made with iron and constantan. They are less accurate than Type E thermocouples but are still widely used.
  • Type K thermocouples are made with chromel and alumel. They are less accurate than Type E thermocouples but have a wider temperature range.
  • Type T thermocouples are made with copper and constantan. They are less accurate than Type E thermocouples but have a very wide temperature range.

Heatcon Sensors – The Manufacturer of All Types of High-Quality Thermocouples For Every Industry!

Thermocouples made with different metals can be used for different purposes. It is important to choose the right type of thermocouple for your application. If you are unsure which type will work best for your process, you can contact the experts at Heatcon Sensors who can certainly help you make the best selection based on your process requirements.

What Is An RTD Thermowell, Its Characteristics, Types, & Selection Criteria?

Uses of Thermowell in Different Environments and Their Types!

How To Select The Most Suitable Thermowell For Your Application Based On Different Selection Criteria?

Call The Experts @Heatcon Sensors To Get Support With Your Selection for The Most Suitable Type of Temperature Sensor for Your Application!

A thermowell is a device that is used to protect a temperature sensor from the environment. It is typically made of stainless steel or other corrosion-resistant material, and it has a flared end to allow for easy insertion of the sensor. The thermowell also has a small borehole that allows the sensor to be mounted flush with the bottom of the well. This ensures that the sensor is in direct contact with the medium being measured. Thermowells are often used in high-temperature or high-pressure applications, or in applications where the sensor must be replaced frequently.

Uses of Thermowell in Different Environments and Their Types!

Thermowells are used in a variety of applications, including in process and boiler vessels, to measure the temperature of liquids and gasses. They are also used in pipelines, tanks, and other vessels where it is not practical to install a sensor directly into the process. Thermowells are available in a variety of shapes and sizes, and they can be customized to meet the specific needs of the application. These are of three main types based on the design of its stem as follows:

  • Straight Thermowell: These are the simplest and most economical type. They’re best suited for applications where the process conditions are relatively benign. However, this design is not well suited for high-velocity applications or applications with a large temperature differential between the well and the process.
  • Stepped Thermowell: These are more robust than straight thermowells and can withstand greater process pressures and temperatures. They’re often used in high-pressure or high-temperature applications. It is designed to minimize the effects of high velocity and large temperature differentials.
  • Tapered Thermowell: The most common type of thermowell is the tapered type, which is designed for use with RTD temperature sensors. The taper of the well allows for the sensor to be inserted into the well and then held in place by friction. It is designed for applications with very high velocities or very large temperature differentials.

 

How To Select The Most Suitable Thermowell For Your Application Based On Different Selection Criteria?

There are a few key factors to consider when selecting the most suitable thermowell for your RTD temperature sensor requirement as follows:

  • Material Selection: The most common materials used for thermowells are stainless steel, brass, and bronze. Stainless steel is the most popular choice because it is the most corrosion resistant. Brass and bronze are less popular because they are not as resistant to corrosion.
  • Bore Size & Length: The length and diameter of the thermowell should be based on the application. For example, if the sensor is inserted into a pipe, then the thermowell should be the same size as the pipe. The diameter of the thermowell should also be considered. A larger diameter thermowell will be more resistant to vibration and will have a longer life.
  • Connection Type: The type of process connection is also important. The most common type of connection is a screw-type. This type of connection is easy to use and is common in small diameter thermowells. A weld-type connection is more difficult to use but is stronger and can be used in larger diameter thermowells.

Call The Experts @Heatcon Sensors To Get Support With Your Selection for The Most Suitable Type of Temperature Sensor for Your Application!

If you are unable to make a selection of the most suitable temperature sensor and thermowell combination, don’t hesitate to consult the experts at Heatcon Sensors, a leading manufacturer of all types of high-quality temperature sensing devices, who can even actually be able to customize one for you after learning your specific application needs.

A Detailed Synopsis on Temperature and Temperature Scales

Heat Balance

The Zeroth Law of Thermodynamics 

Temperature Scale 

Temperature Scales

Any substance’ temperature is basically the degree of its heat or coldness of that particular substance. Hot matter is said to have high temperature, while cold matter has low temperature. So, any substance’ temperature is actually the indication of the average kinetic energy of the molecules of that particular matter. It is a well-known fact that hotness always flows from a body having a higher temperature to some other body which is at a lower temperature than that one. So, this can also be explained in a way that body temperature is basically the property, which is controlling the heat flow. This can be easily shown as this. When any 2 objects having the same type of material are put together, the higher temperature one cools, while the cooler object heats up, until a point is reached at which no further change occurs. 

Heat Balance 

Thermal energy flows from an object with a higher temperature to another at a much lower temperature. In other words, heat flows from a warmer body to a colder one. Heat energy continues to flow from the hotter to the cooler body until the temperatures of both of those bodies come at the same degrees. At that point those 2 bodies are said to reach thermal equilibrium. When 2 bodies reach the same temperature, they are called to be in thermal equilibrium with one other, because only then, heat is not transferred from one body to the other one. The temperature therefore reached is known as the equilibrium temperature. So, we can now say that temperature is actually a quantity that is the same for both systems when they reach the state of thermal equilibrium. 

The Zeroth Law of Thermodynamics 

This Law defines about the 2 systems stating that if they are individually in the state of a thermal equilibrium with the third ones, they should also be in the similar state with one other, and they’ll have the similar temperature, irrespective of which system they actually are.” This law can be reformulated as: If there are 3 or more systems that together are in thermal contact and also in a state of thermal equilibrium, then any 2 systems that are taken together come in equilibrium with one other. 

Temperature Scale 

One of the first attempts to create a standard temperature scale happened in the past when Galen proposed in his medical writings a “neutral” standard temperature consisting of equal amounts of boiling water and ice; on both sides of this temperature there were 4 degrees of heat & 4 degrees of cold, respectively. The oldest temperature gauge or device was called a thermoscope.

All You Need to Know about Thermocouples

Thermocouples

Thermocouple Working Principle

Thermocouple Construction

How Thermocouples Work?

What Is A Probe Thermocouple & Its Applications?

Thermocouple Thermometers!

Various Thermocouple Types Used In Different Industrial Settings!

Advantages of Thermocouples

Disadvantages of Thermocouples

What Are Thermocouples Used for?

How Are Thermocouples Different From RTDs?

Lifespan of Thermocouples

How to Discover If You Have a Bad Thermocouple 

Contact Heatcon Sensors for Best-Quality Thermocouples!

In 1821, a physicist named “Thomas Seebeck” discovered that when 2 dissimilar metal wires are connected at both ends of a single junction in a circuit with a temperature applied to that particular junction, a current called an electromagnetic field (or EMF) would flow through the circuit. The energy thus produced by the circuit is called the Seebeck effect. Using the influence of Thomas Seebeck as a mentor, two Italian physicists, Leopoldo Nobili and Macedonio Mellon, collaborated in 1826 to design a thermoelectric battery called a thermal multiplier. It was based on Seebeck’s discovery of thermoelectricity by connecting a galvanometer, and a hot stack to calculate radiation. Because of his efforts, some people have identified Nobili as the discoverer of thermocouples. 

Thermocouples

Thermocouples can be defined as the types of temperature sensors used for measuring the temperature at some specific point in the form of EMF or electric current. These sensors consist of 2 different metal wires connected together at a junction. At this junction, the temperature can be measured and the change in temperature of the metal wire stimulates the voltages. The amount of EMF generated in the device is very small (millivolts), so very sensitive equipment must be used to calculate the e.m.f generated in the circuit. The most common devices used to calculate e.m.f are the voltage equalization potentiometer and the standard galvanometer. Out of these two, a physically/mechanically balanced potentiometer is often used.

Thermocouple Working Principle

The thermocouple principle mainly depends on three effects namely Seebeck, Peltier and Thompson. 

  • Seebeck Effect: This type of effect occurs between 2 dissimilar metals. When heat is applied to a metal wire, the flow of electrons moves from the hot metal wire to the cold metal wire. Therefore, the DC current stimulates the circuit. 
  • Peltier Effect: This Peltier effect is the opposite of the Seebeck effect. This effect means that a temperature difference can be created between two different wires by applying a potential change between them. 
  • Thompson-Effect: This effect states that when two dissimilar metals are attached to each other and form two junctions, a voltage is induced along the length of the conductor due to a temperature gradient. It is a physical word that indicates the rate and direction of temperature change at a precise location.

Thermocouple Construction

The device structure consists of two different metal wires joined at the connecting end. The intersection is thought of as a measuring head. The connection end or junction is divided into three types, namely grounded, ungrounded, and open or exposed. 

  • Ungrounded-junction: In this type of connection interface, the conductors are completely separated from the protective sheath. This junction is mainly used for high pressure applications. The main advantage of using this feature is to reduce the effect of the stray magnetic field. 
  • Grounded-junction: In this type of connection, the metal wires and the protective cover are connected together. This function is used for temperature measurement in acidic and noise-proof environments. 
  • Exposed-junction: This is suitable for areas where a quick response is required. This type of connection is used to measure gaseous temperature. The metal used to make the temperature sensor basically depends on the operating temperature range.

A thermocouple is usually constructed with two different metal conductors, namely iron and constantan, which identify the element by connecting it to a single junction called the hot junction. It consists of two junctions, one connected to a voltmeter or transmitter which is the cold junction, and the other junction is connected in a process called hot junction.

How Thermocouples Work? 

A thermocouple diagram is shown in the figure below. This circuit can be constructed from two different metals and they are connected together to form two junctions. The two metals surround the joint by welding. In the diagram above, the connections are labeled P and Q and the temperatures T1 and T2. When the temperature of the junction differs, an electromagnetic force is created in the circuit. When the mild temperature at the end of the junction becomes equivalent, as well as a reverse electromagnetic force is produced in the circuit and does not flow through it, the temperature at the end of the junction becomes unbalanced, causing a possible fluctuation in that circuit. The magnitude of the electromagnetic force induced in the circuit depends on the materials used in the manufacturing of the thermocouples. Meters count the total current in a circuit. The electromagnetic force induced in the circuit is calculated using the equation: E = a (∆Ө) b (∆Ө)2 (Where ∆Ө is the temperature difference between the hot thermocouple junction end and the cold thermocouple junction end. reference thermocouple, a and b are constants).

What Is A Probe Thermocouple & Its Applications?

Thermocouple probes are important in many different applications. They are typically used to measure temperatures in difficult or hard-to-reach places. For example, they may be used to measure the temperature of a molten metal, or the temperature inside a furnace. 

A thermocouple probe consists of two wires of different metals that are joined at one end. The probe consists of a metal tip that is placed in contact with the object to be measured. The tip is connected to the rest of the thermocouple by two wires. The other end of the wires is connected to a measuring device.

When the probe thermocouple is placed in a location where the temperature is different from the surrounding environment, a thermocouple voltage is generated. This thermocouple voltage can be measured and used to calculate the temperature. 

Thermocouple probes are often used in industrial applications, but they can also be used in scientific research or in medicine. For example, they may be used to measure the temperature of a patient’s skin or to monitor the temperature inside a laboratory. Thermocouple probes are also important in a variety of applications where accurate temperature measurement is critical. 

Thermocouple Thermometers!

They are very useful in medical devices such as thermometers and blood pressure monitors. They are also used in industrial settings to monitor process temperature, as well as in environmental applications such as weather stations.

Various Thermocouple Types Used In Different Industrial Settings!

Before discussing the types of thermocouples, it should be noted that the thermocouples must be protected in a protective case to isolate it from atmospheric temperatures. This coating significantly reduces the corrosion effect of the device.  There are several types of thermocouples. Let’s look at them in detail. 

  • Type K Thermocouple– Also called a nickel-chromium/nickel-alumel thermocouple. This is the most commonly used type. Its features include better reliability, accuracy and affordability, and it can operate in a wider temperature range.
  • Type J Thermocouple – This is an Iron/Constantan mix. It is also the most commonly used type of thermocouple. Its features include better reliability, accuracy and affordability. This device can only be used at lower temperatures and its service life is short when used at higher temperatures.
  • Type T Thermocouple – This is a copper/Constantan mix. The T-type thermocouple has better stability and is generally used in lower temperature applications such as ultra-low temperature freezer and cryogenic parts.
  • Type E Thermocouple – This is a nickel-chromium/constantan mix. It has better signal capability and better accuracy compared to type J and Type K thermocouples when used at ≤ 1000 0 F.
  • Type N Thermocouple – This is considered either as a Nicrosil thermocouple or a Nisil thermocouple. The temperature as well as the accuracy levels is almost similar to that of type K thermocouple, but this one is more costly than that one.
  • Type S Thermocouple – Considered as either platinum/rhodium or 10%/platinum thermocouple. The S-type thermocouple is widely used in high temperature applications such as biotechnology and pharmacy. Due to its higher accuracy and stability, it is used even in lower temperatures.
  • Type R Thermocouple – Considered as either platinum/rhodium or 13%/platinum thermocouple. Type S thermocouples are for high temperature applications. It contains more rhodium than Type S, making the device more expensive. The features and performance of the R and S are almost identical. Due to its higher accuracy and stability, it is used even in lower temperatures.
  • Type B Thermocouple – Considered as either a 30% platinum rhodium or a 60% platinum rhodium thermocouple. It is widely used at higher temperatures. Of all the above types, type B has the highest temperature limit. At higher temperature levels, the B-type thermocouple maintains better stability and accuracy.

Advantages of Thermocouples

Thermocouples have the following advantages. 

  • It has very high accuracy 
  • It is durable and can be used for example in severe and high vibration conditions. 
  • Thermal response is fast 
  • Operating temperature range is wide. 
  • Costs are low and they are very consistent 

Disadvantages of Thermocouples

Disadvantages of thermocouples are as follows. 

  • Low Voltage 
  • Nonlinearity 
  • Least Stability 
  • Least Sensitivity 
  • Harder Thermocouple Recalibration 

What Are Thermocouples Used for?

Some applications of thermocouples include: 

  • As temperature sensors in thermostats (offices, homes, businesses). 
  • Industry to control metal temperatures in iron, aluminum & other metals. 
  • Cryogenic & low temperature applications in food industries
  • Used as heat pumps for thermoelectric cooling. 
  • Temperature testing in chemical plants and petroleum plants. 
  • For detecting the ignition switch in gas engines.

How Are Thermocouples Different From RTDs?

There are some key differences between thermocouples and RTDs that you should be aware of as follows:  

  • Thermocouples are made of two different metals, while RTDs are made of a single metal.
  • Thermocouples generate a voltage when there is a difference in temperature between the two metal wires, while RTDs measure resistance to determine the temperature.
  • Thermocouples are less accurate than RTDs, but they are faster and more responsive.
  • Thermocouples can be used in a wider range of temperatures than RTDs.
  • Thermocouples are less expensive than RTDs.

Lifespan of Thermocouples

The life of the thermocouple depends on its use. Therefore, the service life of a thermocouple cannot be accurately predicted. If the device is properly maintained, it will have a long service life. After continuous use, they can be damaged due to the aging effect after which they need to be replaced in order to ensure continuity and safety of the process. 

How to Discover If You Have a Bad Thermocouple 

To know if the thermocouple is working perfectly, the device must be tested. Before replacing the device, it is necessary to check whether it really works or not. A multimeter and a basic knowledge of electronics is enough for this. There are mainly three approaches to testing a thermocouple with a multimeter and they are explained as follows: 

  • Resistance Test: To perform this test, the device must be placed in line with the gas device and the necessary equipment is a digital multimeter and alligator clips.
    • Procedure – Connect alligator clips to multimeter parts. Attach clips to both ends of the thermocouple where one end is folded into the gas valve. Now turn on the multimeter and note the reading options. If the multimeter reads ohms in the low order, the thermocouple is fully functional. Or if the reading is 0 ohms or more, it’s not in good shape. 
  • Open Circuit Test: Alligator clips, switch and digital multimeter are used here. Here voltage is calculated instead of resistance measurement. Now the lighter heats the other end of the thermocouple. If the multimeter shows a voltage in the range of 25-30 mV, it is working correctly. Or else, if the voltage is close to 20mV, the device must be replaced. 
  • Closed Loop Test: It uses alligator clips, a thermocouple adapter, and a digital multimeter. Here the adapter is placed inside the gas valve and then the thermocouple is placed on the other end of the adapter. Now turn on the multimeter. If the reading is between 12-15 mV, the device is good. Or if the voltage drops below 12mV, it means a broken device. 

The above test methods can therefore be used to determine whether a thermocouple is working properly or not.

Contact Heatcon Sensors for Best-Quality Thermocouples!

Heatcon Sensors is a leading manufacturer and global supplier of all types of high-quality temperature sensing devices and thermocouples. If you have an industrial process with specific temperature measurement requirements in even most difficult conditions, not only you can get the most suitable and reliable thermocouple for you, but their engineers can even design a custom-made thermocouple that will work best with your process with greater stability and accuracy at lost operational costs.

Important Tips To Follow While Installing Thermocouple & Its Maintenance!

Important Tips For Installing Extension Wires Correctly!

How To Go About General Maintenance of Thermocouple!

A thermocouple is a vital piece of equipment for many industries to adequately measure and maintain temperature of objects in process, especially for processes that work at extreme temperatures. Its efficiency can make a huge difference between a successful operation and a costlier one. Here are some important tips to consider before installing thermocouple to make sure it keeps working at its peak performance.

