Pulsed Temperature Sensor Probe for Aluminum Rolling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing temperature measurement techniques for metal rolling processes, particularly for aluminum, face challenges in accurately measuring surface temperatures due to reflective surfaces, interference from particles and lubricants, and increased error rates in both contact and non-contact methods, especially at low temperatures.

Innovation Solution

A temperature sensor with a probe head that uses a thermocouple element positioned between a conformable sheet material and an elastomeric material, employing pulsed reciprocal movement to minimize contact time and reduce surface damage, while maintaining accuracy through a solenoid-driven shaft and compression spring mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If infrared pyrometry is used to measure surface temperature non-contact, then measurement convenience is improved, but measurement precision deteriorates due to low emissivity of aluminum surfaces and interference from particles and lubricants

Engineering Contradiction:

Improvemeasurement convenienceVSAvoidtemperature measurement accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

A conformable contact element with high emissivity is introduced as an intermediary between the aluminum surface and the infrared detector. This contact element is pressed against the aluminum surface to establish thermal equilibrium, then its back surface is measured by the infrared pyrometer. The high emissivity of the contact element's back surface eliminates emissivity-related measurement errors, while the conformable material ensures good thermal contact with the aluminum surface.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If contact thermocouples are used to measure surface temperature, then measurement precision is improved, but the measured object is damaged due to scratching from continuous contact

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidsurface damage

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The contact element is pressed against the aluminum surface only during brief measurement intervals to establish thermal equilibrium, then quickly removed before the aluminum surface can cool significantly. This periodic contact approach allows accurate temperature measurement while minimizing the duration of contact that could cause scratching or surface damage.

Inventive Principle:

Principle #19Periodic action

3Measurement precision

If contact time is increased to improve thermal equilibrium, then measurement precision is improved, but surface damage increases due to prolonged contact

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidsurface scratching

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The contact element is pressed against the aluminum surface with sufficient force and for sufficient duration to achieve thermal equilibrium and accurate measurement, but not excessively so. The measurement system is designed to capture the temperature reading within the brief contact window, then immediately remove the contact element before damaging forces can accumulate.

Inventive Principle:

Principle #16Partial or excessive action

4Ease of operation

If lubricants are present on the surface to reduce friction, then ease of operation is improved, but measurement precision deteriorates because pyrometry measures lubricant temperature rather than metal surface temperature

Engineering Contradiction:

Improverolling process operationVSAvoidsurface temperature measurement

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The conformable contact element acts as a thermal intermediary that bridges the aluminum surface and the infrared detector. When pressed against the aluminum surface, it rapidly achieves thermal equilibrium with the metal beneath the lubricant layer. The infrared pyrometer then measures the temperature of the contact element's back surface, which accurately reflects the aluminum surface temperature despite the presence of lubricants.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution achieves accurate temperature measurements with reduced error rates (±4°C) and minimizes surface damage, suitable for both moving and stationary surfaces, effectively addressing the limitations of prior art methods.

Implementation Method 1

the probe head is provided with a thermocouple element for measuring the temperature of a surface contacted by the probe head

Methodology Applied

Scientific EffectThermocouple effect: Seebeck Effect

Implementation Method 2

means for generating reciprocal movement of the probe head relative to the main body portion

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Data Source

PatentUS7682075B2Apparatus and method for temperature measurement

Publication Date: 2010.03.23 MEYER ALUMINUM

AI summary

A temperature sensor for measuring a temperature of a moving or stationary surface includes a main body portion and a probe head with thermocouple element, the probe head coupled to the main body portion such that the probe head reciprocates relative to the main body portion in a pulsed manner.