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DEPARTMENT OF MECHANICAL ENGINEERING THERMOCOUPLE

METROLOGY AND INSTRUMENTATION ASSIGNMENT PRESENTATION • A thermocouple is a sensor used to measure the
temperature at one point in the form of EMF(Electro
motive force).
“THERMOCOUPLE AND THERMOPILE”
• Thermocouples consist of two wire legs made from
-Presented by different metals.
MOHAMED SUBIN M 17M125 • The wires legs are welded together at one end, creating
MOHAMED VAJITH IBRAHIM 17M126 a junction.
MUKILAN S N 17M127 • This junction is where the temperature is measured.
MUKKESH KUMAR K B 17M128 When the junction experiences a change in Fig.1 Thermocouple
MURALIDHARAN M 18M406 temperature, a voltage or emf is created. Source:
https://www.elprocus.com/working
• The voltage can then be interpreted using -principle-diagram-applications/
thermocouple reference tables to calculate the
temperature.
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WORKING PRINCIPLE SEEBECK EFFECT

• The working principle of thermocouple is THERMOELECTRIC EFFECT. • It is a phenomenon in which the temperature
• The thermoelectric effect is a phenomenon by which a temperature difference is difference between the two different metals
directly converted to electric voltage and vice versa. induces the potential differences between
them.
• At the atomic scale, an applied temperature gradient causes charge carriers in the
material to diffuse from the hot side to the cold side. • The Seebeck effect occurs between two
different metals.
• The Seebeck, Peltier and Thomson effects are three related reversible
• When the heat provides to any one of the
thermoelectric effects.
metal, the electrons start flowing from hot
Fig.2 Fe-Cu Thermocouple
metal to cold metal. Thus, an emf induces in Source: https://circuitglobe.com/thermocouple.html
the circuit.

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PELTIER & THOMPSON EFFECTS THERMO-ELECTRIC SERIES

Peltier Effect
• The Peltier effect is the inverse of the Seebeck effect.
• It states that the temperature difference can be created between any two
different conductors by applying the potential difference between them.
Thompson Effect
• It states that when two dissimilar metals join together and if they create two
junctions then the voltage induces the entire length of the conductor
because of the temperature gradient.
• The temperature gradient is a physical term which shows the direction and rate
of change of temperature at a particular location.
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• The magnitude and sign of thermo emf depends the materials of the two
conductors and the temperature of the hot and cold junctions.
• After studying the thermoelectric properties of different pairs of metals, arranged
them in a series called thermoelectric series.
• The thermo-electric series of metals is
Bi, Ni, Pd, Pt, Cu, Mn, Hg, Pb, Sn, Au, Ag, Zn, Cd, Fe, Sb
• The thermo emf of any thermocouple was the temperature dependence given by
the relation,
𝑉 = αθ+(½βθ )
where, θ is the temperature difference between the junctions
α and β are constants depending on the nature of the materials.
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How to choose a thermocouple type? CONSTRUCTION

• The following criteria are used in selecting a thermocouple:

- Temperature range
- Chemical resistance of the thermocouple or sheath material
- Abrasion and vibration resistance
- Installation requirements (may need to be compatible with
existing equipment; existing holes may determine probe diameter).

Fig.3: Construction of thermocouple

Source: Engineering Metrology and Measurement by K.Duraivelu and S.Karthikeyan

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• Materials commonly used for thermocouple construction are Copper-Constantan,

WORKING
Iron-Constantan, Chromel-Alumel, Platinum-Rhodium and Chromel-Constantan. • The measuring junctions (hot junction) is introduced in the place
• Measuring junction is formed by joining the any one of the above pair of materials
where the temperature must be measured.
in the wire form.

• Measuring junction is covered by a protective tube and head to prevent it from • The reference junction (cold junction) is maintained at a constant
damage. known temperature.
• The other junction is the reference junction.
• For ease of calculation, it is normally maintained at 0֯ C.
• Two junctions are connected to a voltmeter by means of extension wires
(compensating leads).

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LAWS OF THERMOCOUPLES
• The reading from the voltmeter which depends on the temperature difference • Law of Homogeneous circuit.
between the junctions, is calibrated to give the temperature reading. • Law of Intermediate Temperatures.

E = a*ΔT • Law of Intermediate metals.

where,

E - the emf produced

a - selected material constant

ΔT – temperature difference between two junctions

Fig.4: Laws of thermocouple

Source: Engineering Metrology and Measurement by K.Duraivelu and S.Karthikeyan

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Type K Thermocouple (Nickel-Chromium / Nickel-Alumel)

TYPES OF THERMOCOUPLE • The type K is the most common type of thermocouple.