  • Location Is Key – The thermocouple should be placed in an area where it can accurately measure the temperature. If it is too close to a heat source, it will not be able to give accurate readings.
  • Insertion Depth Must Be Adequate – Carefully select and ensure proper placement and the correct insertion depth to make sure the temperature it records represents the actual process temperature. 
  • Avoid Stem Loss – Make sure that the immersion depth of the thermocouple is at least 10 times the diameter of protection tubing to avoid stem loss. 
  • Make Sure It Is Level – A level thermocouple is essential for accurate readings. If it is not level, the readings will be inaccurate.
  • Use The Correct Wiring – The thermocouple must be wired correctly in order to work properly. Using the wrong type of wire can cause problems.
  • Inspect The Tip – The tip of the thermocouple should be clean and free of debris. Any dirt or debris on the tip can cause inaccurate readings.
  • Check The Calibration – It is important to check the calibration of the thermocouple regularly. This will ensure that the readings are accurate.
  • Check Proper Insulation – Always check for the thermal conductivity of the materials around the thermocouple in order to properly insulate it while installing the thermocouple.
  • Keep It Protected – The thermocouple should be properly installed at a convenient location in order to keep it protected from physical damage and from extreme temperatures that are way beyond its actual calibration.

Important Tips For Installing Extension Wires Correctly!

  • Make sure to use correct extension wires that are compatible with the thermocouple calibration. 
  • Use the correct color code to connect the negative wire to both the negative terminal at both the instrument and the head of thermocouple connection.
  • Try not to run the thermocouple wires parallel to or in the same conduit and always try to keep it away from the power source at least 12”. 
  • Always use shielded conductors and twisted thermocouple extension wires with a drain wire in place in highly noisy conditions.
  •  Use appropriate insulation to meet the exact thermal conditions for best performance. 

How To Go About General Maintenance of Thermocouple!

  • Base metal thermocouples generally do require monthly maintenance, however, frequency of periodic checks can be increased based on individual situations.
  • The rotary switches must be kept free of oxidation and cleaned regularly especially at the points of contact.
  • While reinserting a thermocouple, make sure there are no changes in the depth of insertion or at least try not to decrease it which may result in errors. 
  • For a type K thermocouple to remain accurate, make sure to not expose it to temperatures beyond 16000 F when it is calibrated for temperature measurements up to 10000 F.
  • Always ensure to discard or replace the thermocouple which has burned-out protective tubing. 

Heatcon Sensors – A Go-To Place To Get All The Answers Related To All Types of Thermocouples!

Heatcon Sensors is a leading manufacturer and supplier of all types of thermocouples and related high-quality temperature sensing devices for various and sundry industry verticals. Their engineers have mastered the art of using the temperature sensing technology and devices to ensure highest performance output and complete temperature control even under extreme temperature conditions. If you have an industrial process or situation that needs opinion or direct intervention from experts, you can reach them without hesitation.

What Is A Continuous Thermocouple, Why It Is Important, How It Works, & Its Benefits!

Why Is It Important?

When & How It Can Work As A Switch To Raise An Alarm?

Advantages of Using Continuous Thermocouples!

A continuous thermocouple is a type of thermocouple that is used to measure temperatures over a wide range, i.e., -200 to +1000 degrees Celsius. A continuous thermocouple can also be used in most hostile environments where other types of sensors would not be able to function properly. In addition, this device is relatively inexpensive and easy to install. They are uniquely designed to quickly respond to any abnormal rise in temperatures in order to avoid any dangerous accidents or damage to materials or the equipment. Apart from its accuracy and high temperature sensitivity, a continuous thermocouple is able to withstand any pressure or humidity changes. Because of its high temperature responsiveness, it is extremely useful in applications where temperature changes quite rapidly.

Why Is It Important?

One of the most important factors that affect the accuracy of a thermocouple is the ambient temperature. The reason for this is that the voltage produced by the thermocouple is directly proportional to the temperature difference between the two junctions. If the ambient temperature is not constant, the voltage produced by the thermocouple will also not be constant. To avoid this problem, it is important to use a continuous thermocouple. A continuous thermocouple is a thermocouple that is constantly measuring the temperature difference between the two junctions. This ensures that the voltage produced by the thermocouple is constant, regardless of the ambient temperature.

When & How It Can Work As A Switch To Raise An Alarm?

A continuous thermocouple is designed to act as a switch when the temperature exceeds a certain threshold. This threshold can be set by the user, and is typically between 40 and 50 degrees Celsius. When the temperature exceeds this threshold, the thermocouple will automatically open the circuit and allow the current to flow. This current can then be used to activate a switch or trigger an alarm. 

When an alarm is raised in a continuous thermocouple, it is important to take immediate action. This type of device is used to measure the temperature of a process or material, and if the temperature gets too high, it can be too dangerous. Alarms can be raised for a variety of reasons, but the most common is when the temperature exceeds the set point. If you see an alarm on your thermocouple, take action immediately to prevent any damage to your process or material. 

Advantages of Using Continuous Thermocouples!

  • Continuous thermocouples are more accurate than other types of thermocouples and are designed to withstand extreme temperatures.  
  • Continuous thermocouples are less likely to break than other types of thermocouples and are more durable as compared to other types of thermocouples.  
  • Continuous thermocouples are less likely to be affected by environmental factors than other types of thermocouples such as humidity and air pressure.
  • Continuous thermocouples are less likely to produce false readings and are not affected by things like electromagnetic interference.
  • These types of thermocouples are highly sensitive and responsive to abnormal rises in temperatures. 

Heatcon Sensors – Your Go-To Destination For Procuring High-Quality Continuous Thermocouples!

Heatcon is a leading name in manufacturing all types of high-quality, durable, and most accurate temperature sensing devices. Their explicit experience in manufacturing thermocouples of all types and sizes for varied industries and applications makes it a truly trustworthy brand. If you require a custom-designed continuous thermocouple, they can be your go-to destination to procure one for you.

What Are RTD Temperature Sensor Elements, Their Types, & Their Benefits?

Types of RTD Temperature Sensors & Their Main Advantages?

An RTD temperature sensor is a type of resistance based temperature sensor that uses a resistive element to accurately and precisely measure temperature in extremely high & low temperature applications. The resistive element, usually made of metal such as platinum, changes resistance in response to changes in temperature. This change in resistance is used to determine the temperature of the object or substance being measured. RTD temperature sensors are accurate and stable, making them ideal for use in critical industrial applications. RTD temperature sensors are also generally more rugged and durable than other types of temperature sensors. RTD temperature sensors are used in a wide variety of applications, including industrial and commercial process control, HVAC, and medical industry.

Types of RTD Temperature Sensors & Their Main Advantages?

There are two main types of RTD temperature sensor elements: thin-film and wirewound. Both have their own advantages based on your specific application requirements as below:  

  • Thin-film RTD sensor elements are made using the most advanced technology called photolithography by depositing a thin layer of conductive material onto a substrate. These elements are typically smaller and more accurate than wirewound elements, but they are also more fragile and expensive. The advantages of thin-film sensor elements include:
    • They are more accurate and small in size and quick response time.
    • They have lower thermal mass.
    • They are less susceptible to vibration and shocks.
    • They are more stable over time.
    • They are ideal for critical applications.
  • Wirewound RTD sensor elements are made by winding a thin wire around a substrate, typically glass or ceramic. These elements are typically less accurate than thin-film elements, but they are also more rugged and less expensive. The advantages of wirewound sensor elements include:
    • They are ideal to operate in a wider temperature range with great accuracy and precision.
    • They are known for their integrity and stability and are immune to the effects of vibration and shock, making them ideal for applications where these factors are present.
    • They offer excellent precision and accuracy, making them perfect for applications requiring precise temperature measurements.
    • They are highly repeatable, meaning you can rely on them to provide consistent results time after time.
    • They offer long-term stability, meaning they will maintain their accuracy and repeatability even after years of continuous use.
    • They are easy to install and use making them a great choice for applications where ease of use is a priority.

Contact Heatcon Sensors’ Expert Team To Decide Which Type Of RTD Temperature Sensor Element Is Most Appropriate for Your Industrial Process? 

Depending upon the application type, industry, and size, if accuracy is your top priority, then a thin-film RTD sensor element is the way to go. If ruggedness and affordability are more important to you, then a wire wound RTD sensor element is the better choice. If you still remain confused about your selection, don’t hesitate to consult with experts at Heatcon Sensors who are industry leaders in manufacturing all types of digital temperature sensors and temperature sensing devices which can also be customized as per your specific industry needs.

What Are Temperature Controllers & Their Different Types?

What Are Temperature Controllers?

What are Different Types of Temperature Controllers & How Each Type Works?

What Are Temperature Controllers?

Temperature controllers work by sensing the temperature of the space or system that they are controlling without much intervention from the operator. In a temperature control system, a controller accepts the input received by the sensor or a thermocouple and compares the measured temperature to the desired output temperature known as set point. This output will then be utilized by the element to control the temperature. This set point can be balanced utilizing either a cooling system or a heater as per the difference between the actual and the desired temperatures. If the temperature is too high, the controller will activate the cooling system. If the temperature is too low, the controller will allow the heating system to continue further heating. A controller makes only a part of the entire control system, and in order to install the entire temperature control unit for a process, the entire system configuration needs to be thoroughly analyzed and assessed for its temperature controlling capacity. 

What are Different Types of Temperature Controllers & How Each Type Works?

There are a variety of different types of temperature controllers available on the market. The type of controller that you choose will depend on your specific needs. Some of the most common types of temperature controllers include on-off controller, proportional temperature controller, and PID type controller as detailed below:-

#1 – On-Off Type Temperature Controller: This type of temperature controller is the most basic type of controller where the output can either be turned on or off. It has a defined set point such that when temperature has risen to that particular point, the heater will be automatically switched off. The heater remains on until the temperature of the system is recorded below the set point. For continuity of the heating process, the process controller goes through cycling between on and off since the temperature goes up and down the set point. It is most suitable for processes where precise temperature control is not required or where the mass of the material to be heated is so large that any temperature change happens pretty slowly and gradually. 

#2 – Proportional Temperature Controller: A proportional temperature controller is so designed to eliminate the process cycling that is associated with on-off temperature controllers. This type of controller controls the power being supplied to the heating element as the process temperature is about to reach its set point. This type of controller is extremely useful in processes where temperature needs to be kept stable. 

#3 – PID Temperature Controller: A PID temperature controller is a device that is used to regulate temperature by controlling the amount of heat that is generated. The controller uses a feedback loop to compare the actual temperature to the desired temperature, and then adjusts the heat output accordingly. PID temperature controllers can be used in a wide variety of applications, such as keeping the temperature of an oven or a furnace at a set point. They are often used in industrial settings where precise temperature control is critical. PID temperature controllers work by constantly monitoring the temperature and making adjustments to the heat output as needed. This ensures that the temperature remains at the desired level, even if the conditions around the controller change.

Heatcon – The Leading Manufacturer and Supplier of Top Quality Temperature Controllers for Industries!

For more information on temperature controllers and to figure out which type of temperature controller will work best for your industrial process, you can seek help from the top notch industry experts at Heatcon who can surely be able to help you select the best temperature controller for your industry type.

Learn More About Data Loggers & How They Are Important for Enterprises!

What Is A Data Logger?

What Is Data Acquisition?

Where Data Loggers Are Used?

Why Data Loggers Are Important For Enterprises?

You Can Rely on High-Quality Data Loggers Manufactured by Heatcon!

What Is A Data Logger?

A data logger is an electronic appliance which monitors and stores measurements of environmental parameters in real time. The measurements recorded by this appliance are useful in keeping a record of all changes happening in the environmental parameters such as temperature changes with respect to time. These measurements are then available for critical analysis, validation, and further processing as may be needed by the process. A sensor is used in a data logger to help receive the real-time information which is then stored in the chip of the data logger. One can easily transfer this information to a network computer. 

What Is Data Acquisition?

Data acquisition is the process of obtaining a sample of real-time waveforms and/or signals emitted by the object being monitored and then processing of this info received to obtain real-time information about the changes as desired. A data logger utilizes appropriate sensors to adequately convert measurement of the environmental parameter into an electrical impulse for further processing. 

Where Data Loggers Are Used?

A data logger can be used to monitor many parameters such as pulse or counts, humidity, CO2 levels, temperature, voltage, etc. Data loggers are extremely useful for closely monitoring many industrial processes where any temperature changes and other environmental parameters are critical such as industrial furnaces, warehouses, etc. Various industries need different types of data loggers to monitor and record data of critical environmental factors, as follows:-

  • Metallurgy and environmental research
  • Healthcare and research laboratories
  • Warehouses and logistics
  • Agriculture
  • Manufacturing industries

Why Data Loggers Are Important For Enterprises?

  • To ensure regulatory, statutory, and environmental compliance that needs to be necessarily maintained by various industries
  • To capture critical process data for process improvement and analysis
  • For research and innovation and product improvement studies
  • Careful monitoring of the industrial process in order to ensure safety of the process
  • Keeping a record of accurate and reliable data to make further enhancements and/or amendments in the process

You Can Rely on High-Quality Data Loggers Manufactured by Heatcon!

Heatcon Sensors has been a leading manufacturer of high-quality temperature sensors for over 3 decades. The main advantages of using the data loggers made by Heatcon include:-

  • The data loggers from Heatcon are compact, affordable, and easy to install.
  • A wide range of parameters can be recorded using Heatcon sensors
  • Dual channel Heatcon data loggers are also available to monitor two parameters simultaneously, i.e., humidity and temperature.
  • Suitable for a variety of applications offering different configurations and features
  • They have waterproof and rugged enclosures
  • Good storage capacity to store data safely and for longer periods
  • A Heatcon data logger can be custom-designed as per the need of the process as all the sensors, hardware, and even software are designed in-house making data loggers extremely accurate, reliable. 
  • The Data loggers from Heatcon are extremely popular for enabling enterprises maintain a stringent control on quality along with providing complete flexibility in the way they wish their data to be safely stored and monitored. 

 

If you wish to learn more, call the experts at Heatcon Sensors who will be happy to respond and address all your queries. 

What Are Pyrometers, How They Work, & Their Use In Various Industrial Applications?

What Are Pyrometers And How Infrared Pyrometers Work?

What Are Different Parts Of An Infrared Pyrometer?

What Are Different Types of Infrared Pyrometers Based on Different Spectral Ranges!

What Are The Advantages of Infrared Pyrometers?

What Are Pyrometers And How Infrared Pyrometers Work?

Pyrometers are devices that measure the temperature of an object from a distance without coming in direct contact with the object. For most industrial applications, the infrared pyrometers are widely used to measure temperatures of objects which are required to be heated to very high temperatures such as industrial furnaces. 

Infrared pyrometers work by measuring the infrared radiation emitted by the object as it increases with increase in temperature. So, by measuring the amount of infrared radiation emitted by an object, we can indirectly measure its temperature and monitor even minutest changes in temperature in real-time.

What Are Different Parts Of An Infrared Pyrometer?

Infrared pyrometers usually consist of two main parts: a sensor and a display. The sensor is usually a thermopile, which is a device that converts infrared radiation into electrical energy. The display shows the temperature reading. Thermopiles are very sensitive and can accurately measure even the smallest temperature changes. This makes them ideal for measuring the temperature of hot objects, such as in large industrial furnaces. Some infrared pyrometers also have a built-in temperature compensator. This is a device that automatically adjusts the reading to account for the temperature of the surrounding environment. This ensures that the reading is as accurate as possible.

What Are Different Types of Infrared Pyrometers Based on Different Spectral Ranges!

When it comes to measuring high temperatures, there are different types of pyrometers that can be used, depending on the spectral range. Infrared pyrometers are ideal for measuring temperatures from a distance, and they work by detecting the infrared radiation emitted by an object. Since we all know that metals and non-metals emit different wavelength radiations, different infrared pyrometers are required to measure different types of objects based on their spectral ranges. These infrared pyrometers are meant to be extremely accurate, non-contact type, precise, and quick to measure temperature of even fast-moving objects.

What Are The Advantages of Infrared Pyrometers?

Infrared pyrometers are commonly used in a variety of industries for temperature measurement. The most common advantages of using infrared pyrometers include:

  • They are non-contact instruments, so there is no need to physically touch the object being measured. This is especially beneficial in situations where the object is too hot to safely touch, or in clean room environments where contamination must be avoided.
  • They are very fast, reliable, and accurate and are able to take measurements in as little as one second.
  • They are very versatile and can be used to measure the temperature of both solid and liquid objects.
  • They are relatively affordable compared to other temperature measurement devices.
  • They are relatively easy to use, even by people with no previous experience.

Heatcon Sensors – A Leading Manufacturer of High-Quality Pyrometers for All Types of Industries!

Overall, infrared pyrometers are a very useful tool for measuring the temperature of hot objects. They are accurate and easy to use, making them a popular choice for many industrial applications. If you too are interested in getting one for your particular process or industry, you can talk to the experts at Heatcon who have the expertise and experience in manufacturing high-quality infrared pyrometers.

Comparison of the Categories of Industrial Ovens

Comparison of the Categories of Industrial Ovens

Comparison of Industrial Ovens and Industrial Furnaces

Industrial Ovens 

An industrial oven is a large, powered machine used to heat metal objects. Most ovens use either direct or indirect heating methods to produce the desired temperature in an object. The industrial oven is made up of multiple parts and it is classified according to its function. The industrial oven is able to create a high temperature and then keep the metal at that temperature for a long time. Additionally, the industrial oven is very reliable and it can be used in a wide variety of settings.

