Contactless Temperature Sensor for Moving Copper Wires
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Solution Overview
Problem
Contactless temperature measurement of copper wires in movement is challenging due to copper's low infrared emissivity and small diameter, which results in limited energy flow and distortion from transversal vibrations, making existing pyrometric and convective heat exchange systems complex, costly, and prone to breakdowns.
Innovation Solution
A contactless temperature sensor using an insulated cavity with a highly diffusive sensitive element, where the copper wire transfers heat through convective phenomena, allowing passive thermal equilibrium and measurement with a calibrated pyrometer, eliminating the need for active regulation and control mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pyrometric measurement is used for copper wires, then contactless temperature measurement is achieved, but measurement precision deteriorates due to low infrared emissivity of copper
Solution Approach 1:
The patent introduces an intermediary element (the cavity with high-emissivity coating) between the copper wire and the pyrometer. The copper wire transfers heat to the cavity walls through convection and radiation, and the cavity walls, having high infrared emissivity, radiate this heat towards the pyrometer, enabling accurate contactless measurement
Solution Approach 2:
The patent changes the emissivity parameter by using a cavity with high-emissivity coating (ε > 0.9) instead of measuring the copper wire's low-emissivity surface directly. This parameter transformation allows the pyrometer to receive sufficient infrared radiation for accurate temperature measurement
2Measurement precision
If high magnification optics are used to focus on small wire diameter, then measurement precision improves, but device complexity increases and reliability decreases due to vibration sensitivity
Solution Approach 1:
The cavity acts as an intermediary that decouples the measurement from the wire's physical position. The copper wire transfers heat to the cavity walls, and the pyrometer measures radiation from the cavity walls rather than directly from the moving wire, eliminating vibration-induced focal distortion
Solution Approach 2:
The patent transitions from direct optical measurement in space to thermal equilibrium measurement in time. Instead of focusing on the wire's position in space (which is affected by vibrations), the system measures the thermal energy transferred to the cavity, which integrates over time and is insensitive to positional variations
3Measurement precision
If active regulation and control mechanisms are implemented, then measurement precision improves, but device complexity and cost increase
Solution Approach 1:
The system uses passive thermal equilibrium without active regulation. The cavity naturally reaches thermal equilibrium with the copper wire through convective and radiative heat transfer, and the pyrometer passively measures the resulting temperature without requiring active control mechanisms
Solution Approach 2:
The patent replaces complex mechanical control systems with a passive thermal field-based measurement system. Instead of using active regulation mechanisms to maintain measurement conditions, the system relies on natural thermal equilibrium and passive radiation detection
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The sensor provides a simple, economical, and reliable contactless temperature measurement for copper wires in movement, with reduced breakdown risks and the ability to adapt measurement bandwidth, while being resistant to chemical and corrosive environments.
Implementation Method 1
a drawn copper wire (10) moves inside with a uniform velocity v... the copper wire transfers heat through convective phenomena
Implementation Method 2
The emission spectrum of a generic grey body obeys Planck's law... the temperature of a body can be transduced by measuring the infrared irradiation spectrum
Data Source
Figure 1~2
Figure 3~4
AI summary
A contactless temperature sensor for copper wires in movement, comprising a body of the sensor (12) which provides an insulated sealed cavity (19) wherein an insulated cavity (21,22) is provided inside the sealed cavity, having an axial development and with a sensitive element in the centre made of a material having a high thermal diffusion (11), a pyrometer (16) being positioned in the sensor body (12), which extends inside the sealed cavity (19) and faces the sensitive element with a high thermal diffusion (11).