• It’s inexpensive, accurate, reliable, and has a wide temperature range.

Temperature Range:
BASE METAL THERMOCOUPLE NOBLE METAL THERMOCOUPLE
Thermocouple grade wire, –454 to 2,300F (–270 to 1260°C)
1. TYPE K 1. TYPE S Extension wire, 32 to 392F (0 to 200°C)
2. TYPE J 2. TYPE R
3. TYPE T Accuracy (whichever is greater):
4. TYPE E 3. TYPE B
Standard: +/- 2.2°C or +/- .75%
Special Limits of Error: +/- 1.1°C or 0.4%

Type J Thermocouple (Iron/Constantan) Type T Thermocouple (Copper/Constantan)

• The type J is also very common. It has a smaller temperature range and a shorter lifespan at
higher temperatures than the Type K. It is equivalent to the Type K in terms of expense and
reliability.
Temperature Range:
• The Type T is a very stable thermocouple and is often used in extremely low temperature
applications such as cryogenics or ultra low freezers.
Temperature Range:

• Thermocouple grade wire, -454 to 700F (-270 to 370°C)

• Thermocouple grade wire, -346 to 1,400F (-210 to 760°C)
• Extension wire, 32 to 392F (0 to 200°C)
• Extension wire, 32 to 392F (0 to 200°C)

Accuracy (whichever is greater):

Accuracy (whichever is greater):

• Standard: +/- 1.0°C or +/- .75%

• Standard: +/- 2.2°C or +/- .75%
• Special Limits of Error: +/- 0.5°C or 0.4%
• Special Limits of Error: +/- 1.1°C or 0.4%

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Type E Thermocouple (Nickel-Chromium/Constantan) Type N Thermocouple (Nicrosil / Nisil)

• The Type E has a stronger signal & higher accuracy than the Type K or Type J at • The Type N shares the same accuracy as the Type K. The type N is slightly more
moderate temperature ranges of 1,000F and lower. expensive.

Temperature Range: Temperature Range:

• Thermocouple grade wire, -454 to 2300F (-270 to 392°C)

• Thermocouple grade wire, -454 to 1600F (-270 to 870°C)
• Extension wire, 32 to 392F (0 to 200°C)
• Extension wire, 32 to 392F (0 to 200°C)
Accuracy (whichever is greater):
Accuracy (whichever is greater):
• Standard: +/- 2.2°C or +/- .75%
• Standard: +/- 1.7°C or +/- 0.5% • Special Limits of Error: +/- 1.1°C or 0.4%
• Special Limits of Error: +/- 1.0°C or 0.4%
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Type S Thermocouple (Platinum Rhodium/ Platinum)
• The Type S is used in very high temperature applications.
• It is commonly found in the Bio-Tech and Pharmaceutical industries.
• It is sometimes used in lower temperature applications because of its high
accuracy and stability.
Type R Thermocouple (Platinum Rhodium / Platinum)
• The Type R is used in very high temperature applications.
• It has a higher percentage of Rhodium than the Type S, which makes it more expensive.
• The Type R is very similar to the Type S in terms of performance.
• It is sometimes used in lower temperature applications because of its high accuracy and stability.

Temperature Range: Temperature Range:

• Thermocouple grade wire, -58 to 2700F (-50 to 1480°C) • Thermocouple grade wire, -58 to 2700F (-50 to 1480°C)
• Extension wire, 32 to 392F (0 to 200°C) • Extension wire, 32 to 392F (0 to 200°C)

Accuracy (whichever is greater):

Accuracy (whichever is greater):
• Standard: +/- 1.5°C or +/- .25%
• Standard: +/- 1.5°C or +/- .25% • Special Limits of Error: +/- 0.6°C or 0.1%
• Special Limits of Error: +/- 0.6°C or 0.1%
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Type B Thermocouple (Platinum Rhodium – 30% / Platinum Rhodium – 6%) TEMPERATURE vs VOLTAGE GRAPH
• The Type B thermocouple is used in extremely high temperature applications.
• It has the highest temperature limit of all of the thermocouples listed above.
• It maintains a high level of accuracy and stability at very high temperatures.

Temperature Range:

• Thermocouple grade wire, 32 to 3100F (0 to 1700°C)

• Extension wire, 32 to 212F (0 to 100°C)

Accuracy (whichever is greater):

• Standard: +/- 0.5%

• Special Limits of Error: +/- 0.25%

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ADVANTAGES LIMITATIONS
• Covers a wide temperature range. • For accurate temperature measurement, cold junction compensation is
• High speed of response. necessary.
• Satisfactory measurement accuracy. • The emf induced versus temperature characteristics is somewhat nonlinear.
• Comparatively cheaper in cost. • In many applications, amplification of signal is required.
• Calibration can be easily checked. • Stray voltage pickup is possible.
• Offers good reproducibility.
• Using extension leads and compensating cables, long transmission distances for
temperature measurement possible. This is most suitable for temperature
measurement of industrial furnaces.