Comparison of the Categories of Industrial Ovens 

  • Industrial Batch Ovens: A batch oven operates at a temperature above 1250 degrees F or 676 degrees C. Batch ovens are walk-in types or cabinet-type ovens, ranging in size, which may vary from a few cubic-feet to several cubic-feet. They feature aluminized steel interiors, adjustable ductwork, painted exteriors, digital controllers, and a control panel. This type of oven is designed to process larger single batches at high temperatures and has a much larger capacity & size as compared to laboratory furnaces.
  • Conveyor Ovens: They are designed in a number of configurations, including flat belts, chains, Ferris wheels, carousels, overhead trolleys, serpentines, spindles, and rods. Unlike the batch oven, a conveyor oven requires no loading/unloading/heating & cooling, thus saving labor as well as energy costs. This type of oven is used for preheating, annealing, tempering, curing, heat-shrinking, drying, & heat-forming. This type of oven has lesser flexibility than the batch-type oven. They have a similar temperature as that in a batch oven. Such type of an oven can feed or index continuously through heat zones and is usually automated for big quantities of small and medium-sized products. 
  • Laboratory Ovens: This type of oven is designed for forced volumetric heat convection applications for providing uniform temperature. In this, the processes include annealing, drying, die-bond curing, sterilizing & Polyimide baking. Sizes can vary from as small as 1 cubic foot to as large as 32 cubic feet with temperatures above 350 degrees Celsius. This type of oven is designed to perform heat treatments like drying, heating, heat testing, and aging. Because these types of ovens are so versatile, they are usually seen in testing laboratories, universities & colleges, and for material testing at industrial sites. Unlike industrial ovens, the laboratory ones have latched doors, stainless-steel interior, pressure release panel, solid-state controller & contactor, and chemical-resistant exterior coating.

Comparison of Industrial Ovens and Industrial Furnaces

Often people get perplexed about the differences between an industrial oven and an industrial furnace, and these two terms are used interchangeably. Essentially, both devices talk of the methodology to generate extreme heat in a fireproof enclosure for the purpose of heat treatment. The main differences are described below.

  • Atmosphere: An industrial furnace and industrial oven both operate in an environment with air or inert gas. Unlike an industrial oven, the furnace can operate in a flammable atmosphere consisting of hydrogen or endothermic gasses and exothermic gasses.
  • Temperature: Industrial ovens are designed for aluminum aging as well as for aerospace curing; they operate at temperatures between 450 degrees F and 850 degrees F. On the other hand, Industrial furnaces operate at a temperature between 2000 degrees F and 2250 degrees F.
  • Applications: Air circulation, as well as temperature control, allows an industrial oven to perform the operations like cooking, curing, baking, and other such low-temp operations. On the other hand, high-temp industrial furnaces can perform more vigorous operations like annealing, tempering, & carburizing, etc.
  • Heat Distribution: The air inside industrial ovens gets heated in a chamber separate from the product and is also circulated. Air circulation must be very high for heating the product(s). 
  • Vertical Airflow: The heat in furnaces is in direct contact with the product being processed. Heat sources can be set in different configurations for the purpose of a uniform heating effect.

Wide-Ranging Uses of Muffle Furnaces

Muffle Furnace 

Uses of a Muffle Furnace

Heatcon Muffle Furnace

Steps of the Process

Qualities to Look Forward to

Muffle Furnace 

A muffle oven or a muffle furnace (sometimes also referred to as the retort furnace) is basically a furnace wherein the subject material gets isolated from the fuel as well as from all the products of combustion, to include gasses, flying ash, and cinders, which are drawn through the walls of the furnace where they can be collected for further use or disposal. It is usually used to process metals and ceramics; the high temperatures involved may be used for other materials as well, such as glass and carbon fibers. The word “muffle” is derived from the Latin mūla (“barrier”) and fūsus (“pot”), because a muffle is a type of pot that has been lined with refractory clay.

Uses of a Muffle Furnace

  • Muffle furnaces are widely used in industries such as metallurgy, aluminum production, steelmaking, and coal-fired power plants. In these industrial processes, muffle furnaces use intense heat and flames to produce metals or other materials faster than they can be produced by traditional methods. 
  • These days, muffle furnaces are used as the front-loading box-type ovens or kilns for high-temp applications to fuse glass, to create enamel coating, for ceramics, and for soldering & brazing articles, etc. 
  • Muffle furnaces are also being used in many of the research facilities. For instance, chemists use them for determining the proportions of some samples that are non-combustible & non-volatile (like ash). 
  • Some muffle furnaces’ models use the programmable digital controller(s), which allow automatic execution of ramping/soaking/sintering steps.
  • Advancements in materials for the purpose of heating elements, like molybdenum disilicide, are not capable of producing working temperatures even up to 1,800°C  (3,2720F). This facilitates better and highly sophisticated metallurgy and its application, in which the heat source can be either gaseous or oil-burning ones, but these days, they use electric sources more often.

Heatcon Muffle Furnace

Heatcon Sensors is a company that can manufacture Muffle Furnaces for the specific needs of customers. The company offers different types of muffles, including ones with high performance. Heatcon also makes muffles in various sizes and shapes to fit any application. Customers can choose from models that are affordable and easy to use, or they can opt for more expensive options that deliver top performance. These furnaces are used in a variety of industrial and commercial settings and have a variety of applications. Some of the benefits of choosing to purchase a Heatcon Sensors Muffle Furnace include the following:

  • Durability: Muffle Furnaces are made to last, ensuring that they will provide years of reliable service.
  • Ease of use: The equipment is very easy to use and will suit a wide range of needs.
  • Reliability: The furnaces are made to meet or exceed the standards ensuring that they will work well and be durable.
  • Customization: Muffle Furnaces can be customized to meet the specific needs of customers, meaning that they can choose the features and specifications that are the most important to them.

Steps of the Process

How Heatcon Sensors manufactures Muffle Furnaces varies depending on the type of furnace that is being manufactured. However, general processes involve the basic steps as follows:

  • Design: The design team will work with customers to create a specification that meets their needs.
  • Manufacturing: The furnace is designed and manufactured using state-of-the-art technology.
  • Marketing and Delivery: The furnace is delivered to the customer in a safe and timely manner.

Qualities to Look Forward to

When looking for a Muffle Furnace, it is important to consider the qualities that make Heatcon Sensors a great choice. Customers choose to buy from Heatcon Sensors for several reasons, as follows:

  • Value: It is important to Heatcon Sensors that customers are satisfied with the furnaces they purchase.
  • Quality: Heatcon Sensors is a company that focuses on quality, and its furnaces are no exception.
  • Close proximity to the customer: Heatcon furnaces are manufactured in close proximity to the customer, meaning that repairs are quick and easy.
  • Support: If customers have any questions or concerns, they can always contact Heatcon’s team for support.

Considerations while Purchasing a Humidity Chamber

How to Choose a Humidity Chamber?

The humidity chamber is an essential piece of testing equipment for manufacturers to determine the durability of their products when they are out in the market for public use. Humidity chambers are used by climatologists, plant biologists, and microbiologists, who work with maintaining or fabricating microbial or plant populations in a controlled and reproducible environment. With the help of a humidity chamber, manufacturers can engineer the products in such a way that their durability is maintained by helping the material used to survive under different environmental conditions. To choose the most suitable space for a humidity chamber, it is important to take into account factors such as the size of the space, the temperature and humidity control system, the water supply, and the time. Depending on the purpose of the humidity chamber, the design and layout of the space may also be important.

How to Choose a Humidity Chamber?

There certainly are a few things to take into account while choosing the right humidity chamber for your needs, as follows:

  • Space: Available space is surely a guiding factor while purchasing a humidity chamber. Manufacturers work closely with clients to ensure that the humidity chamber they choose perfectly fits into the space available to them.
  • Temperature: This is also an important consideration as it is important to form vapors and maintain humidity inside the chamber. Many chambers reach up to 200°C. 
  • Water Supply: Chamber design determines the water supply needed for creating humidity. Some type of drainage is also important. The Chamber placement location has to be designed for water supply & drainage.
  • Time: Different chambers have different ramp-up times & pull-down times. While purchasing any such unit, the manufacturers must consult with the researcher(s) and ask them the time frame needed to complete data collection.
  • RH: Most such chambers have this Relative Humidity factor between 20 – 98 percent. This particular consideration is determined by the process of testing and data required. More often than not, this is planned much before disclosing the same to the testing chamber manufacturer.
  • Controller: The type of controller needed accounts for a major factor while buying such a chamber. Features providing great outcomes are the controllers which have microprocessors that can either be LED, LCD, or even touch-LCD.
  • Type: More often than not, the decision for the type of testing chamber is made after checking its available footprint. Limited footprints suggest benchtop/vertical testing chambers. As the important parts of this particular consideration, chamber construction needs to see how the seams will be welded, the internal seals, how the door will open, and also the gaskets.

Humidity Chambers by Heatcon Sensors 

Based upon the above considerations, whichever heating chamber you choose, come to Heatcon Sensors to procure the same! It is a leading name in manufacturing various types of high-quality humidity chambers. For setting up and using a humidity chamber, it is also necessary for you to read the instructions that come with the chamber and to follow them carefully. In most cases, all you need to do is to plug in the chamber, set the desired humidity level, and turn on the humidity control system.

Role of Paperless Recorders in the Present Day Scenario

Paperless Recorders 

Why Are Paperless Recorders the Need-of-the-Hour?

Considerations for Ensuring the Best Selection of a Paperless Recorder for Your Business

Paperless Recorders by Heatcon Sensors

Paperless Recorders 

A lot of people are asking the question, “What exactly is a paperless recorder?” It is an electro mechanical device that captures all the changes happening in a closed system and records the variable values of data in the form of a chart. These charted values then can be stored, processed, and finally displayed using a digital display screen without having to print anything. For example, in a cold storage warehouse, a user can use a paperless recorder to collect real-time temperature changes and monitor and access any recorded fluctuations in temperature even remotely using a paperless recorder.  The industry wide use of such paperless recorders has increased manifold given its potential advantages of capturing and displaying real time data. 

Why Are Paperless Recorders the Need-of-the-Hour?

The need for paperless recorders is a global phenomenon, and it’s only getting more and more important as the time goes on.  Paperless recorders have been developing at a fast pace as a result of technological developments. The design of these recorders has also undergone significant changes as per the industry type and the process requirement. Manufacturers have created these digital recorders that combine technology and innovation at the same time. As the name suggests, these recorders eliminate the use of paper and are able to display real-time data digitally. Users can even configure the displays according to their requirements. Periodic rounds for close monitoring by the user are not at all needed any longer as the real-time data can be accessed easily from a centralized and remote location through a network connection. No pen, no paper, and no ribbon required, plus there is the flexibility of comfortably storing the data captured by the device, without worrying about its degradation. These benefits of a paperless recorder make it a true necessity in today’s time when people are so tied up in their busy schedules.

Considerations for Ensuring the Best Selection of a Paperless Recorder for Your Business

There must be many users who would be perplexed in choosing the ideal paperless recorder for their business. This can be because they are uncertain about their proper usage. They might not know which process in their industry can be easily automated using a paperless recorder and what can be the potential benefits of it. Here are some key points to consider in making sure you choose the best paperless recorder ideal for your industrial process:

  • Accuracy: If your process requires accurate data to be collected in real-time, these paperless recorders are extremely efficient in recording data with great precision and accuracy. With these recorders, data can be recorded error-free and can be considered absolutely reliable. 
  • Enhanced Security of Data: If you wish to keep your process data secure and safe, these paperless recorders are extremely beneficial. A paperless recorder helps maintain a high level of data safety and maintains its integrity without any risk of cyber threats. 
  • Uncorrupt Data: For any entrepreneur, process data is extremely important and it should never get corrupted by any means. So, these recorders are best-suited as the recorded data remains encrypted at all times and logically stored, thus ensuring safety.
  • Firmware Upgrades: A digital paperless recorder has a much larger capacity for being upgraded at the site than a paper recorder. These recorders meet the new guidelines of firmware upgrades.
  • Remote Access: Today, most businesses have separate geographical units so to acquire data in such a scenario, one needs remote access to data which is made possible only with these digital recorders.
  • Understand the Software: The software is a crucial part of these digital recorders. So, it is necessary to have the ability to work with the manufacturer’s software bundles as well as the 3rd party software. The manufacturers must provide such software that permits the following things to be done:
    • Software Must Allow Configurations from PC: Remotely-controlled software must allow installing of fresh configurations to the recorder, entering batch-data, and managing the data-driven files from any remote location. 
    • Capability to Communicate: Communication is that aspect where these recorders gleam. Do not invest in the recorders which do not have networkable Ethernet communication as it is the Ethernet port only where all advanced features can be fed easily. 

Paperless Recorders by Heatcon Sensors

Paperless Recorders by Heatcon Sensors are the latest innovation in this field. They are highly sensitive to record any minutest data variations, have a digital display for real-time monitoring, keep the recorded data secure and safe at all times, and the data can be easily accessed even remotely. If you too have a process that requires capturing of real-time data and doesn’t know which paperless recorder can suffice, contact the highly skilled and expert engineers working with Heatcon to get complete and reliable knowledge about paperless recorders.

What Is An Industrial Furnace & Its Various Components?

The Various Components of an Industrial Furnace!

High-Quality and Extremely Safe Industrial Furnaces by Heatcon Sensors!

An industrial furnace is different from an industrial oven because of the difference in operating temperature ranges between the two. While industrial ovens operate between 5000 ºC to up to 1200 ºC, an industrial furnace is used in applications that require temperatures above 1300 ºC. Such furnaces operate on the principle of high oxidation process by heating various types of metals before forging them into different shapes. High temperatures are also needed to help remove any impurities from the metals before forging by heat oxidation. Thus, various metals, glass, or even ceramics can be heated at high temperatures in an industrial furnace to help with tempering, carburizing, annealing, and pre-treating of such materials. 

The Various Components of an Industrial Furnace!

Industrial furnaces are available in different configurations and sizes based on their application and type of industrial process for which it is required. There are small, compact, and portable furnaces which have swing-open doors which are best used in R&D labs, product and material testing labs, as well as dental labs. Whilst those industrial furnaces required in large metallurgy facilities have a conveyor system for managing high volumes of materials and generally are very huge. It is important to consider and understand the various components of an industrial furnace before choosing the best industrial furnace for any industrial process. These include:-

Type of Fuel: For achieving the highest order of temperatures, the choice of fuel or the power source is the most important factor one should consider. The most common industrial fuels used in industrial furnaces include combustible fuels such as natural gas or coal, but environment-conscious industries nowadays are turning their heads towards non-combustible fuels and prefer electricity-run furnaces. 

Heat Contact or Access: Based on the process requirement how the material is needed to be treated with heat, i.e., either it should come directly in contact with the heat source or indirectly defines the type of furnace needed. There are different furnaces available for meeting both the direct and indirect heating requirements of the process. A furnace with a heat exchanger is best suited for indirect heating the material, and for direct heating where the material comes in direct contact with the flame needs a different type of furnace. In any case, one must ensure safety of the operator which is paramount. 

Emission Type: An industrial furnace is the best which produces the least amount of hazardous emissions. Therefore, eco-friendly industrial furnaces are given preference over other types of furnaces. The best and modern industrial furnaces have undergone a significant design change in terms of keeping the furnace low on carbon monoxide emissions by simply redirecting the carbon dioxide away from the combustion chamber. 

Type of Insulation: Because of highest operating temperature requirements, the type and quality of insulation matters the most in order to ensure safety of the operators at all times. In order to avoid any burns injuries or accidents, the best type of insulation is needed for covering the outer layer of the industrial furnace which becomes too hot during the heating process.

High-Quality and Extremely Safe Industrial Furnaces by Heatcon Sensors!

For procuring the best, extremely safe, and high-quality industrial furnace for your industrial process, Heatcon Sensors is a leading manufacturer in India. You can contact our highly experienced product engineers to get a ready-made solution for your process requirement, or even a custom-made solution designed specifically for your unique industrial application.

RTD Elements – The Most Widely Used Core Temperature Sensing Technology Today!

Importance of Thin Film RTD Element Design!

Heatcon Sensors – The Industry Leaders in Manufacturing High-Quality Custom-Design RTDs For Most Accurate Temperature Readings!

If you’re looking for a reliable and accurate way to measure temperature, you can’t go wrong with a resistance temperature detector, or RTD. RTD elements are made of a material with a known resistance that changes with temperature, making them ideal for precision measurement. It is nowadays considered as a core temperature sensing technology widely used in temperature sensor assemblies and RTD probes. RTDs are generally made from different materials such as copper, nickel, platinum, and gold.

There are many different RTD element designs, but they all work on the same principle. As the temperature of the element changes, so does its resistance. By measuring the resistance, you can accurately determine the temperature of the element. RTD elements are used in a variety of applications, from industrial process control to consumer electronics, and HVAC systems. They’re well-suited for temperature measurement because they’re highly accurate and stable over a wide range of temperatures.

Importance of Thin Film RTD Element Design!

There are many factors to consider when designing an RTD element, such as material selection, resistance value, size, wiring and connection type. 

