Pure sheathed thermocouple device with high insulation and high vibration resistance

Abstract

The application discloses a kind of high insulation high anti-vibration pure armoured thermocouple device, including electrical connector, multiple armoured thermocouples, terminal box;The electrical connector is connected with terminal box, and the armoured thermocouple includes armoured thermocouple body, probe head connected with the front end of armoured thermocouple body, clamping tube sleeved on probe head, the clamping tube end is connected with the armoured thermocouple body by multiple staggered crimping, and the end of the multiple armoured thermocouples is connected in groups with terminal box by multiple adapters multi-section type packaging, the armoured thermocouple body of each armoured thermocouple is externally provided with mounting bayonet one, and is fixed by riveting support two by two between mounting bayonet one, the insulation performance of the armoured thermocouple is improved, the test precision of product is guaranteed, anti-twist is prevented, and the anti-vibration ability is improved.

Description

Technical Field

[0001] This invention relates to the field of thermocouple technology, specifically to a highly insulating and highly vibration-resistant pure armored thermocouple device. Background Technology

[0002] Engine high-temperature combustion gas measurement is one of the most important testing technologies. Temperature is the most critical parameter for determining the performance and lifespan of hot-end components and helps to understand the combustion process in the combustion chamber. Current technologies mostly use thermocouples to measure high-temperature combustion gas in the engine cavity. Improper insulation encapsulation at the thermocouple junction can easily lead to a decline in insulation performance after long-term use. The temperature measurement signal from the thermocouple is a weak voltage signal. When the insulation resistance decreases, shunt errors are easily generated in the temperature measurement, especially when testing high-temperature tolerances. The shunt error has a greater impact, leading to deviations between the test results and the actual results, and low reliability of the measurement results. At the same time, in high-temperature and high-vibration environments, the welded thermocouple connection is prone to breakage.

[0003] Patent CN204514494U discloses a temperature-measuring armored thermocouple device. Multiple armored thermocouples are mounted on the armored thermocouple mounting holes of a flange via compression fittings. Each armored thermocouple has a corundum tube at its hot end, with a through hole for the thermocouple wire to pass through. The extension ends of the thermocouple wires of each armored thermocouple pass through the through hole of the corundum tube and are welded to form a thermal junction. A support tube is fitted over each armored thermocouple and the corundum tube. The hot end of each armored thermocouple is inserted into the protective sleeve, and the thermal junction of the armored thermocouple contacts the protective sleeve. A thermally conductive filler is filled between the thermal junction and the protective sleeve. The support tube is equipped with a sealing device for sealing the protective sleeve. Summary of the Invention

[0004] To address the problems mentioned in the background section, this invention provides a highly insulating and highly vibration-resistant pure armored thermocouple device.

[0005] The technical solution adopted in this invention is:

[0006] A high-insulation, high-vibration-resistant pure armored thermocouple device includes an electrical connector, multiple armored thermocouples, and a junction box. The electrical connector is connected to the junction box. Each armored thermocouple includes an armored thermocouple body, a probe head connected to the front end of the armored thermocouple body, and a clamping tube fitted onto the probe head. The end of the clamping tube is connected to the armored thermocouple body via a multi-segment staggered crimp. The ends of the multiple armored thermocouples are connected to the junction box in a group via multiple adapters and multi-segment encapsulation. Each armored thermocouple has an external mounting slot on its armored thermocouple body, and the mounting slots are connected and fixed in pairs by riveting supports.

[0007] Furthermore, the connection between the probe tip and the armored thermocouple body is achieved through two staggered crimping sections, with the two crimping parts staggered by 30°, and one of the following crimping methods is adopted: hexagonal, tetragonal, or octagonal.

[0008] Furthermore, the housing of the junction box is a rectangular sealed structure.

[0009] Furthermore, the armored thermocouple body is provided with a second mounting slot on the outside, which is fixedly connected to the mounting bracket provided by the engine casing. The mounting bracket can slide freely or be welded and fixed according to its position on the engine.

