Thermocouples

Prepared by :
K Krishna Kishore
4th year ECE
15F41A0440

Presented to: Mr. S. Nanda Kishore (Ph.D.)

What is a Thermocouple? 
• A thermocouple is a sensor for measuring temperature. This sensor consists of
two dissimilar metal wires, joined at one end, and connected to a thermocouple
thermometer or other thermocouple-capable device at the other end. When
properly configured, thermocouples can provide temperature measurements
over wide range of temperatures.

• Thermocouples are known for their versatility as temperature sensors therefore

commonly used on a wide range of applications - from an industrial usage
thermocouple to a regular thermocouple found on utilities and regular
appliances. Due to their wide range of models and technical specifications, it is
extremely important to understand its basic structure, how it works, its ranges as
to better determine what is the right type and material of thermocouple for your
application
How does a thermocouple work?
When two wires composed of dissimilar metals are joined at both ends and one of the ends is
heated, there is a continuous current which flows in the thermoelectric circuit. If this circuit is
broken at the center, the net open circuit voltage (the Seebeck voltage) is a function of the junction
temperature and the composition of the two metals. Which means that when the junction of the
two metals is heated or cooled a voltage is produced that can be correlated back to the
temperature.
SEEBECK EFFECT:
• In 1821 Thomas Seebeck discovered the continuous current flow in
the thermoelectric circuit when two wires of dissimilar metals are
joined at both ends and one of the ends is heated.
Thermocouple types:
• Thermocouples are available in different combinations of metals or calibrations. The
most common are the “Base Metal” thermocouples known as Types J, K, T, E and N.
There are also high temperature calibrations - also known as Noble Metal thermocouples
- Types R, S, C and GB.
Characteristics:
• Each calibration has a different temperature range and environment, although
the maximum temperature varies with the diameter of the wire used in the
thermocouple.

• Although the thermocouple calibration dictates the temperature range, the

maximum range is also limited by the diameter of the thermocouple wire. That is,
a very thin thermocouple may not reach the full temperature range

• K Type Thermocouples are known as general purpose thermocouple due to its

low cost and temperature range.
How to choose a thermocouple
type?
• Because a thermocouple measures in wide temperature ranges and can be
relatively rugged, thermocouples are very often used in industry. The following
criteria are used in selecting a thermocouple:

1. Determine the application where the thermocouple will be used

2. Analyze the temperature ranges the thermocouple will be exposed to
3. Consider any chemical resistance needed for the thermocouple or sheath
material
4. Evaluate the need of abrasion and vibration resistance
5. List any installation requirements
What is the response time of a
thermocouple?
• A time constant has been defined as the time required by a sensor to
reach 63.2% of a step change in temperature under a specified set of
conditions is called response time.
• An exposed junction thermocouple offers the fastest response. Also,
the smaller the probe sheath diameter, the faster the response, but
the maximum temperature may be lower
Response time: (time constant vs
diameter)
• Time constants calculated for air at room temperature and atmospheric pressure moving with
velocity of 65 feet per second for thermocouples shown in fig:
Metal Sheathed Response Study
in Water :
How to choose which junction
type?
• Sheathed thermocouple probes are available with one of three
junction types:
• Grounded
• Ungrounded
• Exposed
Beaded wire thermocouple:
• A beaded wire thermocouple is the simplest
form of thermocouple. It consists of two pieces
of thermocouple wire joined together with a
welded bead.
• It should not be used with liquids that could
corrode or oxidize the thermocouple alloy.
• It good choice for the measurement of gas
temperature.
• Since it can be made very small, they also
provide very fast response time.
Thermocouple probe:
• A thermocouple probe consists of thermocouple wire
housed inside a metallic tube. The wall of the tube is
referred to as the sheath of the probe.
• The tip of the thermocouple probe is available in three
different styles. Grounded, ungrounded and exposed
• A grounded junction provides a fast response time but it is
most susceptible to electrical ground loops.
• In ungrounded junctions, the thermocouple is separated
from the sheath wall by a layer of insulation.
• Exposed junction thermocouples are best suited for air
measurement.
Surface probe:
• Measuring the temperature of a solid surface is
difficult for most types of temperature sensors. In
order to assure an accurate measurement, the entire
measurement area of the sensor must be in contact
with the surface
• This is difficult when working with a rigid sensor and a
rigid surface. Since thermocouples are made of pliable
metals, the junction can be formed flat and thin to
provide maximum contact with a rigid solid surface.
• The thermocouple can even be built in a mechanism
which rotates, making it suitable for measuring the
temperature of a moving surface. Type K is
ChrOMEGA™/AlOMEGA™.
Wireless Thermocouples:
• Bluetooth wireless transmitters that connect
with smartphones or tables to log and monitor
temperature measurements.
• These transmitters measure different sensor
inputs, including but not limited to temperature,
pH, RTD, relative humidity.
• The data transmission is performed via
Bluetooth wireless technology to a smart phone
or tablet with the app installed. The app will
allow the smartphone to pair and set up
multiple transmitters.
Thermocouple color code table
Applications:
• Steel industry
• Gas appliance safety
• Thermopile radiation sensors
• Manufacturing
• Power production
• Process plants
• Thermocouple as vacuum gauge