  • The most important factor in RTD element design is the material selection. The material must have a high resistivity in order to accurately measure temperature. The most common materials used for RTDs are platinum, nickel and copper. 
    • Platinum is the most expensive material, but it is also the most accurate as they provide the best linear resistance change. Platinum RTDs can measure temperatures up to 800 degrees Celsius. 
    • Nickel is less accurate than platinum, but it is cheaper and can measure temperatures up to 500 degrees Celsius. 
    • Copper is the least accurate of the three materials, but it is the least expensive and can measure temperatures up to 300 degrees Celsius.
  • The resistance value is important because it determines the accuracy of the temperature measurement. When selecting the material for an RTD element, it is important to consider the accuracy requirements of the application. For applications that require high accuracy, such as HVAC or automotive, platinum is the best choice.
  • The size and wiring of the RTD element also need to be considered, as they can impact the accuracy of the temperature measurement.

Heatcon Sensors – The Industry Leaders in Manufacturing High-Quality Custom-Design RTDs For Most Accurate Temperature Readings!

If you are searching for the best type of RTD sensor for precise temperature measurement, an RTD is a great choice. With its high accuracy and stability, an RTD can help you get the most accurate temperature readings possible. If you are unsure which RTD element will work best for your application, you should contact experts at Heatcon Sensors who can guide you with your selection, and also you can expect the best custom-made solution to exactly meet the specific needs of your industrial application. The Heatcon Sensors team is highly experienced in customizing the thin film RTD element designs which offer the best value for your money.

What Are Surface Temperature Sensors, Their Types, & Benefits?

Surface Thermocouples

Resistance Temperature Detectors

Surface temperature sensors are used to measure the temperature of a surface. They are typically used in applications where the temperature of the surface is required for further processing, such as in the semiconductor industry.

Surface temperature sensors can be classified into two main types: those that use a physical contact to the surface, and those that don’t. The most common type of surface temperature sensor is the thermocouple. Thermocouples use two conductors of different materials that are joined at one end. When the two conductors are at different temperatures, a voltage is generated. This voltage can then be used to determine the temperature of the surface.

Non-contact surface temperature sensors are also available. These sensors use infrared radiation to measure the temperature of a surface. They are often used in situations where it is not possible to make physical contact with the surface, such as in high-temperature environments.

Surface Thermocouples

A surface thermocouple is a temperature sensor that is typically used to measure the temperature of a solid surface. These sensors are often used in industries such as power generation, chemical processing, and oil and gas production. Their benefits include: 

  • They are less expensive than other types of temperature sensors and are easy to maintain and install. 
  • Surface thermocouples are more rugged and can withstand harsh environments especially in high temperature furnaces.
  • They are very efficient in providing the most accurate temperature readings. This is due to the fact that they measure the temperature at the surface of the object, rather than the air temperature. This is especially important in industries where the temperature of the object being measured is much higher than the surrounding air temperature.

Resistance Temperature Detectors

RTD’s are sensors that measure surface temperature by converting it into a change in resistance. They are very popular because of their stability and precision at extreme temperature conditions. They’re typically made from metals like copper or platinum, and they can be used to measure a variety of temperatures, from -200°C to 550°C. Their Benefits include:

  • Precision: RTD’s are known for their high degree of accuracy, making them ideal for applications where precise measurements are required.
  • Stability: RTD’s are very stable and reliable, meaning they won’t fluctuate over time like some other types of temperature sensors.
  • Versatility: RTD’s can be used to measure a wide range of temperatures, making them a versatile option for many different industrial applications.

Heatcon Sensors – Pioneers in Making All Types of Quality Temperature Sensors For Every Industrial Need!

If you are unable to choose the perfect type of temperature sensor for your industry type of process, contact the highly skilled experts at Heatcon Sensors who can not only help you choose the best type of temperature sensor for your process, but also custom design it for you based on your specific needs.

What Is Mineral Insulation Cable & Its Benefits?

Advantages of Mineral Insulation Cables In Critical Industrial Processes!

A mineral insulation cable is the most preferred type of cable to be especially used in harsh environmental conditions and extremely high temperatures because of its low flammability properties. It is specifically being used in the thermocouple manufacturing industry to manufacture high-quality and accurate thermocouples which are used to measure minute temperature changes in industrial furnaces. The MI cables allow for precise and accurate temperature measurements due to their high resistance to oxidation at extremely high temperatures.

Advantages of Mineral Insulation Cables In Critical Industrial Processes!

  • For wet and chemically active environments, the metal sheathing that clads the mineral insulation cable does not allow for oxidation of the thermocouple wires. This provides for extreme corrosion resistance which makes MI cables ideal for processes where frequent replacement is either impossible or their failure may be too dangerous, as in nuclear power plants where core temperature is critically high. In such a case, it becomes extremely important to monitor accurate temperature and maintain it at all times using a high-quality thermocouple to avoid any major accidents. 
  • MI cables are filled with minerals to provide for excellent insulation, which is a non-reactive coating to help prevent the thermocouple wires from coming in contact with caustic substances like oils, water, and other industrial solvents or with each other. This further helps the temperature sensors to accurately record any temperature changes in critical processes such as sintering or heat treating where any small temperature fluctuations might adversely impact the quality of the product. 
  • The MI cables are insulated in such a way that its insulation will never catch fire in any case making it ideal for processes where any small fire could be disastrous. Nuclear power plants, medical device manufacturing industry, and oil rigs are some examples where the use of high-quality MI cables becomes extremely important. 
  • The insulation of the MI cable protects the thermocouple probes from coming in contact with other electrical wires which helps the thermocouple probes to take most accurate temperature measurements for longer periods without experiencing a malfunction. 
  • The MI cables are calibrated as per international standards to provide for precise and most accurate temperature measurements while operating in long duty cycles. 
  • The mineral insulation of MI cables makes them the perfect choice to be used in extremely high temperature conditions to obtain most accurate temperature readings. Because of this, they are considered ideal for industrial furnaces, firing ceramics, kilns, or heat-treating metals. MI cables are designed to withstand high temperatures, and thus, they are extremely reliable even after exposure to the highest order of temperatures by not losing their accuracy. These cables are extremely useful in industries where high international safety and quality standards are needed to be strictly enforced in order to avoid any industrial accidents.  

Heatcon Sensors – The Pioneers of Manufacturing High-Quality Thermocouples Using International Standard MI Cables!

If you have an industrial process which requires the best quality temperature sensing devices to take the most accurate temperature measurements over long duty cycles, you can contact the experts at Heatcon Sensors who can help you not only decide which option will work best for your process, but also they can help customize and design one for you to meet your specific process needs.

What are Temperature Transmitters & Their Advantages?

What Are Temperature Transmitters?

Why Do More And More Industries Use Temperature Transmitters?

How To Use A Temperature Transmitter?

What Are The Main Advantages of A Temperature Transmitter?

What Are Temperature Transmitters?

Temperature transmitters are devices which convert signals generated by a thermocouple or RTD into 4-20 mA output signals which are essential in appliances developed for taking temperature measurements remotely. Such transmitters have many advantages over conventional types of temperature measurement devices. 

Why Do More And More Industries Use Temperature Transmitters?

In some industrial processes, it is essential to monitor the real-time temperature changes of the system while sitting remotely due to safety reasons. Conventional thermocouples have a common limitation that they produce very low intensity signals. Such devices are required to be connected to a 2-wire transmitter in order to condition and amplify these signals to achieve better quality signals for more accurate temperature readings. These signals can then be easily transmitted using copper wires to other devices such as meters, chart recorders, computers, temperature controllers, and data loggers. 

How To Use A Temperature Transmitter?

A temperature transmitter should be connected to a DC power supply from which it will draw current in proportion to the inputs provided by the sensor. This change in the power supply is actually accounted for by the signal thus transmitted. While measuring the lowest temperature of the process, the input transmitter draws 4 mA of current from the DC supply source. As the temperature of the system rises, it will start drawing more current until the 20 mA mark is reached. The 20-mA mark signals the highest temperature that is sensed. The internal circuitry of the transmitter that conditions the signals defines the temperature range represented by the output current signals. 

What Are The Main Advantages of A Temperature Transmitter?

There are many advantages of using temperature transmitters for measuring temperature accurately over other traditional methods as below:

  • There is no requirement for AC power supply especially at the remote location in order to operate the 2-wire temperature transmitter. A temperature transmitter only requires minimum DC power of 4-20 mA output signals. Additionally, the 24 Vdc signal that is necessary to operate a temperature transmitter is widely accepted as a standard for plants equipped with heavy instrumentation. 
  • There are no problems of signal degradation or electrical noises for the operators using the temperature transmitters. A temperature transmitter’s signals are highly immune to ambient electrical noises. The receiving device usually eliminates any noise generated by the transmitters’ output current signal using common-mode rejection. In addition, the output current signal from the transmitter can travel long distances without much change contrary to most voltage signals. 
  • A temperature transmitter is extremely useful in lowering the wiring costs. The low intensity signals produced by the thermocouple essentially require a shielded cable to travel a significant distance. 

Heatcon – A Global Manufacturer of Top-Quality Temperature Transmitters and Temperature Sensors!

If you too have a process where you can find the use of a temperature transmitter necessary, you can query the experts at Heatcon – a leading global manufacturer of high-quality temperature sensing devices and industrial appliances for complete assistance in fulfilling all your process requirements.

RTDs Vs Thermocouples – What Will Work Best For Your Process?

Considerations For Choosing An RTD Or A Thermocouple For Your Industrial Process!

Heatcon Sensors – The Leading Manufacturer of All Types of High-Quality, Reliable, and Accurate RTDs & Thermocouples!

 

Both RTDs (Resistance Temperature Detectors) and thermocouples are sensors that are used to measure temperature, however, there are some important differences between both of these. There are different specific criteria as for their performance which will help us determine which one of them is best suited for an industrial process that we are looking to install one for as follows:

  • Cost Considerations: For temperatures above 600 degree centigrade RTDs are more expensive than thermocouples. For temperature measurements of the same style and order, an RTD will cost you nearly 2 or 3 times the cost of a thermocouple. Although you can expect to make some savings on RTD installation because of the use of copper wiring at lower temperatures, it is not enough considering the higher cost of the RTD device itself.
  • Temperature Range: For measuring the higher temperatures up to 1800°C , thermocouples are considered to be the best and more reliable than most RTDs which cannot operate efficiently at temperatures lesser than 400°C
  • Sensitivity: Although both RTDs and thermocouples are known to quickly respond to any minute changes in temperature, grounded thermocouples are more sensitive and respond at least 3 times faster than a RTD such as PT100. An exposed-tip thermocouple is considered to be the most sensitive and fastest. 
  • Accuracy: For better accuracy, you should opt for an RTD over a thermocouple for temperatures measurements below 400°C. Typically most RTDs have a better accuracy of about 0.10C in contrast to the thermocouples which are less accurate (1°C). However, some advanced thermocouples are designed to match the accuracy that an RTD can provide. The accuracy of the sensor depends on various factors such as linearity, stability, and repeatability. 
  • Linearity: All RTDs have a linear temperature-resistance relation to operate efficiently in a given sensor range, but you can see an ‘S’ type plot in a thermocouple. 
  • Stability: The readings from an RTD probe generally remain more stable and repeatable over a prolonged period of time, but thermocouple readings have a tendency to drift because of the sensor likely to have oxidative changes overtime. Thus, RTDs remain mostly stable and are considered to be a better choice for long term use. 

Considerations For Choosing An RTD Or A Thermocouple For Your Industrial Process!

We can easily conclude here that if you are looking for an economical temperature sensor, you can opt for a thermocouple because they are cheaper and easier to manufacture rather than an RTD. You can expect to make significant cost savings by selecting a thermocouple for your process especially in case you need a good number of temperature probes for your process. 

On the other hand, if you are looking for a more accurate and reliable temperature sensor, you should opt for an RTD for your process. Not to forget the only constraint with an RTD is the limited temperature range that they can operate optimally. 

Heatcon Sensors – The Leading Manufacturer of All Types of High-Quality, Reliable, and Accurate RTDs & Thermocouples!

If you are still unable to make a decision regarding which sensor type will be best suited for your industrial process, you can contact the experts at Heatcon Sensors who have great experience in designing, customizing, and manufacturing all types of high quality temperature sensors for various and sundry industrial processes.

 

 

What Is A Hygrometer, The Way It Works, & Its Different Types?

How A Hygrometer Works & Its Types?

Heatcon – The Leading Manufacturer & Supplier of High-Quality & Most Accurate Hygrometers in India?

What Is A Hygrometer?

A hygrometer is an important tool for most manufacturing industries as it helps to measure the amount of moisture in the air. It is used in a variety of industries and processes where accurate humidity measurements are critical. It is an important invention for many industries as too much or too little moisture can impact the quality of the products being manufactured. For example, in the electronics industry, a hygrometer is used to ensure that the products being assembled are not damaged by moisture. Some of the industries and processes that use hygrometers include humidity control in food processing and storage as well as indoor air quality monitoring and also pharmaceutical industry. It is extremely required especially in food processing and storage industries in order to prevent the growth of mold and mildew, and to protect sensitive materials from damage due to presence of moisture in the air.

How A Hygrometer Works & Its Types?

There are many different types of hygrometers, but they all work by measuring the amount of water vapor in the air. Let us discuss the most common types of hygrometers as below. 

  • Psychrometer: The most common type of hygrometer is a psychrometer, which consists of two thermometers, one of which is dry and the other of which is wet. The dry thermometer measures the air temperature, while the wet thermometer measures the temperature of the wet bulb. As such, a hygrometer works on the principle phenomenon called evaporative cooling. During the process of evaporation, the surface from which water has evaporated becomes colder since the water molecules absorb the surface heat to change their physical state in the form of vapors. Because of this, the wet bulb thermometer will consistently record lower temperature values than the dry bulb thermometer. In simple terms, you may feel instant cooling while you are in a shower. When you have low humidity levels along with mostly dry air present, it can lead to higher and faster evaporation rate and you will notice a significant decrease in wet bulb temperature. When there is very high humidity in the air, the decrease in wet bulb temperature is very less. When the humidity level is 100%, both dry and wet bulbs will register the same temperature.
  • Electrical Hygrometer: This type of hygrometer uses a fine-layer semiconductor device, and the hygrometer analyzes its variance in electrical resistance to accurately measure the humidity levels. Contrary to this, most hygrometers detect humidity levels based on variations recorded in weight, transparency, and volume of substances to determine the moisture content. Electrical hygrometers are of two types, namely resistive type and capacitive type hygrometers based on changes in resistance or capacitance. Each type has a sensor to detect even the minor variations in the semiconductors’ on-chip layer. 

Heatcon – The Leading Manufacturer & Supplier of High-Quality & Most Accurate Hygrometers in India?

If you’re looking to procure a hygrometer for your industrial process or have a specific requirement for which you are looking for a custom-solution, you can contact the experts at Heatcon who have decades of experience in manufacturing the best type of high-quality and accurate hygrometers.

 

 

What Are Thermocouple Connectors & 5 Most Important Things You Should Know Before Selecting One?

5 Most Important Things To Consider Before Choosing The Best Thermocouple Connector For Your Industrial Process!

 

Thermocouple connectors are devices that are responsible to transmit accurate thermocouple sensor signals in millivolts to the final display or control device. Different thermocouple sensors require compatible thermocouple connectors based on the type of alloy used in the sensor, specific color coding for identifying and matching the thermocouple wires, and finally the functional temperature range at which the specific thermocouple works. Before you go on to select the correct type of thermocouple connector for your thermocouple device, you should be aware of the following:

  • Thermocouple Alloys – For most accurate measurements, the thermocouple pins inside the connector should match with the lead wires or thermocouple sensor wires. You must note here that 9 different types of calibrations of thermocouple alloys are available in the primary connectors. The base metal thermocouples generally have J, K, T, E, and N types of calibrations that are widely used designs.  
  • Color Codes – There are specific color codes for specific types of thermocouple connectors to easily identify and exactly match the thermocouple connector to the sensor and the thermocouple wire. You must refer to the manual provided by the manufacturer to understand this concept in totality as it might be sometimes very confusing due to different international color coding systems such as USA ANSI color coding & International Electrotechnical Commission color coding system.
  • Functional Temperatures – The alloy pins and the thermocouple connector body material plays an important role while selecting the correct thermocouple connector depending on the range of functional temperature they are required to operate. 
    • The metal alloy pins of the thermocouple connector are capable of operating optimally between the temperature ranges of below Zero to up to 2000° F.
    • The thermocouple connector body material is the main factor that helps in determining the functional temperature range where it can efficiently and accurately operate. 
    • Typically the thermocouple connector body materials and the pins are made from either ceramics, thermosets, or thermoplastics all of which operate at a specific functional temperature range, i.e., from -40° F to 1200° F. 

5 Most Important Things To Consider Before Choosing The Best Thermocouple Connector For Your Industrial Process!

  1. Mechanical Durability: The thermocouple connectors made from thermoplastics are most widely used in all types of industries where highly accurate temperature measurements are needed because of their high mechanical durability. They are best suited to operate between -40° F to 400° F and above.
  2. Continuous Exposure To High Temperatures: When you need a connector to work efficiently on a continuous high temperature range of 500° F to 800° F, a thermocouple connector made from a Thermoset would be an excellent choice. 
  3. Heatcon Sensors: These sensors are meant to withstand continuous exposure to high temperatures and operate best between 600° F to up to 1000° F. 
  4. Highest Operating Range: The thermocouple connectors that work the best for highest temperature operating ranges are the ones which are made from high-quality ceramics. They can efficiently work between the temperature range of -20°F to up to 1200° F. Such connectors also work efficiently in vacuum based applications. 
  5. Shape & Size:  Depending on your process requirement and design, you have the option to select either the circular or rectangular shaped connector available both in miniature design and also in standard body design. 

Heatcon Sensors – A Globally Recognized Manufacturer of High Quality Thermocouple Connectors!