[0010] Furthermore, the armored thermocouple body includes a shell, excess thermocouple wires, magnesium oxide powder inside the shell, and multiple pairs of thermocouple wires. Each pair of thermocouple wires is welded to a thermal junction at the two positive and negative thermocouple wires of the probe head, and the thermal junctions of multiple pairs of thermocouple wires are welded to a total thermal junction.

[0011] Furthermore, the junction box is equipped with multiple compensating wires, one end of which is connected to the redundant thermocouple wire of the armored thermocouple, and the other end is connected to the pin of the electrical connector.

[0012] Furthermore, the compensation wire is connected to the electrical connector pin via a crimping transition using a K-grade nickel-chromium or nickel-silicon material crimping tube.

[0013] Furthermore, an insulating sheath is provided at the connection between the compensating conductor and the redundant coupling wire.

[0014] Furthermore, the group connection of the ends of the multiple armored thermocouples to the junction box is achieved by pre-bending the armored thermocouples and then welding them to the junction box, or by first welding the armored thermocouples to the junction box and then bending them into shape.

[0015] Furthermore, the ends of the multiple armored thermocouples are connected in parallel to the junction box through a two-stage encapsulation of adapter one and adapter two. Adapter one includes adapter housing one and insulating material one encapsulated inside adapter housing one. Adapter two includes adapter housing two and insulating material two encapsulated inside adapter housing one. Adapter housing one is connected to the rear end of the armored thermocouple body. One end of adapter housing two is connected to adapter housing one, and the other end is connected to the junction box housing.

[0016] Compared with the prior art, the beneficial effects of the present invention are:

[0017] (1) The internal magnesium oxide powder of the armored thermocouple is compacted by drawing and then forging the entire piece into a small size, which improves the insulation performance of the armored thermocouple; the armored thermocouple is connected to two (or more) adapters by welding, and two (or more) insulating materials are encapsulated inside to ensure that the insulation performance of the back end of the armored thermocouple does not decrease during the long service life; the insulation performance of the back end compensation wire is guaranteed by the sealing and insulation encapsulation design adapted to the high temperature insulation environment in the junction box; the design of the high insulation armored thermocouple assembly is guaranteed by the joint design of multiple methods, and the high insulation armored thermocouple can guarantee the test accuracy of the product.

[0018] (1) The clamping tube end of the present invention is connected to the armored thermocouple body by multi-segment staggered pressing, so as to achieve the design of not reducing the strength of the base material and reliable connection, preventing torsion and tension, and improving vibration resistance.

[0019] (2) The present invention fixes the armored thermocouple body to the casing, and fixes it by mounting bayonet one. It also uses mounting bayonet one for riveting to achieve pairwise connection of the armored thermocouples. It uses mounting bayonet two to connect with the casing mounting support plate to achieve installation and fixation of the irregular space extension section of the armored thermocouple, thereby reducing the load borne by the weak parts of the armored thermocouple when vibrating and improving the vibration resistance of the product. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of a highly insulating and highly vibration-resistant pure armored thermocouple device.

[0021] Figure 2 This is a schematic diagram of a highly insulating and highly vibration-resistant pure armored thermocouple device.

[0022] Figure 3 A schematic diagram of the structure of a pure armored thermocouple, which is a high-insulation and high-vibration-resistant pure armored thermocouple device;

[0023] Figure 4 A schematic diagram of the structure of a pure armored thermocouple body for a high-insulation and high-vibration-resistant pure armored thermocouple device;

[0024] Figure 5 This is a schematic diagram of the structure of a two-section adapter for a highly insulated and highly vibration-resistant pure armored thermocouple device.

