Thermocouple

What is a Thermocouple?
A Thermocouple is a sensor used to measure temperature. 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 is created. There are many types of thermocouples, each with its own unique
characteristics in terms of temperature range, durability, vibration resistance, chemical resistance, and
application compatibility. Type J, K, T, & E are “Base Metal” thermocouples, the most common types
of thermocouples. Type R, S, and B thermocouples are “Noble Metal” thermocouples, which are used
in high temperature applications.

Working Principle

The working principle of thermocouple is based on three effects, discovered by Seebeck, Peltier and
Thomson. They are as follows:

1) Seebeck effect: The Seebeck effect states that when two different or unlike metals are joined
together at two junctions, an electromotive force (emf) is generated at the two junctions. The amount
of emf generated is different for different combinations of the metals.

2) Peltier effect: As per the Peltier effect, when two dissimilar metals are joined together to form two
junctions, emf is generated within the circuit due to the different temperatures of the two junctions of
the circuit.

3) Thomson effect: As per the Thomson effect, when two unlike metals are joined together forming
two junctions, the potential exists within the circuit due to temperature gradient along the entire length
of the conductors within the circuit.
In most of the cases the emf suggested by the Thomson effect is very small and it can be neglected by
making proper selection of the metals. The Peltier effect plays a prominent role in the working
principle of the thermocouple.

Construction:

A thermocouple is constructed of two dissimilar metal wires joined at one end. When one end of each
wire is connected to a measuring instrument, the thermocouple becomes a sensitive and highly accurate
measuring device.
Thermocouples may be constructed of several different combinations of materials. The performance of
a thermocouple material is generally determined by using that material with platinum.
The most important factor to be considered when
selecting a pair of materials is the “thermoelectric
difference” between the two materials. A
significant difference between the two materials
will result in better thermocouple performance.

Other materials may be used in addition to those

shown in Figure 1. For example: Chromel-
Constantan is excellent for temperatures up to Figure 1: illustrates the characteristics of the more
commonly used Thermocouple materials when used with
2000°F; Nickel/Nickel-Molybdenum sometimes platinum.

replaces Chromel-Alumel; and Tungsten-Rhenium

is used for temperatures up to 5000°F. Some
combinations used for specialized applications are
Chromel-White Gold, Molybdenum-Tungsten,
Tungsten-Iridium, and Iridium/Iridium-Rhodium.

Figure 2 shows the Internal Construction of a

Typical Thermocouple. The leads of
the thermocouple are encased in a rigid metal
sheath. The measuring junction is normally formed
at the bottom of the thermocouple housing.
Magnesium oxide surrounds the thermocouple
wires to prevent vibration that could damage the Figure 2: Internal Construction of a Typical
Thermocouple
fine wires and to enhance heat transfer between the
measuring junction and the medium surrounding the thermocouple.

Thermocouple Operation:

Thermocouples will cause an electric current to

flow in the attached circuit when subjected to
changes in temperature. The amount of current
that will be produced is dependent on the
temperature difference between the
measurement and reference junction; the
characteristics of the two metals used; and the
characteristics of the attached circuit.
Figure 3: Simple Thermocouple Circuit
Heating the measuring junction of the thermocouple produces a voltage which is greater than the
voltage across the reference junction. The difference between the two voltages is proportional to the
difference in temperature and can be measured on the voltmeter (in millivolts). For ease of operator use,
some voltmeters are set up to read out directly in temperature through use of electronic circuity.
Other applications provide only the millivolt readout. In order to convert the millivolt reading to its
corresponding temperature, you must refer to tables like the one shown in Figure 4. These tables can be
obtained from the thermocouple manufacturer, and they list the specific temperature corresponding to
a series of millivolt readings.

Figure 4: Temperature-vs-Voltage Reference Table

Following are the advantages of temperature sensor (thermocouple):

Thermocouple measures temperature in -200oC to +2500oC range, RTD measures in -200oC to
+850oC range, thermistor measures in -100oC to +260oC range and IC sensors measures in -45oC to
150oC range. No external power required, simple and rugged in construction, cheaper, support for
wider temperature range etc.
Following are the disadvantages of temperature sensor (thermocouple):
Non linearity, least stability, Low voltage, Reference is needed, least sensitivity etc.

