Integrated Thermocouple Assembly for Accurate Surface Measurement

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Solution Overview

Problem

Existing thermocouple sensor installations for surface temperature measurement are prone to errors and reduced accuracy due to a two-step installation process, which can lead to misalignment and degradation of measurement quality over time.

Innovation Solution

A thermocouple assembly design featuring a mechanically connected positioning pad and shielding, allowing for a one-step installation process that ensures precise positioning and thermal contact, enhancing measurement accuracy and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a two-step installation process is used (weld pad attachment followed by insulation and shielding), then measurement accuracy can be initially achieved, but installation time increases and measurement reliability degrades over time due to potential misalignment and installation errors

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidinstallation time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent combines the weld pad and shielding into a single integrated component that is attached to the tube in one welding operation. This eliminates the need for separate attachment steps, reducing installation time while maintaining measurement accuracy through the unified design that ensures proper positioning and thermal contact in a single process

Inventive Principle:

Principle #5Merging (Combining)

2Measurement precision

If a two-step installation process is used, then measurement accuracy can be initially achieved, but measurement reliability decreases over time due to installation errors and misalignment

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidmeasurement reliability over time

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The integrated design merges the positioning pad and shielding into one component that is welded to the tube in a single operation. This eliminates multiple attachment points that could misalign, ensuring consistent thermal contact and measurement accuracy over time. The unified structure prevents degradation of measurement reliability that occurs with separate components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The positioning pad is pre-formed with a recess that receives the thermocouple sensor before final welding. This preliminary positioning ensures correct alignment of the measurement junction with the tube surface, preventing misalignment errors that would occur with separate attachment steps and ensuring long-term measurement reliability

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If separate weld pad and shielding components are used, then installation flexibility is maintained, but device complexity increases and installation difficulty increases

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent integrates the weld pad and shielding into a single component with a unified structure. The positioning pad includes an integrated recess for the thermocouple sensor, eliminating the need for separate components. This reduces device complexity while maintaining installation flexibility through the single-weld attachment method

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If a one-step installation process is implemented with integrated positioning pad and shielding, then installation time is reduced and measurement repeatability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveinstallation speedVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The positioning pad is pre-formed with a recess during manufacturing that is designed to receive the thermocouple sensor. This preliminary formation of the receiving structure eliminates the need for complex assembly operations during installation, allowing for simple one-step welding while maintaining manufacturing feasibility through standard forming processes

Inventive Principle:

Principle #10Preliminary action

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 design improves measurement repeatability, long-term stability, and reduces installation time and costs by ensuring accurate placement and thermal contact between the thermocouple sensor and the surface, minimizing heat transfer deviations.

Implementation Method 1

ensuring accurate placement and thermal contact between the thermocouple sensor and the surface

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an insulation body, filling the inner free volume of the shielding

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20260029280A1Thermocouple sensor assembly

Publication Date: 2026.01.29 WIKA ALEXANDER WIEGAND SE & CO KG

AI summary

A thermocouple assembly for surface temperature measurement, comprising a sheathed thermocouple sensor cable, a positioning pad, receiving and/or securing a thermocouple sensor end at a desired measuring point, an insulation body, and a shielding, wherein the positioning pad is mechanically connected to the shielding. Additionally methods for the installation of a thermocouple assembly are also provided.