If you are looking to procure a high-quality thermocouple connector for your industrial process or if you are confused about your options to select the best thermocouple connector that will accommodate all your process requirements, you can contact the highly expert team of engineers at Heatcon Sensors who will answer all your queries in this regard and help you make the best informed decision in procuring the one.

 

 

The Assortment of Humidity Chambers

Benchtop Humidity Chambers

Reach-In Humidity Chamber

Walk-In Humidity Chambers

Drive-In Humidity Chambers

Scientific Testing Chambers

 

A humidity chamber is a device used to control the humidity levels. It is often used for scientific testing, but can also be used for other purposes. Different types of humidity chambers can be used in different industry verticals, laboratories for different purposes including product durability testing, and scientific testing, etc. Their types as well as their designs tend to vary as per the kind of testing that is needed, and some other factors decide the size of their parts too. Every industry vertical has its own set of requirements & data types needed to ascertain the quality of products required. This makes it imperative for the manufacturer to design a large variety of such test chambers with different sizes etc. 

Types of Humidity Chambers

Humidity chambers come in varied sizes and also come with different features such as the ability to reach various parts of the chamber, walk-in or drive-in configurations, and benchtop versions.

Benchtop Humidity Chambers

Benchtop humidity chamber units provide more convenience because they sit on a tabletop rather than being attached to a wall as traditional humidifiers do. This type of humidity chamber fits on shelves for testing humidity effects on smaller parts. This one is a cost-efficient way to test any product(s), usually done on small components like electronics parts, sensors, cell phones, etc. These are mainly used in research labs and/or by small businessmen etc. Size can be as small as 0.89 cubic feet and as large as 5.5 cubic feet also. 

Reach-In Humidity Chamber

The reach-in versions of these humidity chambers are perfect for use at work stations where you need easy access to the chamber itself. They have smaller footprints as compared to the models that are larger in size! They have the almost same versatility as that is there in a benchtop model. These come in vertical configurations allowing easy access. They are totally sealed while testing. Designed with casters/wheels for more convenience, they come in different sizes matching the space that is available.

Walk-In Humidity Chambers

As the name suggests, walk-in humidity chambers have big enough room for cars as well as any big computing systems. They can have modular construction wherein these chambers are built on-site or are installed as single units as per customers’ requirements.

Drive-In Humidity Chambers 

Just like the walk-in ones, the drive-in humidity chambers too are big in size. The main use for these types of chambers is seen in vehicle testing, wherein, the vehicle is tested under different mini-environmental conditions for determining its life as well as its durability. This type of chamber is usually engineered for meeting customer requirements, mainly used in the automotive industry.

Scientific Testing Chambers

Scientific testing chambers vary in size, but all of them are designed to control humidity levels in a specific area. They can be used to test products and/or materials, and predict humidity levels in the environment, by creating mini-environments. Their major use is seen in examining specimens for potential issues. The data thus collated becomes highly significant in the development of product(s) in the future related to food science, pertaining to pharmaceuticals, as well as the electronics industry.

Humidity Chambers by Heatcon Sensors 

Heatcon Sensors is one of the leading manufacturers of different types of humidity chambers. The testing chambers produced by them are being used in several industry verticals.

 

 

What Are The Various Reasons That Cause A Thermocouple To Fail?

Thermocouple Failure Modes That Can Cause A Thermocouple To Fail!

Heatcon – A Leading Manufacturer & Distributor of High-Quality Thermocouples!

 

A thermocouple is an electronic device that is required to measure high temperatures especially in the industrial processes and settings. It consists of two wires of different metals that are joined at one end. The other end of the wires is connected to a measuring instrument. The instrument measures the voltage that is generated when the two metals are at different temperatures. There are many environmental and operational factors that can cause a thermocouple to fail beyond a certain time affecting the accuracy of any temperature measurements. So, it becomes extremely important to understand the thermocouple failure modes that can affect the accuracy of a thermocouple in temperature measurements over time, and a thermocouple will subsequently fail to generate accurate measurements. 

Thermocouple Failure Modes That Can Cause A Thermocouple To Fail!

  • Corrosion Due to Oxidation Overtime: One of the most common causes for a thermocouple to fail is due to corrosion. The wires can become corroded if they are exposed to moisture or chemicals. This can cause the wires to break or the connection to the measuring instrument to become loose.
  • Physical Damage: Another reason for a thermocouple to fail is due to physical damage. The wires can become damaged if they are bent or stretched. This can cause the wires to break or wired connections become loose. The physical damage can also be caused if the thermocouple is used in conditions where the temperature levels exceed the temperatures that the device is actually calibrated for. The excessive heat will lead to physical damage to the thermocouple. 
  • Metal Fatigue: Due to continuous exposure to high temperatures, the metals will start showing characteristics of metal fatigue as the metals do expand and contract regularly because of any change in temperature. Such fatigue will lead to weakening of the thermocouple to generate most accurate readings over time. 
  • Welding Issues: During preparation of the metal for the thermocouple, improper welding may lead into open connection which can cause the thermocouple device to fail. As this issue can be easily detected, it should be fixed immediately with the help of an expert, and one should be careful to check the weld while installing a thermocouple. 
  • Using A Wrong Thermocouple: Different thermocouples have obviously different types of characteristics. Based on the type of a thermocouple, it needs appropriate matching type of electronics being used in order to decode signals received from the thermocouple. So, it is important to check the thermocouple parameters from an expert technician.
  • Improper or Inadequate Insulation: If the thermocouple wires are not properly insulated, they can also become damaged. This can cause the wires to become loose or loosening of the connection to the measuring instrument itself, which may result in inaccurate temperature readings. 
  • Calibration Issues: If the measuring instrument is not properly calibrated, the readings can be inaccurate. In such a situation, the thermocouple is required to be replaced. You might need an expert to evaluate the thermocouple device periodically in order to check and verify the calibration in order to fix any such issues. 
  • Poor Installation: Thermocouples can also fail due to poor installation. If the wires are not properly connected or the operating conditions are not compatible with the thermocouple device, it will ultimately lead into failure of the thermocouple device.

Heatcon – A Leading Manufacturer & Distributor of High-Quality Thermocouples!

If you suspect that your thermocouple has failed or is not giving the most accurate readings, you should contact the expert team of engineers at Heatcon to get the best advice for any repairs that are needed, maintenance, or complete replacement of your thermocouple device. It may be any of the above-listed thermocouple failure modes that your thermocouple device has failed, it is always important to have it checked by a qualified technician only.

 

 

Construction of Humidity Chambers

Humidity Chambers Are Available in Many Sizes!

Construction of a Humidity Chamber

Humidity Chambers by Heatcon Sensors

 

A humidity chamber is an equipment used to examine how products under test react when they are exposed to humidity variations. A variety of test methods using humidity chambers have been developed to determine whether a certain product that is being tested using this humidity chamber would be able to withstand adverse weather conditions, which in turn defines its durability. These tests are often performed by technicians, who analyze test results using sophisticated instruments. This testing requires specialized training and experience to interpret properly and accurately for each particular case at hand. After testing, these technicians arrive at an accurate conclusion about a given product or its part or assembly’s suitability for mass production and/or distribution in its intended environment or application (e-g., aerospace, automotive, marine, etc.).

Humidity Chambers Are Available in Many Sizes!

A simple form of a moisture chamber consists essentially of two sealed rooms, one inner and one outer, with walls made from a transparent material such as glass or plastic so that the Relative Humidity (RH) inside can be observed. The principle behind this type of device is that water vapor condenses onto surfaces when it reaches its boiling point-the higher than the RH in either room, more water vapor will precipitate on surfaces within both rooms. Several variables affect the durability of any product(s). These humidity testing chambers are used for ensuring the durability of products and optimizing their performances to provide accurate data about the factors that cause the deterioration of these products. The humidity chamber can be considered as a type of miniature environment that is capable of creating a vast array of environmental conditions, so it is made of durable material(s), which can withstand the weather condition(s) it creates. These testing chambers are available in many sizes from desktop models to even the ones that are big enough to walk inside them. Irrespective of the sizes, all types of these chambers have some common elements, including walls, sealing materials, doors, controllers, observation ports, temperature setting monitors, etc.

Construction of a Humidity Chamber

A humidity chamber is a scientific instrument used to measure and control the humidity in the air, as well as other gasses and liquids. It is composed of several large and small chambers interconnected by a system of pipes and valves. Data collection and analysis are carried out by a computer. The humidity chamber is made up of separate chambers, each of which is heated and cooled. The lower chamber (the one below the surface) is heated by a piece of equipment that emits infrared radiation. The warmer air rises and the cooler air sinks. The condensation on the walls and ceiling of the chamber causes the humidity level to be monitored continuously. The humidity chamber is often used for measuring the humidity in the atmosphere, controlling the humidity in air-conditioning systems, studying the behavior of gasses and liquids at low and high temperatures, and for making products’ tests for their sustainability. This defines the life of any product when it is supplied in the market. A humidity chamber consists of the following:

  • Walls 
  • Sealing Material
  • Doors
  • Controllers
  • Temperature
  • Air supply
  • Humidity system
  • Materials

Humidity Chambers by Heatcon Sensors 

A humidity chamber is an important tool used in many industry verticals. It is useful for reproducing the humidity in the atmosphere, simulating the humidity created by air-conditioning systems, and for testing the durability of products by the behavior of their materials under different environmental conditions. Heatcon Sensors‘ humidity chambers are highly accurate and reliable, meeting or exceeding all applicable standards. Heatcon is the leading manufacturer of high-quality humidity chambers. Their chambers maintain a consistent level of humidity, and these chambers are safe to use, easy to operate, and perfect for industrial requirements. They offer a wide range of humidity chambers, so you can find the perfect one for your needs or get one specifically constructed that suits your needs well.

 

 

Industrial Applications of Humidity Chambers

Industrial Applications of Humidity Chambers

Humidity Chambers by Heatcon Sensors 

 

Gone are the days when products were dissipated in the market with just the hope that they would be durable. This guesswork era has pretty much ended with the development of humidity chambers, which has paved the way for the much-informed introduction of the product(s) in the market! These testing chambers give critical data about product(s) and their material(s) for the designing of fresh products. Many industries today are not just using these humidity chambers, but depending upon them quite a lot to gather significant information about the stability & endurance of their product(s). 

Industrial Applications of Humidity Chambers

Humidity chambers are used in a wide range of industrial applications. Humidity chambers use moist air to control the humidity levels within a given environment. This helps to preserve products or reduce the amount of water needed for specific processes. In many industries, humidity chambers are used to control the humidity levels in a given environment. These chambers are also used in research laboratories to study the effects of humidity on various objects. The air in a humidity chamber is created by putting moist air into the chamber and then sealing the chamber. The humidity level in the chamber is controlled by the amount of water that is present in the air. The reason why humidity chambers are used in various industries is that they allow for the controlled reproduction of humidity levels. This is important because it is difficult to replicate humidity levels in an uncontrolled environment. Many industries today are using humidity chambers to control the humidity levels in a given environment and to study the effects of humidity on various products.

  • Automotive Industry: The major function of this tenting chamber in the automotive industry is to simulate weather conditions, which is done by pumping in moisture-filled hot air inside the chamber. The capability of a car to withstand such abuse, which they endure, is a serious issue for car manufacturers. Ensuring any vehicle’s tolerance over all these types of weather conditions is vital for the life of any such vehicle and also for the safety of the passengers.
  • Rubber Industry: Rubber is a material that gets too affected by any strong climatic condition(s). Rubber sure has high tolerance but it is still prone to the damages/changes owing to the humidity in the air. The sole purpose of a humidity testing chamber here is for testing how rubber will behave when it is subjected to 95 percent humidity. By using such a chamber, the rubber’s cracking/melting property is determined.
  • Pharmaceutical Industry: Considering humidity is a crucial aspect in this industry as moisture can degrade the drugs quickly, making humidity-testing data highly critical to determine the life of any drug. 
  • Plastic Products Industry: Moisture & humidity exposure can lead to discoloration of plastics, and surface crazing/chalking, and making them brittle. So, it is crucial to test any plastic products for such aspects as it can cause the failure of any plastic products in the market.
  • Other Industries: Humidity chambers can be found in various other sectors such as electronics, textiles, chemicals, aerospace, military, medical, battery, and other materials processing industries.

Humidity Chambers by Heatcon Sensors 

Heatcon Sensors is a leading manufacturer of high-quality humidity chambers. Their products are used in many industry verticals by manufacturers, researchers, scientists, and laboratories throughout the world to check and control humidity levels in various environments.

 

 

What Is A Humidity Chamber, How It Works, And Its Different Types?

How A Humidity Chamber Works?

Most Widely Used Types of Humidity Chambers! 

Heatcon – The Leading Manufacturer of High-Quality Humidity Chambers!

 

A humidity chamber is a controlled environment used to test the effects of specified levels of humidity on objects or materials. It has a specific application in manufacturing processes where manufacturers can do environmental testing using different control parameters of humidity and temperature to ensure their products can withstand the harshest of weather conditions. It is helpful in ascertaining the shelf life of the products and the point beyond which the product quality will start to deteriorate or completely fail. It is helpful for product design engineers to fine-tune their product design and materials that are better resilient to the environmental conditions. 

How A Humidity Chamber Works?

If you need to store or test materials that are sensitive to moisture, you may need to use a humidity chamber. These chambers can help to regulate the level of humidity in the air, providing a controlled environment for your materials. Humidity chambers work by circulating air through a humidifier and then trapping it inside the chamber for test durations. This allows the air inside the chamber to reach the desired level of humidity. A hygrometer is used to easily monitor the humidity level inside the chamber. If you need to store materials that are sensitive to moisture, a humidity chamber can help to protect them. By regulating the level of humidity in the chamber, you can create a safe and controlled environment for your materials. By measuring the most optimum humidity levels, you can easily vary your materials and designs to increase the shelf life of your final product. 

Most Widely Used Types of Humidity Chambers! 

There are different methods of introducing both heat and moisture into a humidity chamber. You can use a bath or spray technique to introduce water, and likewise, you can use a heating element or a coil type of heater for generating heat. Some of the most widely used humidity chamber types include:

  • Steam Generator: One of the most common types of chambers is the steam generator that uses immersion type of heaters for creating the desired level of humidity. The advantage of this type of chamber is that it can create very high levels of humidity, which is perfect for testing materials that need to be exposed to extreme conditions. The inside temperature can be easily varied between 300 0C to up to 1300 0C.  
  • Atomizer Test Chamber: Another type of chamber is the atomizer test chamber which is fitted with a spray nozzle for inducing atomized water for creating moisture inside the chamber. The advantage of this type of chamber is that it is less expensive to operate than a steam generator. However, atomizers can be less effective in creating high levels of humidity.
  • Water Bath Test Chambers: These use a water bath to create the desired level of humidity. The advantage of this type of chamber is that it is very effective in creating high levels of humidity.
  • AGREE Test Chambers: Such chambers are the most expensive ones, but they are also the most effective. These chambers use a combination of steam and atomization to create the desired level of humidity. AGREE chambers are perfect for testing materials that need to be exposed to extreme conditions. The unique feature of such a chamber is that it also offers vibration testing at the same time along with environmental testing. 

Heatcon – The Leading Manufacturer of High-Quality Humidity Chambers!

If you too are looking to procure a robust solution for your product testing needs, you can contact the sales team of Heatcon Sensors who can assist you with getting the most suitable type of humidity chamber that will work best for your process after thoroughly understanding your process needs.

 

 

What Are Hot Air Blowers & Their Benefits?

How to Choose the Right Hot Air Blower for Your Industrial Process?

Benefits of Hot Air Blowers!

Heatcon’s Hot Air Blowers Are Truly World-Class!

 

What are Hot Air Blowers?

Hot air blowers are devices which are capable of generating high-velocity hot air in a controlled and focused manner which is then used to heat up materials or to provide drying power. The air gets heated when it is passed through a heated element thereby raising the temperature of the air which is ready to be blown out. Such blowers are commonly used in a variety of industrial and domestic applications. A hot air blower is a truly versatile tool that can be used in a variety of industries, including the automotive, food processing, ceramic, plastic, and textile industries. An industrial hot air blower is used to move compressed hot air around, and they are often used to dry or heat up objects or materials by using high-velocity hot air. Industrial hot air blowers can be used in a number of different manufacturing processes such as aspirating, ventilating, conveying, and exhausting, and they are available in a variety of sizes.

How to Choose the Right Hot Air Blower for Your Industrial Process?

When it comes to hot air blowers, there are a lot of different options available in the market. Choosing the right one for your industrial process can be tricky. The best hot air blowers have a built in thermocouple to generate optimum heat, has an on-board temperature sensor, and can generate air flow in a controlled manner. There are a few other things you must consider when making your decision.

  • On-Board Thermocouple: An air blower that comes with an on-board thermocouple gives you the option to monitor, measure, and control the temperature. Thus, you can easily make sure it meets your process’ heating requirements perfectly. 
  • Size of the Unit: You need to think about the size of the unit. The larger the unit, the more powerful and expensive it will be. You need to make sure that the unit you choose is powerful and compact enough to handle your specific heating requirements.
  • Air Flow Control: A blower that offers air flow controls gives you more options and can be very useful in applications where you need to vary the air flow. 
  • Temperature Requirement & Space to Be Heated: You need to think about the specific needs of your process. What are the temperature and humidity requirements? What are the airflow requirements? Make sure that the unit you choose can meet all of the needs of your process.
  • Cost of the Unit: You must think about the cost of the unit. There are a lot of different hot air blowers on the market, and they all vary in price. Make sure you get a unit that fits your budget. You should also consider the warranty. 

