Thermocouple is one of the most commonly used temperature detection elements in

industry. The working principle of thermocouple is based on seeback effect,

that is, two ends of conductors with different components are connected into a
circuit. If the temperature of two connecting ends is different, thermal
current will be generated in the circuit.The advantages are: ① high
measurement accuracy.Because the thermocouple is in direct contact with the
object to be measured, it is not affected by the intermediate medium.② The
measurement range is wide.Common thermocouples can be continuously measured
from - 50 ℃ to - 1600 ℃. Some special thermocouples can be measured from -
269 ℃ (such as gold, iron, nickel, chromium) to + 2800 ℃ (such as tungsten
rhenium).③ Simple structure and convenient use.Thermocouples are usually
composed of two different kinds of metal wires, and they are not limited by the
size and the beginning. There is a protective sleeve outside, which is very
convenient to use.1. The basic principle of thermocouple temperature
measurement is to weld the conductors or semiconductors A and B of two
different materials to form a closed circuit, as shown in the figure.When there
is a temperature difference between two rigid points 1 and 2 of conductors A
and B, electromotive force will be generated between them, thus forming a large
and small current in the circuit. This phenomenon is called thermoelectric
effect.Thermocouples use this effect to work.Commonly used thermocouple
materials are: thermocouple graduation thermoelectric pole material positive
electrode s Platinum Rhodium 10 pure platinum r platinum rhodium 13 pure
platinum B platinum rhodium 30 platinum rhodium 6 K nickel chromium nickel
silicon t pure copper copper nickel J iron copper nickel n nickel chromium
silicon nickel e nickel chromium copper nickel 2. Types and structure formation
of thermocouples(1) The types of thermocouples commonly used can be divided
into standard thermocouple and non-standard thermocouple.The standard
thermocouple refers to the thermocouple whose relationship between thermal
potential and temperature, allowable error and unified standard graduation
table are specified in the national standard. It has its supporting display
instrument for selection.The non-standard thermocouple is not as good as the
standard thermocouple in the scope of use or order of magnitude, and generally
there is no unified scale, which is mainly used in some special occasions.Since
January 1, 1988, all thermocouples and thermal resistances in China have been
produced in accordance with IEC international standards, and seven kinds of
standardized thermocouples (s, B, e, K, R, J, t) have been designated as
unified design thermocouples in China.(2) In order to ensure the reliable and
stable operation of the thermocouple, the structural requirements of the
thermocouple are as follows: ① the welding of the two thermoelectric poles
that make up the thermocouple must be firm; ② the two thermoelectric poles
should be well insulated from each other to prevent short circuit; ③ the
connection between the compensation wire and the free end of the thermocouple
should be convenient and reliable;④ The protective sleeve shall be able to
ensure that the thermoelectric pole is fully isolated from the harmful
medium.3. The temperature compensation of the cold end of the thermocouple is
generally expensive (especially when the precious metal is used), and the
distance from the temperature measuring point to the instrument is far. In
order to save the thermocouple material and reduce the cost, the compensation
wire is usually used to extend the cold end (free end) of the thermocouple to
the control room with relatively stable temperature and connect it to the
instrument terminal.It must be pointed out that the function of thermocouple
compensation wire is only to extend the thermoelectric pole and move the cold
end of thermocouple to the instrument terminal in the control room. It can not
eliminate the influence of the cold end temperature change on the temperature
measurement, and it does not play a compensation role.Therefore, it is
necessary to use other correction methods to compensate for the influence of
cold end temperature t0 ≠ 0 ℃.When using thermocouple compensation wire, the
model must be matched, the polarity cannot be connected wrongly, and the
temperature between compensation wire and thermocouple connection end cannot
exceed 100 ℃.
 
Cold junction compensation principle of thermocouple http://www.tiankangcable.com
When measuring the temperature of a thermocouple, the temperature of its cold end (the measuring end is
the hot end, and the end connected with the measuring circuit through the lead wire is called the cold
end) is required to remain unchanged, and its thermal potential is proportional to the measured
temperature.If the temperature of cold end (environment) changes during measurement, it will affect the
accuracy of measurement seriously.It is called the cold junction compensation of thermocouple to take
some measures to compensate the influence caused by the change of cold junction temperature.The cold
junction compensation of thermocouples usually uses a thermal resistance bridge connected in series at
the cold junction.The three arms of the bridge are standard resistors, and the other arm is made of
(copper) thermistor.When the cold end temperature changes (for example, increases), the thermoelectric
potential generated by the thermocouple will also change (decrease), and the thermoelectric resistance
value in the series bridge will also change and the voltage at both ends of the bridge will also change
(increase).If the parameters are selected well and the wiring is correct, the voltage generated by the
bridge is exactly equal to the amount of thermoelectric potential changing with the change of
temperature, and the total output voltage (potential) of the whole thermocouple measuring circuit
exactly reflects the measured temperature value.This is the cold junction compensation principle of
thermocouple.
 