[0025] Wherein: 1-1 is the housing; 1-2 is the redundant thermocouple wire; 1-3 is magnesium oxide powder; 2-1 is the probe head; 2-2 is the compensating wire; 2-3 is the adapter housing two; 2-4 is the second insulating material; 2-5 is the insulating sheath; 2-6 is the adapter housing one; 2-7 is the first insulating material; 2-8 is the armored thermocouple body; 2-9 is the mounting base; 2-10 is the clamping tube; 3-1 is the electrical connector; 3-2 is the socket mounting plate; 3-3 is the junction box housing; 3-4 is the first mounting bayonet; 3-5 is the riveting support; 3-6 is the screw and nut; 3-7 is the armored thermocouple; 3-8 is the second mounting bayonet. Detailed Implementation

[0026] To clearly illustrate the technical features of this solution, the present invention will be described in detail below through specific embodiments and in conjunction with the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application; however, this application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited to the specific embodiments disclosed below. Furthermore, it should be understood in the description of this application that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first" and "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified. In this application, unless otherwise explicitly specified and limited, the terms "installed," "connected," "linked," "fixed," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances. In this application, unless otherwise explicitly specified and limited, "on" or "below" a second feature can mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. In the description of this specification, references to terms such as "an embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that the specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples.

[0027] Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by those skilled in the art. The technical terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the scope of the invention.

[0028] Unless otherwise specified, all raw materials, reagents, instruments, and equipment used in this invention can be purchased commercially or prepared using existing methods.

[0029] Example 1

[0030] Please see Figures 1 to 3 One embodiment provided by the present invention:

[0031] A highly insulating and highly vibration-resistant pure armored thermocouple 3-7 device includes an electrical connector 3-1, multiple armored thermocouples, and a junction box;

[0032] The electrical connector 3-1 is connected to the socket mounting plate 3-2 and the junction box housing 3-3 to form a sealed cavity.

[0033] The junction box housing 1-1 is a rectangular sealed structure. The junction box contains multiple compensating wires 2-2. One end of each compensating wire 2-2 is connected to the redundant thermocouple wire 1-2 of the armored thermocouple, and the other end is connected to the pin of the electrical connector 3-1. The compensating wires 2-2 are made of high-temperature insulating sheath material 2-5 (such as polyimide or glass fiber). The internal potting insulation material is made of high-temperature material (different materials are selected according to the temperature field requirements, such as silicone rubber potting and magnesium oxide powder 1-3 compacted filling).

[0034] The armored thermocouple includes an armored thermocouple body, a probe head 2-1 connected to the front end of the armored thermocouple body, and a clamping tube 2-10 sleeved on the probe head 2-1.

[0035] The armored thermocouple body includes a shell 1-1, redundant thermocouple wires 1-2, and magnesium oxide powder 1-3 inside the shell 1-1. The thermocouple wires are single, double, or multiple K-indexed thermocouple wires. The magnesium oxide powder 1-3 is formed by multi-segment drawing to ensure that the internal magnesium oxide powder 1-3 has a certain density. Then, a rotary forging process with small-size deformation of the thermocouple is added. Through high-speed radial hammering, the internal magnesium oxide powder 1-3 is further compacted to improve the insulation performance.