Benefits of Hot Air Blowers!

  • Hot air blowers are very efficient for heating small spaces quickly. 
  • They have low operational costs. 
  • Since there is no use of oil or water filters, they provide clean air. 
  • There is no condensate with the air exhausted. 
  • They are independently functional as there is no need for external piping or use of any sort of heavy equipment to run them.

Heatcon’s Hot Air Blowers Are Truly World-Class!

If you have a query about which hot air blower will be perfect for your process, you can contact Heatcon Sensors’ technical team. Heatcon is a leading manufacturer of high-quality thermocouples and hot air blowers for a variety of different industrial processes, and can also provide you with a custom-made solution to best fit your requirements for a quality hot air blower. 

 

 

Reasons Why Heatcon Sensors are Most Trusted By Industries Needing High-Temperature Furnaces?

Industrial Applications for High-Temperature Furnaces!

Heatcon’s Temperature Sensors – Especially Designed to Measure Accurate Temperatures of High-Temperature Furnaces!

 

What are High-Temperature Furnaces?

High-temperature furnaces are furnaces that are usually required to operate at high temperatures as much as 1200 degrees Celsius and above. They are used in a variety of industries for a variety of applications. Some of the most common applications for high-temperature furnaces include heat treating, glass making, and ceramics. Heat treating is the process of using heat to change the properties of a material. This can be done to strengthen the material, to simplify machining, or for other purposes. The industries that most commonly use high-temperature furnaces include mining, battery manufacturing, dental, aerospace, quality control laboratories, and powder metallurgy applications.  

Industrial Applications for High-Temperature Furnaces!

High-temperature furnaces are used in a variety of industries and applications. These furnaces can reach temperatures above 2000 degrees Celsius, making them ideal for certain manufacturing processes. There are many different types of high-temperature furnaces, each with its own advantages and disadvantages. 

  • The most common type of furnace is the electric resistance furnace. These furnaces use electricity to heat metal elements, which in turn heat the air inside the furnace. Electric resistance furnaces are very efficient, but they can be expensive to operate.
  • Another type of high-temperature furnace is the gas-fired furnace. These furnaces use natural gas or propane to heat the air inside the furnace. Gas-fired furnaces are less efficient than electric resistance furnaces, but they are less expensive to operate.
  • High-temperature furnaces are used in a variety of industries, including the steel industry, the glass industry, and the semiconductor industry. These furnaces are used to create new materials, or to modify existing materials. For example, high-temperature furnaces are used to create steel alloyed with other metals, or to create tempered glass.

If you are in an industry that uses high-temperature furnaces, it is important to choose the right type of furnace for your application. Moreover, you need the right type of temperature sensor, irrespective of the furnace type, that can be utilized to accurately measure the extreme high-temperatures and are truly beneficial and reliable in terms of cost efficiency and longevity. 

You can rely on Heatcon Sensors extensive knowledge in designing and manufacturing high temperature furnaces. Call Heatcon Sensors today if there’s a need to manufacture a high temperature furnace.

Heatcon’s Temperature Sensors – Especially Designed to Measure Accurate Temperatures of High-Temperature Furnaces!

As proficient as they are in the manufacturing of high temperature furnaces, Heatcon Sensors also manufacture a range of temperature sensors including thermocouples and RTDs.

If you are looking for a high-temperature furnace sensor, you should consider exploring the range of temperature sensors that Heatcon Sensors manufactures which are very popular and especially designed to withstand and perform efficiently at extremely high temperatures. 

Here are five things that make Heatcon Sensors the most appropriate sensors for high-temperature furnaces:

  1. Wide Temperature Range – Heatcon Sensors can withstand temperatures up to 3,000 degrees Fahrenheit, making them ideal for high-temperature furnaces.
  2. Quick Response Time – Heatcon Sensors respond quickly to changes in temperature, ensuring accurate readings.
  3. Rugged Construction – Heatcon’s temperature sensors are built to withstand the rigors of industrial environments, making them ideal for use in high-temperature furnaces.
  4. Easy Installation – Heatcon’s temperature sensors can be easily installed in existing furnaces, making them ideal for retrofit applications.
  5. Competitive Pricing – Heatcon’s temperature sensors are competitively priced, making them an affordable option for high-temperature furnace sensors.

Contact Heatcon Sensors Today To Get Your High Temperature Furnace Manufactured and also the Best Fit, High-Quality Temperature Sensor for Your Furnace.

 

Types and Categories of Industrial Ovens Explicated

Categories of Industrial Ovens

Heatcon Sensors – The Largest Manufacturer of Industrial Ovens

 

What Are Industrial Ovens?

Industrial ovens are the devices, which are used for generating high temperatures for the heat treatment of parts, metal conditioning, and curing of the metal coating. The 2 major types of industrial ovens are the continuous ovens and the batch ovens. As their names suggest, a batch oven can do the treatment of a big number of parts at once. Continuous ovens are often the major part of mass production and can consist of heating as well as cooling functionalities. The operation of an industrial oven depends largely upon its usage requirement. Gas ovens, electric ones, steam ovens, hot water ovens, and microwave ovens are the conveyor-loaded industrial ovens. Product loading patterns and airflow patterns are important for the success of industrial ovens. 6 different airflow patterns are there, depending on the product type and how they have been loaded. Heat gets circulated by forced convection.

Categories of Industrial Ovens

Below are some of the common categories of industrial ovens, which are unique in their creation, structure, product handling, as well as flexibility:

  • Industrial Electric Oven: This type of oven uses electricity. It has a quick heat-up time, and precise temperature control, and is available at a comfortable rate. This type of oven is perfect to deal with the combustible product(s) and/or work with some metals namely aluminum that may discolor when they are heated by gas.
  • Laboratory Oven: This type of oven is used for testing samples during the product development process or while completing the light-duty productions of smaller parts.
  • Industrial Batch Oven: This type of oven is used for processing a large number of products. This type comes in different sizes, which vary from some cubic meters to even several cubic feet. 
  • Conveyor Oven: This type of oven is used in automated productions and this is usually designed for fitting into some particular manufacturing processes. This type of oven can operate at varying speeds. It consists of multiple heat zones, a cooling zone, and also an exhaust hood. It does the work of curing, preheating, drying, bonding, tempering, stress-relieving, annealing, and forming.
  • Curing Oven: This type of oven causes powder/paint to be bonded with metal(s). It is capable of hardening the products that are made from rubber, plastic, or some metal.  
  • Direct Gas Oven: This type of oven is more costly to be constructed than an electric oven but it is less costly to use as the gas cost is lesser than the cost of electricity. 
  • Drying Oven: This type of oven is used for removing moisture, heat-treating metal(s) for extrusion processes, for sterilizing medical equipment(s). It uses natural/forced convection.
  • Tunnel Oven: This type of oven has an open-ended chamber(s), which are connected to a metal belt; this has a baking platform too. Products get baked straight away on a pan or on the hearth. 
  • Microwave Oven: This type of oven has been very common for cooking and heating food in houses, but recent developments have resulted in the use of these ovens for industrial purposes as well. 
  • Baking Oven: This type of oven releases moisture, trapped gasses, or volatile compounds from the coatings on the finished products. 
  • Vacuum Oven: This type of oven controls atmospheric pressure inside the heating chamber for removing any contaminants, and for providing better control over the treatment process.
  • Infrared Oven: This type of oven uses high-intensity lighting for maximizing production and for minimizing the use of energy. 

Heatcon Sensors – The Largest Manufacturer of Industrial Ovens

If you wish to have more information about the industrial ovens for your application(s), you can contact the experts at Heatcon Sensors; they happen to be one of the largest manufacturers of high-quality industrial ovens.

 

 

A Quick Read to Discover What Is an Induction Furnace

Types of Induction Furnaces

Heatcon Sensors – The Best Place to Procure an Induction Furnace

Induction Furnaces by Heatcon Sensors

Features of Induction Furnaces by Heatcon Sensors

Applications of Induction Furnaces by Heatcon Sensors

Specifications of Induction Furnaces by Heatcon Sensors

What Is an Induction Furnace?

An induction furnace is a type of furnace that uses electromagnetic induction to heat materials. Induction furnaces are used in a variety of industries, including the steel, aluminum, copper, and glass industries. The major components of induction furnaces include sensor(s), furnace(s), power supply, capacitor(s) & control system(s). When the action of alternating electromagnetic fields happens in induction furnaces, eddy currents get generated in the material(s) for achieving a heating effect/melting effect. In the stirring effect of alternating magnetic field(s), material composition as well as material temperature in the furnaces become uniform (relatively), and forging heat-temperature(s) can even reach up to 1250°C, and the melting point(s) can even reach up to 1650°C. Besides being heated/smelted in the atmosphere, induction furnaces can even be heated/smelted in a vacuum, and can even be heated/smelted inside a protective atmosphere like argon/helium for meeting specific quality requirement(s).

Types of Induction Furnaces

Induction furnaces are broadly divided into 2 main types, as given below:

  • Heating Induction Furnaces: These electric furnaces heat material with the help of an induced current that gets generated through the induction-coil. If the material (metal) gets heated, then it’s placed inside a crucible, which is made from the refractory material. If the material (non-metal) is heated, then it’s placed inside a graphite crucible. When AC frequency increases, the frequency of that induced current gets augmented accordingly, and the heat that is being generated is also amplified. 
  • Melting Induction Furnaces: Melting induction furnaces are divided into 2 major types, as follows:
  • Core Induction Furnaces: These have a core passing through the inductor, powered by the commercial-frequency power-supply. These are largely utilized for the purposes of melting as well as for heat preservation of various metals including bronze, cast iron, zinc, brass, etc. 
  • Coreless Induction Furnaces: These have no iron core to pass through the inductor, and these are further divided into the following types:
    • High-frequency induction furnaces
    • Triple-frequency induction furnaces 
    • Power-frequency induction furnaces
    • Thyristor intermediate-frequency induction furnaces 
    • Generator-set intermediate-frequency induction furnaces 

Heatcon Sensors – The Best Place to Procure an Induction Furnace

If you wish to have more information about the induction furnaces for your application(s), you can contact the experts at Heatcon Sensors (https://mithermocouple.com/induction-heaters-furnace/); the perfect place to procure a high-quality induction furnace.

Induction Furnaces by Heatcon Sensors

The features, applications, and specifications of the induction furnace provided by Heatcon Sensors are mentioned below:

Features of Induction Furnaces by Heatcon Sensors

  • Portable
  • Lightweight 
  • Speedy cycles of heating (lower than 99 sec)
  • Much reduced oxidation having better quality joint(s)
  • The auto-shutdown feature is available, and it helps during any fault condition
  • Effective IGBT/MOSFET-Based induction furnace (Compact bench Top module)

Applications of Induction Furnaces by Heatcon Sensors

  • Soldering/brazing of cutting & drilling tool
  • In the brazing of a precious metal (gold/silver/platinum/palladium etc.)
  • Used for the heat treatments of metal parts that may consist of hardening/tempering/shrink heating/instant heating needed for forging

Specifications of Induction Furnaces by Heatcon Sensors

  • Product Size: 200x450x400 mm
  • Power Supply: ac-220/440V 60 Hz
  • Output Frequency: 30kHz – 80 kHz
  • Heat Oscillate Current: 200A – 1000A
  • Power Rating: 3Kw, 5Kw, 10 Kw, and above
  • Flow Rate of Cool Water: 0.2 Mpa, 10L/min

 

 

A Quick Guide about the Types of Industrial Furnaces

Types of Industrial Furnaces

Where Are Industrial Furnaces Used?

Heatcon Sensors – One of the Biggest Manufacturers of Industrial Furnaces

Heatcon’s Industrial Furnace (High-Temperature up to 1200℃)

 

The normal functionality of industrial furnaces is the heat treatment of metals, which is done to anneal, temper, or carburize and pre-treat the material for the purpose of forging. Although metals are the common materials for such treatments using industrial furnaces, there are other material (s) too that can be heated during the process of preparing them to shape, including glass and some ceramics as well. Irrespective of the material(s), an industrial furnace heats these material(s) to extreme temperatures using different fuels as well as formats. Although an industrial furnace and an oven both are used to heat material(s) for processing, yet there’s a clear-cut distinction between them. Often, these 2 different terms are referred to interchangeably for describing the heating process, but there happen to be some differences between the two; the most distinct one is the range of temperature. Typically, an industrial oven may operate from 250° F up to 900° F while an industrial furnace reaches up to the temperature of even 2000° F or maybe higher than this too.

Types of Industrial Furnaces

When these industrial furnaces first appeared many years back, their very purpose was primarily heating metals to cast, mold, and shape. From its inception, and then for several years afterward, this type of industrial furnace remained the only variety available then. As industrialization proceeded, an industrial furnace became an important part of many industrial operations, serving a variety of applications. Below is a brief description of the most common types of industrial furnaces available today. Industrial furnaces are divided into two major categories depending on the heat source: fuel-fired industrial furnaces and electric industrial furnaces, as described below: 

  • Fuel-Fired Furnaces: Fuel-fired furnaces include gas and oil furnaces, wood furnaces, and coal furnaces. These furnaces burn fuel to create heat. 
  • Electric Furnaces: Electric furnaces include resistance furnaces, induction furnaces, and arc furnaces. These furnaces use electricity to create heat. 

Where Are Industrial Furnaces Used?

Industrial furnaces are used in a variety of industries, such as metal processing, glassmaking, and ceramics. 

  • Metals Processing: Furnaces are used to melt and alloy metals, heat metals before shaping and forming them, and heat metals before treating them (heat treating). 
  • Glassmaking: Furnaces are used to melt and fuse glass. 
  • Ceramics: Furnaces are used to bake clay products, incinerate waste, and create heat for other industrial processes.

Heatcon Sensors – One of the Biggest Manufacturers of Industrial Furnaces

If you want to attain more knowledge about industrial furnaces for your application(s), you can contact the experts at Heatcon Sensors (https://mithermocouple.com/industrial-furnaces/); as it is the largest manufacturer of high-quality industrial furnaces. 

Heatcon’s Industrial Furnace (High-Temperature up to 1200℃)

Heatcon’s industrial furnaces are divided into 2 main types, as follows: 

  • Medium temperature industrial furnace (Ambient – 950℃) 
  • High-temperature industrial furnace (Ambient – 1200℃)

Features:

  • Annealing 
  • Quenching
  • Casting iron parts
  • High chromium castings 
  • Manganese steel castings
  • Aging/heat-treatments of mechanical parts
  • Used in research institutes as well as laboratories

Specifications:

  • Durable 
  • Less heat loss
  • Fiber-ceramic lining
  • Thermal efficiency is high
  • 4-sided heat device that can achieve exceptional temperature uniformity
  • Builds a silicon-carbide plate (horizontal) or a high-temp cast steel plate for the trolley
  • Clever program-temperature controller, which exists for editing & saving any multi-segment program(s) 

 

 

Bobbin Heaters

What are Bobbin Heaters & Their Key Features!

Top 5 Benefits of Bobbin Heaters

Benefits and Applications of Bobbin Heaters!

Heatcon Sensors – The Largest Manufacturer of High-Quality Bobbin Heaters!

 

What Are Bobbin Heaters?

Bobbin heaters are heating elements that are used in large industrial units in processes where direct and indirect heating is required. They are made of a cylindrical shape and are made of high-quality materials that can withstand high temperatures. Bobbin heaters have a high heating efficiency and are very durable. Such heaters are used for directly heating the air mixtures whilst they can be used for indirectly heating the liquids. These heaters are installed in a small pocket that is inside the processing tank but can be accessed from outside for easy replacement without having the need to empty the entire contents of the processing tank. These heaters are highly efficient in terms of energy consumption as the solution comes in direct contact of the element. 

Top 5 Benefits of Bobbin Heaters 

If you’re looking for a versatile and reliable heating element, then a bobbin heater is a great option. Here are five benefits of bobbin heaters:

  1. Versatile Design – Bobbin heaters can be used in a wide range of applications, from small electronic devices to large industrial machines. They come in various specifications and sizes to meet the exact heating requirements of the process. 
  2. Reliable – Bobbin heaters are made with high-quality materials that ensure long-lasting performance. The sheathing material comes in different ranges including copper, nickel plated mild steel, nickel plated copper, and stainless steel. 
  3. Fast & Uniform Heating – Bobbin heaters can reach high temperatures quickly, making them ideal for applications that require fast heating and they are immersive type heaters to spread heat uniformly over the mixtures. 
  4. Pinpoint Heating – Bobbin heaters offer precise temperature control so that you can always get the exact level of heat that your application needs.
  5. Absolutely Safe – Bobbin heaters are designed to ensure complete peace of mind and are absolutely safe to use even at high temperatures. They are usually made to offer horizontal mounting, but can be easily customized for vertical mounting as well. 

Benefits and Applications of Bobbin Heaters!

  • They are best utilized to heat the mixtures from low temperatures up to a maximum of 600 0C.  
  • They are excellent heaters for heating both water and liquid chemicals.
  • They can also be used to heat semisolid items such as oil, bitumen, wax, etc. 
  • They can be best suited to heat liquids and gasses as such heaters are pocket-fitted or protected with protection tubing inside the processing tank.
  • They can be easily used for applications where you don’t need the entire liquid drained from the processing tank allowing for easy replacement of the heating element.  