 
 
 
 
 
 
Thermocouple thermometer is the most widely used thermometer at present. Thermocouple
thermometer is a kind of temperature electrical measuring instrument. It usually consists of
three parts: thermocouple, thermocouple cold end temperature compensation device (or
element) and display instrument. The three parts are connected by wires.
Principle of thermocouple temperature measurement
Thermocouples are formed by welding one end of two different conductors or semiconductor
linear materials a and B. A and B are called thermoelectric poles (or thermocouple
wires).The welded end is placed at the temperature T to be measured, which is called the hot
end (or measuring end, working end) of the thermocouple; the non welded end is called the
cold end (or reference end, free end), and the cold end is placed in the environment with
the temperature t0 outside the tested object.
If the two cold ends of the thermocouple are also connected to form a closed circuit, as
shown in Figure 2-1, when the temperature of the hot end and the temperature of the cold end
are not equal, i.e. t ≠ to, there is current flowing through the circuit, which means that
the electromotive force is generated in the circuit. The electromotive force generated due
to the temperature difference between the two contacts of the thermocouple is called
thermoelectric (dynamic) force, and the above-mentioned theory is called thermoelectric
effect, orCalled the Seebeck effect.Thermocouple is to use thermoelectric effect to measure
temperature.Further study shows that thermoelectric potential is composed of contact
potential and thermoelectric.
 

 
1.Contact potential
When two kinds of homogeneous conductors A and B contact, due to the different density of
free electrons in a and B (set free electron density Na > NB), conductor a will diffuse free
electrons to conductor B through the contact, then a loses electrons, and B accumulates
electrons, so that potential difference is generated on both sides of the contact, and the
electrostatic field E is established, as shown in Figure 2-2, the left side of electrostatic
field E will prevent free electrons from continuing to diffuse.When the interaction of
diffusion force and electric field force is balanced.The diffusion of electrons stops
relatively, and the potential is finally generated between two sides of the contact. This
potential is called contact potential, which is represented by the symbol EAB (T), where t
is the temperature of the contact. The contact potential is related to the temperature of
the contact surface and the properties of the two conductors. The direction is shown in
Figure 2-2, from the electrode with small electronic density to the electrode with large
electronic density http://www.tksiliconerubbercable.com.

 
 
2.Thermoelectric potential
Because the free electron density of conductor will increase with the increase of
temperature, when the temperature of both ends of the same conductor is different (as shown
in Figure 2-3), the free electron density of the end with high temperature will be higher
than that of the end with low temperature, so there will be a similar spontaneous electron
diffusion process in contact potential between the two ends, and finally a potential
difference will be generated between the two ends of conductor to establish the potentialThe
potential is called thermoelectric potential, which is expressed by the symbol EA (T, to).
Its size is related to the temperature T, to and conductor properties at both ends of the
conductor, as shown in Figure 2-3, from the low temperature end to the high temperature
end.For the convenience of analysis, the thermoelectric potential is sometimes written in
the form of EA (T, to) = EA (T) - EA (to).

 
 
3.Thermal potential
To sum up, in the thermocouple circuit shown in Figure 2-1, when t > T0, Na > Nb, two
contact potentials (T) and EAB (to), two temperature difference potentials (T, to) and EB
(T, to) will be generated in the circuit.The direction of each potential is shown in the
figure.
At this time, the total potential of the loop, i.e. the thermal potential EAB (T, to), is
the algebraic sum of these contact potentials and the thermoelectric potential, i.e
EAB(t，to)= eAB(t) - eA(，to) - eAB(to) + eB(t，to)
　　　　= eAB(t)-[eA(t) - eA(to)] - eAB(to) + [eB(t) - eB(to)]
　　　　= [eAB(t) - eA(t) + eB(t)] - [eAB(tO) - eA(to) + eB(to)]
　　　　= fAB(t) – fAB(to)
Because the thermoelectric potential is smaller than the contact potential and T > to, the
contact potential EAB (T, to) accounts for the largest percentage in the total potential EAB
(T, to). Therefore, the direction of the total potential EAB (T, to) depends on the
direction of EAB (T).Because of the high electron density of a, a is the positive electrode
and B is the negative electrode. In the positive hot electrode, the direction of the
potential is from the hot end to the cold end.
The above formula shows that when the materials of the two thermoelectric poles are
selected, the thermoelectric potential is the difference between the two functions related
to the contact temperature respectively.If the cold end temperature to remains the same,
then FAB (to) = C (constant), then EAB (T, to) = FAB (T) - C, the thermoelectric potential
and the hot end temperature t have a one-to-one correspondence.Therefore, when the
thermoelectric potential EAB (T, to) is measured, the value of the measured temperature T
can be determined, which is the principle of thermocouple temperature measurement.
For the convenience of use, the corresponding relationship between the hot end temperature
and the thermoelectric potential of the standardized thermocouple can be found in the
function table.This kind of function table is made by experiment under the condition of cold
end temperature of 0 ℃, which is called thermocouple graduation table.The thermocouple
scale can be used to express the thermoelectric characteristics of thermocouples.See table
1-5 for the graduation table of several common thermocouples.It should be noted that when to
is not equal to 0 ℃, the index table cannot be used to directly check the value of EAB (T,
to) or EAB (T, to)
 