[0036] The ends of the multiple armored thermocouple bodies are connected to the junction box in a two-stage encapsulation via two adapters. The armored thermocouples 3-7 are pre-bent and then welded to the junction box for fixation. The adapters encapsulate the cold junction of the armored thermocouples 3-7, ensuring insulation and preventing moisture absorption by the magnesium oxide powder 1-3 inside the armored thermocouples 3-7. Simultaneously, the adapters are welded to the junction box housing 3-3, ensuring insulation encapsulation within the housing. The compensating wire 2-2 inside the junction box is welded to the thermocouple wires of the armored thermocouples 3-7 within the adapters, and the solder joint is encapsulated within the adapters to prevent short circuits caused by solder joint contact, which would lead to inaccurate temperature measurements. The multiple armored thermocouples are connected in parallel to the junction box via two-stage encapsulation via adapter one and adapter two. Adapter one includes an adapter housing 2-6 and an insulating material 2-7 encapsulated inside the adapter housing 2-6. The adapter housing 2-6 is welded to the rear end of the armored thermocouple body 2-8. The insulating material 2-7 is made of glass, and its coefficient of thermal expansion is comparable to that of the metal material of the adapter housing 2-6, preventing excessive deformation and micro-cracks caused by temperature changes. Adapter two includes an adapter housing 2-3 and an insulating material 2-7 encapsulated inside the adapter housing 2-6. 4. The insulating material 2-4 is made of epoxy resin. The expansion coefficient of the insulating material 2-4 is similar to that of the metal material of the adapter housing 2-3, to prevent the insulating material 2-4 from deforming too much due to temperature changes and causing micro-cracks. One end of the adapter housing 2-3 is connected to the adapter housing 2-6 by laser welding or argon arc welding, and the other end is connected to the junction box housing 3-3 by resistance welding, brazing, or laser welding. The excess coupling wire 1-2 is welded to the compensating wire 2-2 in the junction box (resistance welding, brazing, or laser welding), and the welding point of the coupling wire and the compensating wire 2-2 is separated (by heating the shrink tubing or using tooling to physically separate them).

[0037] The armored thermocouple body is provided with mounting slots 3-4 on the outside. The mounting slots 3-4 are connected and fixed in pairs by riveting pillars 3-5 or screws and nuts 3-6, which can rigidly connect multiple armored thermocouples 3-7 together, improve the overall strength, and effectively prevent multiple armored thermocouples 3-7 from colliding with each other when they vibrate randomly.

[0038] The probe head 2-1 is protected by an armored seal.

[0039] The clamping tube 2-10 is fastened to the probe head 2-1 by welding or crimping. The mounting base 2-9 (flange) is fastened to the clamping tube 2-10 by welding. The front end of the clamping tube 2-10 is welded to ensure that the high-temperature gas flow inside the engine casing will not escape through the gaps and affect the temperature field of the external environment. The connection between the end of the clamping tube 2-10 and the armored thermocouple body is made by multi-segment staggered crimping to ensure that the strength of the armored thermocouple 3-7 housing 1-1 does not decrease. The hexagonal crimping ensures the reliability of the crimping and the axial uniform distribution deformation. The two-segment staggered crimping, with the two crimping parts staggered by 30°, effectively prevents the effect of additional torque.

[0040] Example 2

[0041] Please see Figures 1 to 3 One embodiment provided by the present invention:

[0042] A highly insulating and highly vibration-resistant pure armored thermocouple 3-7 device includes the electrical connector 3-1 in Embodiment 1, multiple armored thermocouples in Embodiment 1, and the junction box in Embodiment 1;

[0043] The ends of the multiple armored thermocouple bodies are connected to the junction box in a two-stage encapsulation via two adapters. The group connection is achieved by first welding and fixing the armored thermocouples 3-7 to the junction box, and then bending them into shape.

[0044] Furthermore, an insulating sheath 2-5 is provided at the connection between the compensating conductor 2-2 and the redundant coupling wire 1-2.

[0045] Example 3

[0046] Please see Figures 1 to 3 The present invention provides an embodiment of a high-insulation and high-vibration-resistant pure armored thermocouple 3-7 device, comprising the electrical connector 3-1 in embodiment 1, multiple armored thermocouples in embodiment 1, and junction box in embodiment 1;

[0047] Furthermore, the armored thermocouple body is provided with a mounting slot 3-8 on the outside. The design of the mounting slot 3-8 is based on the outer diameter and curvature of the armored thermocouple body 2-8, and the inner hole size is designed accordingly to ensure that after the mounting slot 3-8 is pressed, the mounting slot 3-8 and the armored thermocouple body 2-8 are in a tight fit. The mounting slot 3-8 is fixedly connected to the mounting bracket provided by the engine casing. The mounting bracket can slide freely or be welded to fix it according to its position on the engine.

