Quick Connect Temperature Sensor with Magnetic Docking
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Solution Overview
Problem
Temperature sensing devices in harsh environments, such as high-temperature reactor vessels, face challenges in providing accurate and long-lasting measurements due to extreme temperatures, leading to frequent replacements and costly processing downtime.
Innovation Solution
A quick connect temperature sensing assembly featuring a thermocouple device with a magnetic or weldable docking system and thermally insulative materials, allowing for easy installation and maintenance at desired locations, with a spring-loaded adapter to maintain junction point proximity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensor is fixedly attached to structure surface by welding, then measurement reliability is improved, but sensor replacement time and processing downtime increase
Solution Approach 1:
The temperature sensing system is divided into separate modular components: a thermocouple assembly and a mounting assembly. This segmentation allows the sensor to be independently replaced without replacing the entire mounting structure, significantly reducing replacement time and downtime while maintaining measurement reliability through consistent mounting geometry.
Solution Approach 2:
The mounting assembly incorporates a spring-loaded adapter that dynamically adjusts to maintain consistent contact pressure between the thermocouple junction and the structure surface. This dynamic adjustment ensures reliable thermal contact during operation and facilitates easy detachment during replacement, resolving the contradiction between measurement reliability and replacement speed.
2Measurement precision
If temperature sensor is fixedly attached to structure surface, then measurement accuracy is improved, but sensor replacement complexity and cost increase
Solution Approach 1:
By separating the thermocouple sensor from the mounting assembly, the system enables simple sensor replacement without complex welding or disassembly operations. The modular design maintains measurement accuracy through precise geometric relationships while dramatically improving ease of repair.
Solution Approach 2:
The invention replaces permanent welding connections with a mechanical spring-loaded adapter system. This substitution maintains consistent thermal contact for accurate measurements while allowing tools-free installation and removal, making sensor replacement simple and cost-effective.
3Adaptability or versatility
If new temperature sensor is added to structure surface, then measurement coverage is improved, but installation downtime and cost increase
Solution Approach 1:
The mounting assembly is designed as a universal platform that can accommodate thermocouple sensors at various locations on the structure surface. The standardized interface and spring-loaded design enable rapid deployment of additional sensors without requiring specialized installation procedures, improving measurement coverage while minimizing installation downtime.
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
Enables accurate and reliable temperature measurements over extended periods with reduced downtime and maintenance costs by allowing for quick and secure attachment and detachment of sensors in extreme conditions.
Implementation Method 1
a magnetic or weldable docking system
Implementation Method 2
thermally insulative materials
Implementation Method 3
a spring-loaded adapter to maintain junction point proximity
Data Source
AI summary
A quick connect temperature sensing assembly for measuring the surface of a structure includes a thermocouple device, a docking device and a spring loaded adapter to connect the thermocouple device with the docking device. The docking device can be made of a magnetic material so that the assembly can be quickly connected and disconnected from the surface of a structure for sensing the temperature of the surface. When disconnected, the end of the thermocouple device extends beyond the bottom surface of the docking device. When the bottom surface of the docking device engages the surface of the structure, the end of the thermocouple is retracted and the spring loaded adapter maintains a biasing force on the thermocouple to maintain the end of the thermocouple in contact with the surface.