Attached table 1: graduation table of Pt Rh 10 Pt thermocouple (graduation s; reference end
temperature 0 ℃; MV)
Attached table 2: platinum rhodium 13 platinum thermocouple graduation table (graduation R;
reference end temperature 0 ℃; MV)

Attached table 3: Pt Rh 30-pt RH 6 thermocouple graduation table (graduation B; cold end

temperature 0 ℃; MV)
Attached table 4: graduation table of Ni Cr Ni Si thermocouple (graduation number is K; cold
end temperature is 0 ℃; MV)

Attached table 5: graduation table of Ni Cr Cu Ni (Constantan) thermocouple (graduation No.

E; cold end temperature 0 ℃; MV)
 
 
 
 
 
 
 
 
 
(S-type thermocouple) Platinum Rhodium 10 platinum thermocouple Platinum Rhodium 10 platinum
thermocouple (S-type thermocouple) is a precious metal thermocouple.The diameter of the
coupling wire is specified as 0.5mm, and the allowable deviation is - 0.015mm. The nominal
chemical composition of the positive electrode (SP) is platinum rhodium alloy, including 10%
rhodium, 90% platinum, and the negative electrode (SN) is pure platinum, so it is commonly
known as single platinum rhodium thermocouple.The maximum operating temperature of the
thermocouple is 1300 ℃ in the long term and 1600 ℃ in the short term.S-type thermocouples
have the advantages of the highest accuracy, the best stability, wide temperature
measurement range and long service life.It has good physical and chemical properties,
thermoelectric stability and oxidation resistance at high temperature. It is suitable for
oxidation and inert atmosphere.As S-type thermocouple has excellent comprehensive
performance and conforms to the international temperature standard, it has been used as the
interpolation instrument of international temperature standard for a long time. "ITS-90"
stipulates that it will not be used as the internal inspection instrument of international
temperature standard in the future, but the international temperature Advisory Committee
(CCT) recognizes that S-type thermocouple can still be used to approximate the international
temperature standard.The disadvantages of S-type thermocouples are thermal potential, small
thermoelectric potential rate, low sensitive reading, low mechanical strength at high
temperature, very sensitive to pollution, expensive precious metal materials, so a large
one-time investment.(R type thermocouple) platinum rhodium 13 platinum thermocouple platinum
rhodium 13 platinum thermocouple (R type thermocouple) is a precious metal thermocouple.The
diameter of the coupling wire is 0.5mm and the allowable deviation is - 0.015mm. The nominal
chemical composition of the positive electrode (RP) is platinum rhodium alloy, including 13%
rhodium, 87% platinum, and the negative electrode (RN) is pure platinum. The maximum long-
term service temperature is 1300 ℃ and the maximum short-term service temperature is 1600
℃.The R-type thermocouple has the advantages of the highest accuracy, the best stability,
the wide temperature range and the long service life.It has good physical and chemical
properties, thermoelectric potential stability and oxidation resistance at high temperature.
It is suitable for oxidation and inert atmosphere.As the comprehensive performance of R-type
thermocouple is similar to that of S-type thermocouple, it is difficult to popularize in
China. Except for the application of temperature measurement on imported equipment, it is
rarely used in China.From 1967 to 1971, NPL in the UK, NBS in the US and NRC in Canada
carried out a cooperative study. The results show that the stability and reproducibility of
R-type thermocouple are better than that of S-type thermocouple. At present, no research has
been carried out in China.The disadvantages of R-type thermocouple are thermal potential,
small thermoelectric potential rate, low sensitive reading, low mechanical strength at high
temperature, very sensitive to pollution, expensive precious metal materials, so a large
one-time investment.(type B thermocouple) platinum rhodium 30 - platinum rhodium 6
thermocouple platinum rhodium 30 - platinum rhodium 6 thermocouple (type B thermocouple) is
precious metal thermocouple.The diameter of the coupling wire is specified as 0.5mm, and the
allowable deviation is - 0.015mm. The nominal chemical composition of its positive electrode
(BP) is platinum rhodium alloy, including 30% rhodium, 70% platinum, and the negative
electrode (BN) is platinum rhodium alloy, containing 6% rhodium. Therefore, it is commonly
known as double platinum rhodium thermocouple.The maximum operating temperature of the
thermocouple is 1600 ℃ in the long term and 1800 ℃ in the short term.B-type thermocouple
has the advantages of the highest accuracy, the best stability, wide temperature measurement
range, long service life, high temperature upper limit, etc.It can be used in oxidizing and
inert atmosphere, or in vacuum for a short time, but not in reducing atmosphere or
atmosphere containing metal or non-metal vapor.An obvious advantage of B-type thermocouple
is that it does not need compensation wire, because the thermal potential is less than 3 μ
V in the range of 0 ~ 50 ℃.The disadvantages of B-type thermocouple are thermal potential,
small thermoelectric potential rate, low sensitive reading, low mechanical strength at high
temperature, very sensitive to pollution, expensive precious metal materials, so a large
one-time investment.(K-type thermocouple) Ni Cr Ni Si thermocouple Ni Cr Ni Si thermocouple
