Tangential-Bore Coupling Element for Accurate Surface Temperature Sensing
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Solution Overview
Problem
Non-invasive temperature determination in containers, such as tanks and pipelines, faces challenges due to heat dissipation issues, leading to measurement inaccuracies, especially when direct contact is compromised, and existing solutions for replacing thermocouples are time-consuming and costly.
Innovation Solution
A coupling element with a tangentially aligned bore in its main body allows for improved thermal contact between the container wall and a sensor element, enhancing heat conduction and reducing measurement errors by minimizing the distance between the sensor and the container surface, enabling precise temperature and flow rate/velocity determination without invasive immersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-invasive temperature determination is used with surface thermometers, then the container structure is preserved and replacement is simpler, but thermal contact is insufficient leading to measurement inaccuracies
Solution Approach 1:
The patent introduces a coupling element as an intermediary component between the surface thermometer and the container wall. This coupling element includes a contact surface that interfaces with the container wall and a bore that receives the temperature sensor, thereby mediating the thermal contact and solving the contradiction between easy replacement and measurement accuracy.
Solution Approach 2:
The system is segmented into three distinct components: the container wall, the coupling element, and the temperature sensor. This segmentation allows the coupling element to be designed with specific functional features (contact surface and tangential bore) that address both the mechanical attachment requirement and the thermal contact requirement, enabling easy replacement while maintaining measurement accuracy.
2Measurement precision
If the temperature sensor is immersed directly in the medium, then thermal equilibrium is achieved and measurement accuracy is high, but the measurement becomes invasive requiring container modification
Solution Approach 1:
The coupling element serves as a mediator that enables non-invasive temperature measurement while maintaining conditions for accurate measurement. By providing a dedicated bore with tangential alignment and a contact surface for thermal coupling, it allows the sensor to achieve thermal equilibrium with the container wall without requiring invasive immersion or container modification.
Solution Approach 2:
The patent transitions from one-dimensional thermal contact (direct immersion) to a two-dimensional contact geometry. The tangential bore and contact surface create a planar interface between the coupling element and container wall, providing thermal coupling through a different geometric dimension while avoiding invasive penetration into the container or medium.
3Measurement precision
If thermocouples are welded directly to the container surface, then good thermal contact is achieved, but replacement is time-consuming and costly requiring process shutdown
Solution Approach 1:
The system separates the thermal contact function (performed by the coupling element's contact surface) from the sensing function (performed by the temperature sensor in the bore). This segmentation allows the sensor to be replaced by simply detaching it from the coupling element, eliminating the time-consuming welding process and enabling quick replacement without process shutdown.
Solution Approach 2:
The coupling element acts as a permanent intermediary attached to the container wall that provides stable thermal contact. The temperature sensor can be easily attached and detached from this intermediary without affecting the container wall or requiring welding, thus maintaining good thermal contact while enabling rapid sensor replacement.
4Ease of operation
If the bore is aligned perpendicular to the contact surface, then sensor installation is simple, but thermal contact distance is maximized reducing measurement accuracy
Solution Approach 1:
The patent changes the bore orientation from the conventional perpendicular alignment to a tangential alignment relative to the contact surface. This dimensional reorientation brings the bore closer to the container wall, minimizing the thermal contact distance and improving thermal coupling efficiency while still allowing straightforward sensor installation along the tangential path.
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 coupling element significantly improves measurement accuracy by ensuring better thermal equilibrium and reducing heat dissipation errors, allowing for efficient non-invasive temperature monitoring with minimal modifications to existing field devices.
Implementation Method 1
The coupling element significantly improves measurement accuracy by ensuring better thermal equilibrium and reducing heat dissipation errors
Data Source
AI summary
A coupling element for a device for determining and/or monitoring a process variable, more particularly the temperature, the flow rate or the flow velocity, of a medium in a container includes a main body having a contact surface designed such that the main body can be applied to the container face to face via the contact surface, in which the main body includes a bore for receiving a sensor element of the device, which is configured for determining and/or monitoring the process variable, and a longitudinal axis of the bore runs tangentially to the contact surface.