Heatcon Sensors – The Largest Manufacturer of High-Quality Bobbin Heaters!

If you wish to have more information about bobbin heaters for your application, you can contact the experts at Heatcon Sensors who are the largest manufacturers of diverse, high-quality commercial Bobbin Heaters.

In today’s modern world, there is a need for accurate temperature measurements in a variety of industries. From food and beverage processing to molten metal production, precise temperature control is essential. Bobbin heaters, hygrometers, and thermocouples are all important tools for temperature measurement and control. Bobbin heaters are used to heat up cylindrical objects, such as pipes or rods. They are often used in applications where precise temperature control is required, such as in food processing. Hygrometers are used to measure the moisture content in the air. They are commonly used in weather stations and greenhouses. Thermocouples are devices that measure temperature by measuring the voltage between two conductors. They are used in a wide variety of applications, from industrial furnaces to medical devices. There are two main types of thermocouples: noble metal and molten metal. Noble metal thermocouples are made of two different metals, such as copper and nickel. They are used in applications where high temperatures are involved, such as in the steel industry. Molten metal thermocouples are made of a single metal, such as iron. They are used in applications where the temperature is not as high, such as in the food industry. Heatcon sensors are used in a variety of industries to measure temperature.

 

 

Tubular Heaters

Top 5 Benefits of Using High-Quality Tubular Heaters

Different Variety of Metal Sheaths Are Used to Manufacture Tubular Heaters Based on Type and Size of The Industrial Application! 

Heatcon Sensors – A Trusted Name in Manufacturing High Quality Tubular Heaters!

 

What are Tubular Heaters?

Tubular heaters are a type of resistance heater. They are made up of a metal tube that is coiled or wound into a spiral. The metal tube is then filled with a resistive material, such as Nichrome or Kanthal. The resistive material heats up when electric current is passed through it. This resistance to the flow of electricity generates heat. Use of tubular heaters is a very efficient and reliable way to generate greater amounts of heat. Such heaters are especially designed for use in industrial units and large volume appliances. They are durable and can withstand high temperatures. They are also easy to control and can be turned on and off as needed. Tubular heaters are available in a variety of shapes and sizes. The size and shape of the heater can be customized easily depending upon the industrial application it is going to be used for. 

Tubular heaters are used in a variety of applications, such as air heating, gas heating, and liquid/chemical heating processes. They are particularly well suited for industrial applications where high temperatures are needed, such as in large industrial furnaces. Tubular heaters can also be used in lower temperature applications, such as in food warmers and hair dryers. 

Different Variety of Metal Sheaths Are Used to Manufacture Tubular Heaters Based on Type and Size of The Industrial Application! 

Tubular heater’s sheath is made of metal. Metal sheaths are the most common type of sheath used in tubular heaters. They are typically made from stainless steel, Inconel, or titanium. Metal sheaths are effective at conducting heat and are also very durable.

Heatcon Sensors – A Trusted Name in Manufacturing High Quality Tubular Heaters!

Heatcon Sensors is a leading manufacturer of high-quality tubular heaters that offer many benefits. Some of the key benefits of using Heatcon’s tubular heaters include:

1.Efficiency – Tubular heaters are extremely efficient at heating larger volume operating units. They use less energy than other types of heaters, so you’ll save money on your energy bills.

2. Uniform Heat Distribution – Heatcon Sensors tubular heaters are very popular because of their characteristic even heat distribution. Thus, you need not to worry about hot and cold spots in your application.

3. Durability – Heatcon Sensors tubular heaters are built to last. They are made of high-quality materials that can withstand years of use and can easily withstand high temperatures.

4.  Safety – Heatcon’s tubular heaters are absolutely safe and are well designed to prevent any kind of accidental fires or electrical shocks.

5.  Easy to Install – Heatcon Sensors’ tubular heaters are very easy to install and are easy to operate. 

So, if you too are looking for an efficient and the most economical way to run your industrial application on the best quality tubular heaters, try contacting the experts at Heatcon Sensors who can surely help you in making the best possible selection, or customizing a tubular heater to suit your business’ application best.

Looking for high-quality tubular heaters? Look no further than Heatcon Sensors! We manufacture some of the best bobbin heaters, hot air blowers, and hygrometers in the business. Top 5 benefits of using high-quality tubular heaters manufactured by Heatcon Sensors include reliability, accuracy, supreme quality, durability and perfection! If you’re looking for a reliable and accurate way to measure temperature, Heatcon Sensors is the way to go!If you’re looking for high-quality and durable sensors for your industrial or commercial applications, you can’t go wrong with Heatcon Sensors. We offer a wide range of products including Bobbin Heaters, Hygrometers, Thermocouple Connectors, and MI Thermocouples. Plus, our thermocouple connectors are the best in the industry. With many years of experience, we are confident that we can provide you with the best sensor solution for your needs.There are two main types of thermocouple connectors: male and female. Male connectors are used to connect thermocouples to female connectors. Female connectors are used to connect thermocouples to male connectors.

 

 

Specifications of Noble Metal Thermocouples by Heatcon Sensors!

Noble Metal Thermocouples Are Well Known For Their High Accuracy And Temperature Sensitivity!

Temperature Sensitivity of R Type, S Type, and B Type of Noble Metal Thermocouples!

Top Quality Noble Metal Thermocouples by Heatcon Sensors!

 

Thermocouples are used in a wide variety of industrial applications, from measuring the temperature of industrial furnaces to measuring the temperature of molten metals. Thermocouples are generally made by joining two wires of different metals together at one end. The junction between the two wires is then heated to a high temperature to fuse the metals into a joint. There are many different types of thermocouples, but the most common types are made from metals such as platinum, rhodium, and tungsten. The different metals used in the thermocouples to form the joint, creates a voltage difference when subject to heat, and the produced voltage is proportional to the temperature difference between the two wires. This voltage can be measured using a voltmeter, and the temperature can be calculated from the produced voltage.

Noble Metal Thermocouples Are Well Known For Their High Accuracy And Temperature Sensitivity!

Noble metal thermocouples are made from a combination of two different metals, typically platinum and rhodium. These thermocouples are very accurate and stable, making them ideal for use in industrial applications where regular high-temperature measurements and high accuracy are needed. Noble metal thermocouples are much more accurate and stable than other types of thermocouples. This makes them ideal for use in applications where precise temperature measurement is critical, such as in industrial furnaces.

Temperature Sensitivity of R Type, S Type, and B Type of Noble Metal Thermocouples!

The temperature range of a noble metal thermocouple is determined by its type. There are three main types of most popular noble metal thermocouples namely R type, S type, and B type. Let’s understand in detail their different temperature sensitivities:

  • The R type has the widest temperature range, from -50 to 1400 degrees Celsius. R type thermocouples are made of platinum and rhodium. They are the most accurate and stable type of noble metal thermocouples.
  • The S type has a narrower range, from -50 to 1200 degrees Celsius. S type thermocouples are made of platinum and palladium. They are less accurate than R type thermocouples but are more resistant to corrosion on higher temperature ranges.
  • The B type has the narrowest range, from -50 to 1000 degrees Celsius. B type thermocouples are made of boron and silicon. They are the least accurate type of thermocouples but are the most resistant to high temperatures.

Top Quality Noble Metal Thermocouples by Heatcon Sensors!

If you’re looking for accurate temperature measurement readouts for your industrial appliances, you can’t go wrong when choosing the best noble metal thermocouple from Heatcon Sensors. Their thermocouples are made from the highest quality materials, and their quality manufacturing process is almost second to none. Heatcon Sensors has been manufacturing thermocouples for over the last three decades, and their experience shows in the quality of all their products. You can be surely confident about the accuracy of their thermocouples as most of their globally satisfied customers’ reviews and ratings strongly stand behind them. If you need a reliable and highly accurate temperature measurement solution, look no further than Heatcon Sensors. Contact them today to learn more about their wide range of high-quality noble metal thermocouples for your next project.

How to Choose the Most Suitable Thermocouple Type for Molten Metal Applications?

5 Most Important Factors to Consider While Choosing the Best Thermocouple for Molten Metal Appliances!

 

As we all know that thermocouples are the devices that are used to measure temperature in various and sundry appliances. There are four main types of thermocouples which are widely in use in all industry types: Type K, type S, type B, and type R. Each type has its own unique characteristics, and each is best suited for different industrial processes and applications.

The Most Widely Used Thermocouple Types & Their Respective Temperature Sensitivity Ranges!

    • Type K Thermocouples: K type thermocouples are most widely used in industrial applications. Made of chromel and alumel, these are resistant to oxidation and corrosion. They can be used in a wide range of temperatures, from -200 to +1250 degrees Celsius.
    • Type S Thermocouples: These are made of pure platinum and purer gold. They are the most accurate type of thermocouple, but they are also the most expensive. They are best suited for high-temperature applications, from 0 to +1500 degrees Celsius.
    • Type B Thermocouples: Such thermocouples are made of boron-doped silicon and tungsten. They are less accurate than type S thermocouples, but they can be used in a wider range of temperatures, from 600 to +1800 degrees Celsius.
    • Type R Thermocouples: These are made of platinum and rhodium. They are the least expensive type of thermocouple, and they are best suited for low-temperature applications, from 0 to +1500 degrees Celsius.

5 Most Important Factors to Consider While Choosing the Best Thermocouple for Molten Metal Appliances!

If you’re looking for a thermocouple for a molten metal appliance, there are a few important factors to consider as follows: 

  1. Choose One That Will Work The Best: You need to decide which type of thermocouple is the best for your particular application. There are four main types of thermocouples as discussed above. Each type has its own merits and demerits, so it’s very important to choose the best one that will be most suitable to match your needs. 
  2. Consider Temperature Range: Another important factor to consider is the temperature range. Thermocouples are rated for different temperature ranges, so you need to make sure you choose one that is rated for the temperatures you’ll be measuring. 
  3. Consider The Area to be Measured and Choose The Appropriate Size Sensor: Depending on the area to be measured, one at a time or multiple areas simultaneously as in the entire furnace, it is essential to use an appropriate size sensor.  
  4. Cost of Thermocouple: Most thermocouples have two components with the exception of some industrial thermocouples which are relatively costlier and are available as one single component. Your process may need only the top component which will be sufficient to do the trick for you.  
  5. Environment of Operational Area: Finally, you need to think about the environment in which the thermocouple will be used. Some thermocouples are better suited for harsh environments than others. Make sure you choose a thermocouple that can withstand the conditions it will be exposed to.

 

By considering the above listed factors, you can be sure to choose the right thermocouple for your molten metal appliance. If you’re still not sure which thermocouple will work best for your molten metal appliance, talk to the experts at Heatcon Sensors who will be more than willing to help you with any of your queries related to choosing the best thermocouple for your industrial process.

Hygrometers are used to measure the humidity in the air. When it comes to choosing the most suitable thermocouple type for molten metal applications, there are a few key factors to consider. The first is the operating temperature range. This is important because it will dictate the type of thermocouple that can be used. The second factor is the accuracy required. This will impact the choice of thermocouple material. The third factor is the response time. This is important because it will determine how quickly the temperature can be measured. RTD vs Thermocouple: Thermocouples and RTDs are both electronic devices that measure temperature by sensing a change in resistance or voltage, respectively. If you are encountering thermocouple failure modes in your application, may be your Thermocouple needs replacement. There are many different types of thermocouples, each with its own unique set of characteristics. So, which one would be the rightest for your type of application? Well! Heatcon can be the answer! Heatcon Sensors offers a wide range of products including chemical immersion heater, thermocouple connector, etc. Thermocouple connectors are used to connect thermocouples to other devices, such as controllers or displays.

 

 

Top 7 Factors To Consider While Choosing The Right Type Of Chemical Immersion Heater For Your Application!

How You Should Use Chemical Immersion Heaters For Your Industrial Applications?

The Most Common Type of Immersion Heaters Available for Industrial Use!

Top 7 Factors To Consider While Choosing The Right Type Of Chemical Immersion Heater For Your Application!

 

What Are Chemical Immersion Heaters?

Chemical immersion heaters are devices that are used to heat liquids. Generally such chemical immersion heaters are made of corrosion resistant materials such as stainless steel. Typically they have a heating element that is immersed in the liquid to be heated. The heaters are often used in industrial and commercial applications, such as in chemical processing plants.

How You Should Use Chemical Immersion Heaters For Your Industrial Applications?

In order to properly use them, it is important to understand how the chemical immersion heaters work and what precautions need to be taken. Immersion heaters work by heating a fluid directly. This can be done by either circulating the fluid through the heater or by immersing the heater in the fluid. Either way, the fluid must be in contact with the heating element in order to be heated.

The Most Common Type of Immersion Heaters Available for Industrial Use!

There are many different types of immersion heaters available, each with its own merits and demerits. The type of heater you use will depend on the specific application. Some of the most common types of immersion heaters include:

  • Element Heaters: Element heaters are the most basic type of immersion heater. They consist of a heating element that is submerged in the fluid. The element is usually made of metal, such as stainless steel.
  • Coil Heaters: Coil heaters are similar to element heaters, but they have a coil of tubing instead of a single element. This allows for better heat transfer and more efficient heating.
  • Tube Heaters: Tube heaters are the most efficient type of immersion heater. They consist of a tube that is submerged in the fluid. The tube is usually made of stainless steel or another type of metal.

When using immersion heaters, it is important to take precautions to prevent accidents. The most common type of accident is overheating, which can cause fires or explosions. It is also important to make sure that the fluid being heated is compatible with the heater. Some fluids, such as water, can damage the heating element.

Top 7 Factors To Consider While Choosing The Right Type Of Chemical Immersion Heater For Your Application!

When it comes to finding the right type of chemical immersion heater for your application, there are a few key factors to keep in mind. Here is the list of top 7 factors that you should consider:

  1. The Type of Fluid Being Heated: This is the most important factor to consider when choosing a chemical immersion heater. Different fluids have different heating requirements, so it’s important to select a heater that is specifically designed for the fluid you’re using.
  2. The Temperature You Need To Achieve: Make sure to select a heater that can reach the desired temperature for your application.
  3. The Size And Shape Of The Heater: The size and shape of the heater will be determined by the size and shape of the container in which it will be used. Make sure to select a heater that fits the dimensions of your container.
  4. The Wattage: This is a measure of the heater’s power and will be determined by the size and type of fluid being heated. Make sure to select a heater with the appropriate wattage for your application.
  5. The Material: The material of the heater should be compatible with the fluid being heated. Make sure to check the compatibility before making your selection.
  6. The Price: Immersion heaters can vary widely in price, so it’s important to select one that fits your budget.
  7. The Warranty: To buy some kind of peace of mind regarding your investment, make sure to check the warranty of the immersion heater before making your final selection.

Keep these factors in mind when choosing a chemical immersion heater and you’ll be sure to select the right one for your application. If you are unsure about your selection, call the experts at Heatcon Sensors, a leading manufacturer of the best quality chemical immersion heaters.

Hygrometers measure the humidity in air. Thermocouples are temperature sensors that measure temperature by measuring the voltage between 2 conductors. An important part of a humidity chamber is Thermowell, which is a protective sleeve placed over the thermocouple. Heatcon Sensors offers a wide range of products including Hygrometers, Thermocouple Connectors, multipoint thermocouples and MI Thermocouples etc. When it comes to choosing the right type of chemical immersion heater for your application, there are a few key factors to keep in mind, given underneath:

  • The type of fluid being heated: This is arguably the most important factor to consider when choosing a chemical immersion heater. Different fluids have different thermal properties, and therefore require different types of heating elements.
  • The desired temperature: Knowing the desired temperature is important for both selecting the right type of heating element, as well as for sizing the heater.
  • The size of the tank: The size of the tank will dictate the size and power of the immersion heater required.
  • The presence of other elements in the tank: Other elements in the tank, such as stirring motors or agitators, can generate heat which can affect the required size and power of the immersion heater.
  • The thermal conductivity of the fluid: The thermal conductivity of the fluid being heated will affect the required size and power of the immersion heater.
  • The density of the fluid: The density of the fluid being heated will also affect the required size and power of the immersion heater.
  • The desired heating rate: The desired heating rate is important for both selecting the right type of heating element, as well as for sizing the heater.

 

 

Heatcon Sensors – The Leading Manufacturers of High-Performance, Custom-Made Mineral Insulated Thermocouple probes!

MI Thermocouples are Available in Different Designs & Can Also Be Custom-Made!

The Three Most Popular Types of MI Thermocouples! 

Explore the Limitless Possibilities of Customization with Heatcon Sensors!

Why to Choose MI Thermocouples from Heatcon Sensors?

 

What is a Mineral Insulated Thermocouple?

In order to understand mineral insulated thermocouples, it is necessary to understand what a thermocouple is. A thermocouple is a device that measures temperature by converting the thermal energy into electricity. The mineral insulated thermocouple is a type of thermocouple that uses a metal sheath to protect the internal components from external damage. The mineral insulated thermocouple is a popular choice for many applications because of its durability and accuracy. The metal sheath surrounding the internal components helps to protect them from damage and also ensures that the thermocouple is able to maintain its accuracy for longer periods.

MI Thermocouples are Available in Different Designs & Can Also Be Custom-Made!

Mineral insulated thermocouples are more durable and have a longer lifespan than standard thermocouples. They’re also more accurate and have a faster response time. However, they’re more expensive and can at times be difficult to install. MI thermocouples can easily withstand up to 1250 0C of high temperatures and their temperature sensitivity and accuracy largely depends on their design and the type of material used to make the MI thermocouple. 