(K-type thermocouple) is the most widely used low-cost metal thermocouple at present, and
its consumption is the sum of other thermocouples.The nominal chemical composition of the
positive electrode (KP) is Ni: Cr = 90:10, the nominal chemical composition of the negative
electrode (KN) is Ni: Si = 97:3, and the service temperature is - 200 ~ 1300 ℃.K-type
thermocouple has the advantages of good linearity, large thermoelectric potential, high
sensitivity, good stability and uniformity, strong oxidation resistance, low price, etc. it
can be used in the oxidizing inert atmosphere.Widely used by users.K-type thermocouple can
not be directly used in the atmosphere of sulfur, reducibility or reduction, oxidation
alternation and vacuum at high temperature, nor is it recommended to be used in the
atmosphere of weak oxidation.(n-type thermocouple) Ni Cr Si Ni Si thermocoupleNi Cr Si Ni Si
thermocouples (n-type thermocouples) are low-cost metal thermocouples. They are the latest
internationally standardized thermocouples. They were developed by the laboratory of the
Australian Ministry of defense in the early 1970s. They overcome two important shortcomings
of K-type thermocouples: the instability of thermoelectric potential caused by the short-
range ordering of Ni Cr alloy lattice in the range of 300-500 ℃; the instability of
thermoelectric potential caused by the short-range ordering of Ni Cr alloy lattice in the
range of 800 ℃Thermoelectric potential instability caused by preferential oxidation of Ni
Cr alloy.The nominal chemical composition of the positive electrode (NP) is Ni: Cr: Si =
84.4:14.2:1.4, the nominal chemical composition of the negative electrode (NN) is Ni: Si: Mg
= 95.5:4.4:0.1, and the service temperature is - 200 ~ 1300 ℃.The n-type thermocouple has
the advantages of good linearity, large thermoelectric potential, high sensitivity, good
stability and uniformity, strong oxidation resistance, low price, not affected by short-
range ordering, and its comprehensive performance is better than the K-type thermocouple,N-
type thermocouple can not be directly used in the atmosphere of sulfur, reducibility or
reduction, oxidation alternation and vacuum, nor in the atmosphere of weak oxidation.(E-type
thermocouple) nichrome copper nickel thermocouple (E-type thermocouple), also known as
nichrome constantan thermocouple, is also a kind of low-cost metal thermocouple. The
positive electrode (EP) is: nichrome 10 alloy, the chemical composition is the same as KP,
the negative electrode (EN) is copper nickel alloy, the nominal composition is: 55% copper,
45% nickel and a small amount of manganese, cobalt, iron and other elements.The temperature
of the thermocouple is - 200 ~ 900 ℃.The thermoelectric force and sensitivity of e-type
thermocouple are the highest among all thermocouples. It is suitable to make thermopile to
measure small temperature change.It is not sensitive to the corrosion of high humidity
atmosphere, so it is suitable for the environment with high humidity.E thermocouple also has
the advantages of good stability, better oxidation resistance than copper constantan, iron
constantan thermocouple, low price, etc., which can be used in oxidizing and inert
atmosphere and widely used by users.E-type thermocouple can not be directly used in sulfur
at high temperature, reducing atmosphere, thermal potential uniformity is poor.(J-type
thermocouple) Fe Cu Ni thermocouple (J-type thermocouple), also known as fe-constantan
thermocouple, is also a cheap low-cost low-metal thermocouple.The nominal chemical
composition of its positive electrode (JP) is pure iron, and its negative electrode (JN) is
copper nickel alloy, which is often vaguely called constantan. Its nominal chemical
composition is 55% copper and 45% nickel, as well as a small amount of very important
elements such as manganese, cobalt and iron. Although it is called constantan, it is
different from that of nickel chromium constantan and copper constantan, so it cannot be
replaced by en and TN.The temperature range of iron constantan thermocouple is - 200 ~ 1200
℃, but the commonly used temperature range is 0 ~ 750 ℃.J-type thermocouples can be used
in vacuum, oxidation, reduction and inert atmosphere, but the positive iron oxidizes faster
at high temperature, so the use temperature is limited, and it can not be directly used in
sulfurization atmosphere at high temperature without protection.(T-type thermocouple) copper
copper copper nickel thermocouple copper nickel thermocouple (T-type thermocouple) is also
known as copper constantan thermocouple, which is also the best low-temperature low-cost
metal thermocouple.Its positive electrode (TP) is pure copper, its negative electrode (TN)
is copper nickel alloy, often constantan. It is common with constantan en of nichrome
constantan, but not with constantan jn of iron constantan. Although they are all called
constantan, the measuring temperature range of the cover of copper copper nickel
 thermocouple is - 200 ~ 350 ℃.T-type thermocouple has the advantages of good linearity,
large thermoelectric potential, high sensitivity, good stability and uniformity, low price,
etc., especially in the temperature range of - 200 ~ 0 ℃, better stability, annual
stability can be less than ± 3 μ V, which can be used as the second-class standard for
low-temperature value transfer after low-temperature verification.The oxidation resistance
of positive copper of T-type thermocouple is poor at high temperature, so the upper limit of
use temperature is limited.
 
