Thermocouple Docking Assembly with Heat Shield for Furnace Monitoring
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Solution Overview
Problem
Existing temperature sensing devices in high-temperature environments, such as furnaces, face challenges in providing accurate and reliable measurements due to harsh radiant and thermal conditions, leading to device failure and costly downtime for replacement and preparation processes.
Innovation Solution
A temperature sensing assembly with a thermocouple device and docking system that includes a heat shield and mounting pad, allowing for precise thermal coupling and easy replacement, reducing exposure to heat sources and eliminating the need for extensive surface preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensing device is exposed to high radiant energy and open flames in a furnace, then the device can measure surface temperature, but the device longevity deteriorates due to detrimental thermal effects
Solution Approach 1:
The temperature sensing device is divided into separate functional components: a protective sheath that shields the thermocouple from direct thermal exposure, a mounting pad that provides thermal coupling to the tube surface, and a docking device that facilitates easy installation and removal. This segmentation allows the sensing element to be protected while maintaining measurement capability.
Solution Approach 2:
A mounting pad acts as an intermediary between the temperature sensing device and the tube surface. This pad provides a controlled thermal coupling interface that protects the device from direct exposure to harsh furnace conditions while maintaining accurate temperature measurement through conductive heat transfer from the tube surface.
2Reliability
If a temperature sensing device is welded directly to the tube surface, then the device can be securely mounted, but the complexity of removal and replacement increases due to time-consuming surface preparation
Solution Approach 1:
The mounting system is segmented into a separate mounting pad and docking device that can be independently installed on the tube surface. The temperature sensing device itself is not permanently welded to the tube, but rather to the removable mounting pad, which simplifies replacement procedures while maintaining secure mounting during operation.
Solution Approach 2:
The mounting system transitions from a static permanent weld to a dynamic removable connection. The docking device with its recess and thermal coupling features allows the sensing device to be securely mounted during operation but easily removed for replacement without permanent attachment to the tube surface.
3Ease of operation
If the thermocouple sheath is blindly fed into position through a guide, then the device can be easily installed, but the positioning precision and thermal contact quality deteriorate
Solution Approach 1:
The mounting pad serves as an intermediary that provides a controlled interface for positioning the thermocouple sheath. Instead of blindly feeding the sheath through a guide, the mounting pad with its recess and thermal coupling features ensures precise positioning and adequate thermal contact with the tube surface while maintaining ease of installation.
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 provides accurate temperature measurements with reduced device longevity issues and processing downtime by ensuring reliable thermal contact and easy maintenance, minimizing the need for frequent replacements and costly preparation processes.
Implementation Method 1
The portion of the sheath is protected from heat from sources other than the tube surface by a heat shield
Implementation Method 2
the thermocouple device is closely coupled thermally to the surface of the tube
Data Source
AI summary
A temperature sensing assembly for measuring the temperature of a surface of a structure includes a thermocouple device having a sheath containing a pair of conductors of dissimilar materials connected at a junction point to provide indications of temperature. The assembly further includes a docking device with a recess formed in a top surface to receive a portion of the sheath that is proximate the junction point. The bottom surface of the docking device is attached to the surface of the structure. The recess extends through the bottom surface of the docking device so that when the thermocouple device is positioned in the recess, the junction point is adjacent the surface of the tube. A heat shield can be attached to the docking device to shield the sheath proximate the junction point from direct and radiant heat sources.