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• The cold junctions are typically placed on the silicon substrate to provide an
effective heat sink. In the hot regions, there is a black body for absorbing the
THERMOPILES infrared, which raises the temperature according to the intensity of the
incident infrared.
• Thermopile is a device that converts thermal energy into an electrical
signal. A thermopile is composed of several thermocouples connected
usually in series or rarely in parallel.
• A thermopile is a series of thermocouples interconnected in series,
each of which consists of two different materials with a large
thermoelectric power and opposite polarities. The thermocouples are
placed through the hot and cold regions of a structure and the hot
junctions are thermally isolated from the cold junctions.

Fig.5: Thermopile
Source: https://images.app.goo.gl/f5849AhHoYKqsj9m8/
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• Thermopiles do not respond to absolute temperature, but generate an

output voltage proportional to a local temperature difference or temperature gradient. The
amount of voltage and power are very small and they are measured in milli-watts and milli-volts
using controlled devices that are specifically designed for such purpose.
• The output of a thermopile is usually in the range of tens or hundreds of millivolts.
THERMOPILE CONNECTIONS
• With a couple of thermocouples connected in series. The two top thermocouples are a connected
junction are at temperature T1 while the two bottom thermocouple junction is at temperature
T2. The output voltage from the thermopile delta V is directly proportional to the difference in
temperature or T1-T2, across the thermal resistance layer and the number of thermocouple
junctions pairs.

Fig.6: Heat transfer in thermopile

Source: https://automationforum.co/what-are-thermopiles-applications-of-thermopile/ Fig.7: Thermopile connections
Source: https://images.app.goo.gl/AJ74LUnKwZtRBrx47/
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TWO BASIC DESIGNS OF A THERMOCOUPLE

Fig.9: Thermopile
Fig.8: Basic designs Source: https://images.app.goo.gl/9bhQn3PW3fq9U4N87/
Source: https://images.app.goo.gl/frYfhxSFtCwQCxVg8
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STANDARDS FOR THERMOCOUPLE APPLICATIONS OF THERMOCOUPLE

• IEC 60584-1: Thermocouples: Basic and tolerance values of the • Automobile industry
thermoelectric voltages
• Food industry
• IEC 60584-3: Thermocouples: Thermocouple cables and
compensating cables • Gas furnaces
• ASTM E230: Standard specification and temperature-electromotive
force tables for standardized thermocouples.

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FOOD INDUSTRY AUTOMOBILE INDUSTRY

• Consistent temperature reading (precise cooking, frying or heating to • Brake block and disc temperature measurement
protect the food from overcooked or undercooked )
• Brake temperature as an input for a traction control system.
• Cooking equipment
• Estimate the life of the brake pad.
• Ovens, warmers, fryers, toasters and grills.
• Dishwashers and food inspection systems.
• Sensors used for food temperature measurements should be encased in a • Exhaust gas temperature measurement
metal sheath. • Turbo charger (Type N thermocouple)
Response time: 6 seconds
Probe diameter: 4mm (maximum)
• Type T thermocouple is generally used. (no oxidation even in moisture)

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GAS FURNACE APPLICATIONS OF THERMOPILES

• Located near the pilot light burner. • Non-contact temperature measurement in the process industry
• Commercial building HVAC and lighting control
• Safety device that shuts off the gas if the
• Security human presence and detection
pilot light goes out.
• Blood glucose monitoring
• Excess gas build-up could cause high CO • Automatic HVAC control
emissions. • Fire detection in transportation tunnel
• Type N thermocouple is generally used. • Aircraft flame and fire detection
(stable and wide temperature range) • Monitor the temperature of circuits in devices such as PCs, laptops, tablets and
Fig.10 Thermocouple in gas furnace
Source: smartphones to prevent overheating.
https://home.howstuffworks.com/ho • Used to monitor body temperature.
w-to-repair-gas-furnaces3.htm
• Safety control system for fire and gas leak detection.

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REFERENCE
• Duraivelu K & Karthikeyan S, “ Engineering Metrology and Measurement”,
Universities Press (India) Private Limited, Hyderabad, 2018.

• Raghavendra N.V & Krishnamurthy L , “ Engineering Metrology and

Measurements”, Oxford University Press, New Delhi, 2013.

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