DEPARTMENT OF MECHANICAL ENGINEERING

METROLOGY AND INSTRUMENTATION ASSIGNMENT

PRESENTATION

“THERMOCOUPLE AND THERMOPILE”

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

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 WORKING PRINCIPLE
• The working principle of thermocouple is THERMOELECTRIC EFFECT.
• The thermoelectric effect is a phenomenon by which a temperature difference is directly
converted to electric voltage and vice versa.
• 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, Peltier and Thomson effects are three related reversible thermoelectric effects.

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 SEEBECK EFFECT
• It is a phenomenon in which the temperature
difference between the two different metals induces
the potential differences between them.
• The Seebeck effect occurs between two different
metals.
• When the heat provides to any one of the metal, the
electrons start flowing from hot metal to cold metal.
Thus, an emf induces in the circuit.

Fig.2 Fe-Cu Thermocouple

Source: https://circuitglobe.com/thermocouple.html

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 PELTIER & THOMPSON EFFECTS
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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 THERMO-ELECTRIC SERIES
• 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 = α θ + ( ½ β θ2 )
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?
• 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).

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 CONSTRUCTION

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, Iron-
Constantan, Chromel-Alumel, Platinum-Rhodium and Chromel-Constantan.

• Measuring junction is formed by joining the any one of the above pair of materials in the
wire form.

• Measuring junction is covered by a protective tube and head to prevent it from damage.

• The other junction is the reference junction.

• Two junctions are connected to a voltmeter by means of extension wires (compensating

leads).

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 WORKING
• The measuring junctions (hot junction) is introduced in the place where the
temperature must be measured.

• The reference junction (cold junction) is maintained at a constant known

temperature.

• For ease of calculation, it is normally maintained at 0֯ C.

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• The reading from the voltmeter which depends on the temperature difference
between the junctions, is calibrated to give the temperature reading.

E = a*ΔT

where,

E - the emf produced

a - selected material constant

ΔT – temperature difference between two junctions

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 LAWS OF THERMOCOUPLES
• Law of Homogeneous circuit.

• Law of Intermediate Temperatures.

• Law of Intermediate metals.

Fig.4: Laws of thermocouple

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

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 TYPES OF THERMOCOUPLE

BASE METAL THERMOCOUPLE NOBLE METAL THERMOCOUPLE

1. TYPE K 1. TYPE S
2. TYPE J 2. TYPE R
3. TYPE T
4. TYPE E 3. TYPE B
 Type K Thermocouple (Nickel-Chromium / Nickel-Alumel)

• The type K is the most common type of thermocouple.

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

Temperature Range:

Thermocouple grade wire, –454 to 2,300F (–270 to 1260°C)

Extension wire, 32 to 392F (0 to 200°C)

Accuracy (whichever is greater):

Standard: +/- 2.2°C or +/- .75%

Special Limits of Error: +/- 1.1°C or 0.4%
 Type J Thermocouple (Iron/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:

• Thermocouple grade wire, -346 to 1,400F (-210 to 760°C)

• Extension wire, 32 to 392F (0 to 200°C)

Accuracy (whichever is greater):

• Standard: +/- 2.2°C or +/- .75%

• Special Limits of Error: +/- 1.1°C or 0.4%

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 Type T Thermocouple (Copper/Constantan)

• 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)

• Extension wire, 32 to 392F (0 to 200°C)

Accuracy (whichever is greater):

• Standard: +/- 1.0°C or +/- .75%

• Special Limits of Error: +/- 0.5°C or 0.4%

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 Type E Thermocouple (Nickel-Chromium/Constantan)

• The Type E has a stronger signal & higher accuracy than the Type K or Type J at moderate
temperature ranges of 1,000F and lower.

Temperature Range:

• Thermocouple grade wire, -454 to 1600F (-270 to 870°C)

• Extension wire, 32 to 392F (0 to 200°C)

Accuracy (whichever is greater):

• Standard: +/- 1.7°C or +/- 0.5%

• Special Limits of Error: +/- 1.0°C or 0.4%

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 Type N Thermocouple (Nicrosil / Nisil)

• The Type N shares the same accuracy as the Type K. The type N is slightly more expensive.