References:
 https://www.thermocoupleinfo.com/
 https://www.brighthubengineering.com/manufacturing-technology/53682-what-is-a-thermocouple-how-
thermocouple-works/
 https://instrumentationtools.com/thermocouple-construction/
 http://www.rfwireless-world.com/Terminology/Advantages-and-Disadvantages-of-temperature-Sensor.html
Pyrometer

A Pyrometer, or radiation thermometer, is a non-

contact instrument that detects an object's surface
temperature by measuring the temperature of
the electromagnetic radiation (infrared or visible)
emitted from the object.

The wavelength of thermal radiation ranges from 0.1 to

100 µm (4 ~ 4,000 µin), i.e., from the deep ultraviolet
(UV) across the visible spectrum to the middle of the Figure 1: Typical Broadband Pyrometer
infrared region (IR).

Figure 2: The Electromagnetic Radiation Spectrum

Pyrometers are essentially photodetectors which are capable of absorbing energy, or measuring the
EM wave intensity, at a particular wavelength or within a certain range of wavelengths.

Common pyrometers include:

• Optical Pyrometer (a.k.a. Brightness Pyrometer or Disappearing Filament Pyrometer)

- Designed for thermal radiation in the visible spectrum.

- Utilizes a visual comparison between a calibrated light source and the targeted surface. When
the filament and the target have the same temperature, their thermal radiation intensity will
 match causing the filament to disappear as it blends into the targeted surface in the
background.

- When the filament disappears, the current passing through the filament can be converted into a
temperature reading.

• Infrared Pyrometer

- Designed for thermal radiation in the infrared region (0.75 ~ 1000 µm; 30 µin ~ 0.04 in)
usually 2 ~ 14 µm (80 ~ 550 µin)

- Constructed from pyroelectric materials, e.g., triglisine sulfate (TGS), lithium tantalate
(LiTaO3), or polyvinylidene fluoride (PVDF).

- Similar to the charge generated by stressed piezoelectric materials, a pyroelectric charge

dissipates in time. Hence, a rotating shutter is required to interrupt the incoming radiation to
obtain a stable output.

Optical Pyrometer

Definition: The optical pyrometer is a non-contact type temperature measuring device. It works on
the principle of matching the brightness of an object to the brightness of the filament which is placed
inside the pyrometer. The optical pyrometer is used for measuring the temperature of the furnaces,
molten metals, and other overheated material or liquids.

It is not possible to measures the temperature of the highly heated body with the help of the contact
type instrument. Hence the non-contact pyrometer is used for measuring their temperature.

Construction of Optical Pyrometer

The construction of the optical pyrometer is

quite simple. The pyrometer is cylindrical
inside which the lens is placed on one end
and the eyepiece on the other end. The lamp
is kept between the eyepiece and the lens.
The filter is placed in front of the eyepiece.
The filter helps in getting the monochromatic
light. The lamp has the filament which is
connected to the battery, ammeter and the
rheostat.
 Working of Optical Pyrometer

The optical pyrometer is shown in the figure below. It consists the lens which
focuses the radiated energy from the heated object and targets it on the electric
filament lamp. The intensity of the filament depends on the current passes
through it. Hence the adjustable current is passed through the lamp.

The magnitude of the current is adjusted until the brightness of the filament is
similar to the brightness of the object. When the brightness of the filament and
the brightness of the object are same, then the outline of the filament is
completely disappeared.

The filament looks bright when their temperature is more than the temperature of
the source.

The filament looks dark if their temperature is less than that required for equal
brightness

Advantages of Optical Pyrometer

 The optical pyrometer has high accuracy.

 The temperature is measured without contacting the heated body. Because of this property, the
pyrometer is used for the number of applications.

Disadvantages of Optical Pyrometer

The working of the pyrometer depends on the intensity of light emitted by the heated body. Thereby,
the pyrometer is used for measuring the temperature having a temperature more than 700-degree
Celsius. The accuracy of the pyrometer depends on the adjustment of the filament current. Also, the
pyrometer is not used for measuring the temperature of clean gases.

References:

 https://www.efunda.com/DesignStandards/sensors/pyrometers/pyrometers_intro.cfm
 https://circuitglobe.com/optical-pyrometer.html