The Three Most Popular Types of MI Thermocouples! 

There are three main types of MI thermocouples: miniature plug, standard plug, and DIN plate. Each one has its own advantages and disadvantages, so it’s important to choose the right one for your needs.

  • Miniature Plug Thermocouples: Such thermocouples are the most common type. They’re small and easy to install, but they’re not as accurate as other types.
  • Standard Plug Thermocouples: Such thermocouples are larger and more accurate than miniature plug thermocouples. They’re also more durable, but they’re more difficult to install.
  • DIN Plate Thermocouples: These are the most accurate type. They’re also the most difficult to install, but they’re the most durable.

Explore the Limitless Possibilities of Customization with Heatcon Sensors!

As the demand for more customized and specific products increases, so does the need for custom-made MI thermocouples. Mineral insulated thermocouples are able to handle very high temperatures, making them ideal for a variety of applications. If you too are looking for custom-MI thermocouples for your process, you can explore the limitless possibilities of customization offered by Heatcon Sensors, a leading manufacturer of custom-made MI thermocouples. 

Why to Choose MI Thermocouples from Heatcon Sensors?

There are a number of benefits of choosing MI Thermocouples from Heatcon Sensors

  • They are extremely durable and can withstand a variety of temperature conditions almost up to 1000 0C and above. 
  • They are extremely accurate making them ideal for a variety of applications.
  • They can be easily customized to meet the specific needs of your application. They are available in a variety of sizes and configurations, making it easy to find the right one for your needs.
  • They can be easily shaped into the right shape and size to best fit your appliance. 
  • The thermocouple junctions can be left exposed, grounded, or insulated depending on the suitability of their application. 

If you are too looking for a custom-design mineral insulated thermocouple, be sure to check out the selection available with Heatcon Sensors. They offer a variety of options to exactly meet the requirements of your specific industrial application. Contact them today to learn more about customized, high quality MI thermocouples and how they can help you find the perfect solution for your application.

Are you looking for a reliable and accurate way to measure temperature in a high temperature environment? If so, then Heatcon Sensors has the perfect solution for you. We offer a wide range of products including molten metal thermocouples, chemical immersion heaters, high temperature furnaces, hot air blowers, and multipoint thermocouples. All of our products are designed to provide accurate and reliable temperature readings in a variety of different applications. Whether you need a single point or multipoint thermocouple, we have a solution that will meet your needs. Our molten metal thermocouples are designed for use in molten metal baths, and our chemical immersion heaters are perfect for measuring temperature in aggressive chemicals. If you need a high temperature furnace or hot air blower, we have a variety of models to choose from. No matter what your temperature measurement needs are, Heatcon Sensors has a solution for you. Contact us today to learn more about our products and how we can help you achieve accurate and reliable measurements.

 

 

How Thermowell Protects the Thermocouple from Damage?

Thermowell

Thermocouples Are Used in Conjugation with a Thermowell

How Thermowell Protects the Thermocouple from Damage?

 

Thermocouples

Thermocouples are used to measure temperature in a wide variety of applications. They are often exposed to high temperatures and can be subject to damage. Thermocouples are made of two different metals that are joined together at the tip. The junction of the two metals is where the temperature is measured. The two metals are held together by a weld. Thermocouples are often used in high-temperature applications. The tip of the thermocouple can be exposed to temperatures that exceed the melting point of the metals. If the thermocouple is not properly protected, the weld can break and the thermocouple can be damaged.

Thermowell

A Thermowell is a metal sleeve that is inserted into process equipment to protect a temperature sensor. A thermocouple, being a temperature sensor, consists of two different metals that are joined together. When the two metals are at different temperatures, a small voltage is generated. This voltage can be used to measure the temperature difference between the two metals.

Thermocouples Are Used in Conjugation with a Thermowell 

Thermocouples are often used in conjunction with a Thermowell. Thermowell is a device that is used to protect a temperature sensor from the environment in which it is used. It is also used to allow the sensor to be removed and replaced without having to shut down the process.

How Thermowell Protects the Thermocouple from Damage?

The Thermowell helps to protect the thermocouple from damage and allows the thermocouple to be used in high-temperature applications. Thermowell is a kind of protection sleeve that is used to protect the thermocouple from damage. It is installed in the process’ piping or equipment. The Thermowell transfers the heat from the process media to the thermocouple and protects the thermocouple from the corrosive attack of the process media. Thus, a Thermowell forms a protective sleeve that is placed over the thermocouple. It helps to protect the thermocouple from damage. The Thermowell is usually made of the same material as the thermocouple. The Thermowell helps to protect the thermocouple from damage by providing a barrier between the high temperatures and the thermocouple.

Conclusion 

More often than not, most temperature sensing devices tend to be usually prone to deterioration(s) from continuous exposure to heat, pressure, and flow. As time passes, these harsh processing environments tend to pose a direct effect on the performance of these devices and also on the structural integrity of these sensors. For example, the metals that are used in the fabrication of thermocouples’ probes become susceptible to corrosive processing environments. Additionally, thermocouple wires measuring an average of 0.10 inches to 0.20 inches in diameter tend to undergo some metallurgical changes due to the continued exposure to heat. A Thermowell protects these measuring sensor(s) from the harsh damaging effects of the process environment for preventing the measurement drift.

Contact Heatcon for the right kind of product(s) per your requirement(s)

There are different types of humidity chambers available in the market, each designed for a specific purpose. Hygrometers are used to measure the humidity in the air, while thermocouple connectors are used to connect the thermocouple to the industrial oven. The construction of humidity chamber is very important, as it needs to be able to withstand the high temperatures and humidity levels. One of the most important parts of the humidity chamber is the Thermowell. The thermowell is a protective sleeve that is placed over the thermocouple. It is used to protect the thermocouple from damage, as well as to prevent the tips from coming into contact with the hot air or humidity. The thermowell is made of a material that has a high melting point, such as ceramic or glass. The thermowell is placed in the center of the humidity chamber, and the thermocouple is placed inside the thermowell. The thermocouple is then connected to the industrial oven. The thermowell is placed in the center of the humidity chamber so that it is not in direct contact with the hot air or humidity. This helps to protect the thermocouple from damage. The thermocouple is placed inside the thermowell so that it is not in direct contact with the hot air or humidity. This helps to prevent the tips from coming into contact with the hot air or humidity.

 

 

4 Types of Temperature Sensors Commonly Used In the Industry for Temperature Measurement!

NTC Thermistor a.k.a. Negative Temperature Coefficient Thermistor

RTD Sensor OR Resistance Temperature Detector

Thermocouples 

Semiconductor OR Integrated Circuit Temperature Sensors 

Temperature sensors are one of the most important tools that scientists and engineers use to measure the temperature of the objects around us. From industries needing controlled environments for carrying out different processes to fire safety equipment, temperature sensors are so much so important these days to ensure the optimum temperatures at all times. They come in all shapes and sizes, and each one is designed to measure temperature in a different way. Each type of sensor has its own advantages and disadvantages, so it’s important to choose the right sensor for the job. No matter what type of temperature sensor you use, it’s important to calibrate it regularly to ensure accuracy. Temperature sensors are an essential tool for anyone who needs to measure temperature, whether they’re scientists, engineers, or even just amateur hobbyists. Here, we are going to discuss 4 Types of Temperature Sensors Commonly Used In the Industry for Temperature Measurement.

  1. NTC Thermistor a.k.a. Negative Temperature Coefficient Thermistor

A Negative Temperature Coefficient thermistor, or NTC thermistor, is a type of resistor that decreases in resistance as temperature increases. The resistance of an NTC thermistor decreases as temperature increases because the increase in thermal energy causes the atomic particles in the material to vibrate more, which reduces the number of available electrons. The resistance of an NTC thermistor can be used to measure temperature in applications where high accuracy is required as even small changes in temperature can cause changes in resistance of the thermistor in a big way. They are commonly used in temperature sensing applications which operate in the range of anywhere between -50 0C and 250 0C.

  1. RTD Sensor OR Resistance Temperature Detector

RTDs or resistance temperature detectors are made of metal, and they work by measuring the resistance of the metal to changes in temperature. The choice of the metal for creating an RTD is responsible for its accuracy and stability. While platinum based RTD is most stable and accurate, the copper and nickel based RTDs have lower costs and are little unstable for repeated use. RTDs are used in a variety of applications, including HVAC, automotive, and industrial control. RTDs are more accurate than other types of temperature sensors, and they are also more stable over time. However, RTDs are more expensive than other types of temperature sensors. If you need a temperature sensor for your application, an RTD may be the best option. They are applicable in systems where high accuracy linear output is needed and platinum based RTD operates between a great range of -200 0C and 600 0C.

  1. Thermocouples 

A thermocouple is a temperature sensor that consists of two dissimilar metals that are joined together at one end. When the two metals are at different temperatures, a voltage is generated. This voltage can be used to determine the temperature difference between the two metals. Thermocouples are very common in industrial applications. They are used to measure the temperature of things like ovens, furnaces, and pipelines. Thermocouples can also be used to measure the temperature of the environment. They have the widest temperature range and operate between -200 0C to 1750 0C. 

  1. Semiconductor OR Integrated Circuit Temperature Sensors 

Semiconductor temperature sensors are used to measure the temperature of semiconductor materials and electronic devices. These sensors are made from materials that have a high thermal conductivity, such as silicon or germanium. Semiconductor temperature sensors can be used to measure the temperature of electronic devices, such as CPUs and GPUs. These sensors are accurate and reliable, and can be used to monitor the temperature of devices in real-time. They are slowest in their responsiveness and have the lowest accuracy. They offer linear response to temperature changes and operate between the temperature ranges of -70 0C to 150 0C. 

For the best temperature sensors and to understand what type of temperature sensor works best for your industry, you may contact one of the experts from Heatcon Sensors; a leading global manufacturer of quality temperature sensors.

A molten metal thermocouple is a temperature sensor that is used in a variety of industrial applications to control temperature. There are many different types of molten metal thermocouples, each with its own unique set of characteristics. The most common type of molten metal thermocouple is the Bobbin Heaters which is made up of two different metals that are placed in a ceramic cup. The two metals are then connected to a power source and the resulting voltage is used to measure the temperature of the metals. Bobbin Heaters are often used in chemical immersion heater and hot air blower.

Another type of molten metal thermocouple is the chemical immersion heater which is often used in industrial applications to control the temperature of a variety of different liquids. Whereas, the hot air blower is often used in humidity chambers to control the humidity levels which is why most industrial applications of humidity chambers prefer to use a hot air blower.

Multipoint Thermocouples and Their Varied Applications

About Multipoint Thermocouples

Applications of Multipoint Thermocouples

Different Application Areas of Multipoint Thermocouples

Thermocouples are one of the most commonly used temperature sensors in the industry. They are rugged, have a wide temperature range, and are relatively inexpensive. A thermocouple consists of two different metals (usually copper and iron) that are joined at one end. When the junction of the two metals is heated, a voltage is generated that can be measured. Multipoint thermocouples are used when it is necessary to measure the temperature at multiple points within a system. 

About Multipoint Thermocouples

Multipoint Thermocouples are the types of temperature sensors consisting of two or more thermocouples connected in series. The advantage of using multipoint thermocouples is that they can measure the temperature at multiple points along the length. This makes them ideal for applications where the temperature needs to be monitored at multiple points, such as in a furnace or kiln. Some of the useful features of multipoint thermocouples are as follows:

  • Multiple detection points with a single access point.
  • Efficiently measure temperature profile(s) for various applications.
  • It is possible to efficiently replace the individual sensor(s) without the need to affect the whole.
  • Cost-effective compared to placing individual sensors.
  • Custom designs are available for different temperature ranges and signal accuracy.
  • All sensors are totally metal-sheathed with useful mineral insulation.
  • Some designs feature resistive elements as the chief sensor for providing more accuracy in the results.

Applications of Multipoint Thermocouples

There are many industrial applications for multipoint thermocouples. Here are the top 5:

  • Heat treating furnaces: One common application is in furnaces, where it is important to know the temperature at multiple points to optimize the process. Additionally, multipoint thermocouples can be used to measure the temperature profile of a material as it is being processed. Multipoint thermocouples can be used to measure the temperature of heat-treating furnaces. This is important to ensure that the furnace is operating at the correct temperature.
  • Boilers: Multipoint thermocouples can be used to measure the temperature of boilers. This is important to ensure that the boiler is operating at the correct temperature.
  • Ovens: Multipoint thermocouples can be used to measure the temperature of ovens. This is important to ensure that the oven is operating at the correct temperature.
  • Furnaces: Multipoint thermocouples can be used to measure the temperature of furnaces. This is important to ensure that the furnace is operating at the correct temperature.
  • Refrigeration units: Multipoint thermocouples can be used to measure the temperature of refrigeration units. This is important to ensure that the unit is operating at the correct temperature.

Different Application Areas of Multipoint Thermocouples

  • Chemical industry
  • Petrochemical industry
  • Reactors & Distillation fractionator(s)
  • Fuel depots
  • Hydrocrackers 
  • Hydro treaters
  • Fluid catalytic cracking unit(s)
  • Crude oil distillation unit(s)
  • In the processes of catalytic reformation 

If you are looking for a reliable and accurate way to measure temperature, you can’t go wrong with multipoint thermocouples. A multipoint thermocouple is a temperature measurement device that consists of two or more thermocouples connected in series. The thermocouples are typically made of metals with different thermal coefficients of expansion, such as copper-constantan and iron-constantan. The main advantage of multipoint thermocouples is that they can provide a more accurate measurement of temperature than a single-point thermocouple. This is because the multiple points of contact allow for better heat transfer and more consistent readings. Another advantage of multipoint thermocouples is that they can be used to measure temperature at multiple points along a length of material. This is often used in industrial applications to monitor the temperature of large objects, such as pipes or furnaces. If you require a reliable and accurate way to measure temperature, a multipoint thermocouple is a great option. Contact Heatcon Sensors today to place your order!

Temperature sensors are an essential tool for industries globally. They provide a way to monitor and adjust temperatures in almost all industrial settings. It is extremely important to select the ideal temperature sensor based on your specific industrial requirements for a variety of reasons. They help to ensure that products are manufactured correctly, keep production costs down, and protect workers from hazardous conditions. 

The manufacturers of high quality temperature sensors design these temperature sensors in order to accommodate the needs of various and sundry industrial processes. These temperature sensors differ in their design, shape, working principle, their operating temperature range, environmental factors, etc. 

The most widely used temperature sensors include multipoint thermocouples, thermowells, noble metal thermocouples, and MI thermocouple which are designed to remain stable and accurate over time. However, in industries where these sensors are exposed to a variety of chemicals and come in direct contact with highly reactive compounds, the chemical immersion heater is the most popular choice in order to avoid any accidents or environmental hazards. So, you must plan your temperature sensing requirements carefully before you make a selection for an ideal temperature sensor for your process. 

Thermocouples: Construction, Colour Codes and Amplification

Thermocouple Construction

Colour Codes of Thermocouples

Thermocouple Amplification

Among all the different types of temperature sensors, thermocouples have taken the spot for being the most widely used. This is mainly because of its simplicity and small size, speed with which it responds when any kind of temperature change is detected and also based on how easy it is to use. Another reason why thermocouples are so commonly used is because they provide the widest range of temperature measurements when compared with any temperature sensors available today, ranging between -200℃ to over 2000℃.

To put it in simple terms, thermocouples are basically thermoelectric sensors which have two junctions made from dissimilar metals that have been welded together; metals like constantan and copper, for instance. One of these junctions is known as the measuring (Hot) junction, and the other is known as the reference (Cold) junction, and is maintained at a constant temperature. When a voltage gets generated between the junction, the generated voltage is utilised in the measurement of the temperature detected by the sensor, provided that both the junctions are at different temperatures.

Thermocouple Construction

Understanding how a thermocouple operates is actually very simple. A “thermo-electric” effect is created when two different metals like constantan  and copper are joined together, resulting in the generation of a potential difference of a few millivolts (mV). The voltage difference that is generated between the two junctions is known as the “Seebeck effect”; the resulting temperature gradient that is produced across the conducting wires results in the generation of an emf. Due to this, the resulting output voltage is treated as a function of temperature change.

No output voltage is produced when either of the junctions are maintained at a constant temperature; which means the potential difference across the two junctions is zero. In such a case, the voltage output produced can be mathematically written as V1 = V2. Nonetheless, an output voltage will be detected when the junctions are at varying temperatures, and the resulting voltage is basically the difference in temperature between the two junctions, V1 – V2. Until such a time that the junction has not reached its peak voltage level, the difference in voltage tends to rise when the temperature continues to rise.

It is possible to make thermocouples using a multitude of materials thereby allowing the possibility to measure extreme temperatures between -200℃ to +2000℃. As there is a wide choice of temperature range and materials when it comes to thermocouples, picking the ideal thermocouple sensor that would serve a particular application, thermocouple colour codes and internationally recognised standards have been set.

Colour Codes of Thermocouples

Thermocouple Sensor Colour Codes Extension and Compensating Leads

Code Type

Conductors (+/-) Sensitivity British BS 1843:1952

E

Nickel Chromium / Constantan -200℃ to 900℃

J

Iron / Constantan

0 to 750℃

K

Nickel Chromium / Nickel Aluminium -200℃ to 1250℃

N

Nicrosil / Nisil

0 to 1250℃

T

Copper / Constantan -200℃ to 350℃

U

Copper / Copper Nickel Compensating for “S” and “R”

0 to 1450℃