[0048] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention, and no reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A high insulation high vibration resistant pure sheathed thermocouple device, characterized by, The utility model provides a kind of armored thermocouple, including electric connector, multiple armored thermocouples, terminal box;The electric connector is connected with terminal box, and the armored thermocouple includes armored thermocouple body, probe head connected with the front end of armored thermocouple body, clamp tube sleeved on probe head, the connecting place of the end of clamp tube and armored thermocouple body is connected by multiple staggered crimping, and the end of multiple armored thermocouples is connected with terminal box by multiple adapter multiple section encapsulation in group, and each armored thermocouple body of the armored thermocouple is provided with mounting bayonet one outside, and mounting bayonet one is connected and fixed by riveting pillar two by two between mounting bayonet one. The armored thermocouple body includes shell, multiple redundancy thermocouple wires, magnesium oxide powder inside shell, the magnesium oxide powder is formed by multiple drawing, and then is compacted by rotary swaging process and radial high-speed hammering;The end of multiple armored thermocouples is connected with terminal box in parallel by two-section encapsulation of adapter one and adapter two, the adapter one includes adapter shell one and insulating material one encapsulated in adapter shell one, the adapter two includes adapter shell two and insulating material two encapsulated in adapter shell one, the rear end of armored thermocouple body is connected with adapter shell one, one end of adapter shell two is connected with adapter shell one, and the other end is connected with terminal box shell, the insulating material one uses glass, and the insulating material two uses epoxy resin glue.

2. A pure sheathed thermocouple assembly of high insulation and high vibration resistance as claimed in claim 1 wherein, The connecting place of the end of probe head and armored thermocouple body is connected by two staggered crimping, and the two crimping parts are crimped at 30 ° staggered, and one of hexagonal, quadrangular and octagonal crimping is used.

3. A pure sheathed thermocouple assembly of high insulation and high vibration resistance as claimed in claim 1 wherein, The shell of terminal box is rectangular sealed structure.

4. A high insulation high vibration resistant all-sheathed thermocouple assembly as claimed in claim 1, wherein, Mounting bayonet two is arranged outside armored thermocouple body, and mounting bayonet two is fixedly connected with mounting support plate provided by engine case, and mounting support plate is freely slid or welded and fixed according to the position of engine installation.

5. A high insulation high vibration resistant all-sheathed thermocouple assembly as claimed in claim 1, wherein, The armored thermocouple body includes shell, multiple redundancy thermocouple wires, magnesium oxide powder inside shell, multiple pairs of thermocouple wires, one thermocouple junction is formed by welding two positive and negative thermocouple wires of each pair of thermocouple wires in probe head, and multiple thermocouple junctions of multiple pairs of thermocouple wires are collectively encapsulated in probe, to generate multiple temperature measurement signal outputs.

6. A high insulation high vibration resistant all-sheathed thermocouple assembly as claimed in claim 1, wherein, Multiple compensation wires are arranged in terminal box, one end of compensation wire is connected with redundancy thermocouple wire of armored thermocouple, and the other end is connected with pin of electric connector.

7. A high insulation high vibration resistant all-sheathed thermocouple assembly as claimed in claim 6, wherein, The compensation wire is connected with pin of electric connector by K-degree nickel-chromium and nickel-silicon material crimping tube crimping transition.

8. A high insulation high vibration resistant all-sheathed thermocouple assembly as claimed in claim 6, wherein, Insulating sheath is arranged at the connecting place of compensation wire and redundancy thermocouple wire.

9. A high insulation high vibration resistant all-sheathed thermocouple assembly as claimed in claim 1, wherein, The group connection of the end of multiple armored thermocouples and terminal box is realized by pre-bending armored thermocouple, welding and fixing armored thermocouple and terminal box or welding and fixing armored thermocouple and terminal box, and then bending.

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