Thermocouple Sensor Assembly for Single-Step Surface Welding
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Solution Overview
Problem
The installation process of sheathed thermocouple sensor cables for surface temperature measurement is prone to errors, leading to reduced measurement accuracy and offset, especially when the two-step welding process is not performed correctly.
Innovation Solution
A thermocouple assembly design featuring a mechanically connected positioning pad and shielding, allowing for a single-step installation by welding, which secures the sensor cable end in a defined location, improving measurement repeatability and accuracy through controlled heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a two-step welding process is used to install the thermocouple sensor cable with separate weld pad and shielding, then the installation can be completed, but the measurement accuracy is reduced due to installation errors and the process complexity increases
Solution Approach 1:
The patent combines the weld pad and shielding into a single integrated component that is welded to the tube in one step. This merging eliminates the alignment errors between separate components and reduces the installation process from two welding steps to one, directly improving measurement accuracy while reducing process complexity
Solution Approach 2:
The integrated weld pad/shielding component is pre-configured with the thermocouple sensor cable positioned in a defined location before installation. This preliminary positioning ensures correct thermal contact and geometric alignment are built-in from the start, eliminating alignment errors that would otherwise occur during the installation process
2Ease of manufacture
If a two-step welding process is used with separate weld pad and shielding, then the components can be installed, but the installation time and costs increase
Solution Approach 1:
By merging the weld pad and shielding into one integrated component, the installation process requires only one welding operation instead of two separate welding steps. This directly reduces installation time and associated costs while making the installation process easier and more straightforward
Solution Approach 2:
The integrated component is pre-assembled with the thermocouple sensor cable positioned correctly before installation. This preliminary configuration eliminates the need for time-consuming alignment and positioning steps during installation, reducing both installation time and complexity
3Measurement precision
If the thermocouple sensor cable end is not positioned in a defined location, then installation is simpler, but measurement repeatability and accuracy degrade
Solution Approach 1:
The integrated weld pad/shielding component includes a pre-configured position for the thermocouple sensor cable end, ensuring it is located in a defined position relative to the welding area. This preliminary positioning guarantees repeatable thermal contact and consistent measurement geometry across all installations without requiring complex positioning structures
Solution Approach 2:
By integrating the positioning function into the weld pad/shielding component itself, the patent achieves precise positioning through the unified structure rather than requiring separate positioning mechanisms. The single welding process naturally establishes the correct geometric relationship between the sensor cable end and the measurement point
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 simplifies installation, reduces errors, and enhances measurement accuracy by ensuring the sensor cable end is positioned correctly, with improved thermal contact and reduced material usage, resulting in cost-effective and durable installations.
Implementation Method 1
The shielding and mechanically connected positioning pad may be fixed to the structure in one step, e.g. by one single welding process
Implementation Method 2
an insulation body, filling the inner free volume of the shielding
Implementation Method 3
improve measuring characteristics of a thermocouple sensor assembly... controlled heat transfer
Data Source
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.