Temperature Range:

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

• Extension wire, 32 to 392F (0 to 200°C)

Accuracy (whichever is greater):

• Standard: +/- 2.2°C or +/- .75%

• Special Limits of Error: +/- 1.1°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.

Temperature Range:

• Thermocouple grade wire, -58 to 2700F (-50 to 1480°C)

• Extension wire, 32 to 392F (0 to 200°C)

Accuracy (whichever is greater):

• Standard: +/- 1.5°C or +/- .25%

• Special Limits of Error: +/- 0.6°C or 0.1%

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 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:

• Thermocouple grade wire, -58 to 2700F (-50 to 1480°C)

• Extension wire, 32 to 392F (0 to 200°C)

Accuracy (whichever is greater):

• Standard: +/- 1.5°C or +/- .25%

• Special Limits of Error: +/- 0.6°C or 0.1%

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Type B Thermocouple (Platinum Rhodium – 30% / Platinum Rhodium – 6%)

• 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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 TEMPERATURE vs VOLTAGE GRAPH

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 ADVANTAGES
• Covers a wide temperature range.
• High speed of response.
• Satisfactory measurement accuracy.
• Comparatively cheaper in cost.
• Calibration can be easily checked.
• 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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 LIMITATIONS
• For accurate temperature measurement, cold junction compensation is necessary.
• The emf induced versus temperature characteristics is somewhat nonlinear.
• In many applications, amplification of signal is required.
• Stray voltage pickup is possible.

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 THERMOPILES
• 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.

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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
infrared, which raises the temperature according to the intensity of the
incident infrared.

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.

Fig.6: Heat transfer in thermopile

Source: https://automationforum.co/what-are-thermopiles-applications-of-thermopile/

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 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.7: Thermopile connections

Source: https://images.app.goo.gl/AJ74LUnKwZtRBrx47/
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 TWO BASIC DESIGNS OF A
THERMOCOUPLE

Fig.8: Basic designs

Source: https://images.app.goo.gl/frYfhxSFtCwQCxVg8
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 Fig.9: Thermopile
Source: https://images.app.goo.gl/9bhQn3PW3fq9U4N87/

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 STANDARDS FOR THERMOCOUPLE
• IEC 60584-1: Thermocouples: Basic and tolerance values of the
thermoelectric voltages
• IEC 60584-3: Thermocouples: Thermocouple cables and
compensating cables
• ASTM E230: Standard specification and temperature-electromotive
force tables for standardized thermocouples.

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 APPLICATIONS OF THERMOCOUPLE
• Automobile industry
• Food industry
• Gas furnaces

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 AUTOMOBILE INDUSTRY
• Brake block and disc temperature measurement
• Brake temperature as an input for a traction control system.
• Estimate the life of the brake pad.

• Exhaust gas temperature measurement

• Turbo charger (Type N thermocouple)

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 FOOD INDUSTRY
• Consistent temperature reading (precise cooking, frying or heating to protect the
food from overcooked or undercooked )
• Cooking equipment
• Ovens, warmers, fryers, toasters and grills.
• Dishwashers and food inspection systems.
• Sensors used for food temperature measurements should be encased in a metal
sheath.
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
• Located near the pilot light burner.
• Safety device that shuts off the gas if the pilot
light goes out.
• Excess gas build-up could cause high CO
emissions.
• Type N thermocouple is generally used. (stable
and wide temperature range)

Fig.10 Thermocouple in gas furnace

Source:
https://home.howstuffworks.com/ho
w-to-repair-gas-furnaces3.htm

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 APPLICATIONS OF THERMOPILES
• Non-contact temperature measurement in the process industry
• Commercial building HVAC and lighting control
• Security human presence and detection
• Blood glucose monitoring
• Automatic HVAC control
• Fire detection in transportation tunnel
• Aircraft flame and fire detection
• Monitor the temperature of circuits in devices such as PCs, laptops, tablets and smartphones to
prevent overheating.
• Used to monitor body temperature.
• 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.

• https://home.howstuffworks.com/how-to-repair-gas-furnaces3.htm

• https://www.Vernier.com/innovate/experimenting-with-a-thermocouple/

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