 
 

The basic knowledge of thermocouples - the causes of common faults

of thermocouples and their solutions
　
4、 Causes of common faults of thermocouples and Solutions
See table 4-1 for common fault causes and treatment methods of thermocouples
Table 4-1 common fault causes and treatment methods of thermocouples

Fault phenomenon Possible reasons processing method

The thermoelectric Find out the cause of short

potential is smaller circuit. If it is caused by
than the actual value Thermoelectric short circuit humidity, dry it; if it is
(the indicated value caused by insulator damage,
of the display replace the insulator
instrument is lower)
Dust accumulated at the terminal of
Ash cleaning
thermocouple, causing short circuit

Find out the short circuit

Short circuit between compensating wires point, strengthen the insulation
or replace the compensation wire

If the length allows, cut out

Thermocouple thermal electrode the metamorphic section and weld
deterioration again, or replace the
thermocouple with a new one

Compensation conductor and thermal dipole

Reconnect correctly
connected reversely

Compensation wire is not matched with Replace the matching

thermocouple compensation lead

The installation position of thermocouple Re install as required

is not recorded or the insertion depth
does not meet the requirements
 Temperature compensation of thermocouple
Adjust the cold end compensator
cold end does not meet the requirements

Thermocouple is not matched with display More thermocouple or display

instrument instrument to match

The thermoelectric Thermocouple is not matched with display More thermocouple or display
potential is larger instrument instrument to match
than the actual value
Compensation wire is not matched with Replace the compensation lead to
(the indicated value
thermocouple match
of the display
instrument is higher) There is DC interference signal entering Eliminate DC interference

Poor contact between thermocouple

Tighten the terminal screws
terminal and thermoelectric pole

The insulation of thermocouple measuring

Find out the fault point and
line is damaged, causing intermittent
repair the insulation
short circuit or grounding
Unstable
thermoelectric Fasten thermocouple, eliminate
Thermocouple installation is not firm or
potential output vibration or take shock
external vibration
absorption measures

The thermoelectric pole will not break Repair or replace thermocouple

External interference (AC leakage, Find out the interference source

electromagnetic induction, etc.) and take shielding measures

Thermoelectric pole metamorphism Replace the hot electrode

Thermal potential
Improper installation position of
error of thermocouple Change installation position
thermocouple
is large
Surface area of protective pipe grey Ash removal

  

Correct use of thermocouples

Xue Fu Lian

The correct use of thermocouples can not only accurately get the temperature value, ensure the
product is qualified, but also save the material consumption of thermocouples, save money and ensure
the product quality.Incorrect installation, thermal conductivity and time lag are the main errors of
thermocouple in use.

1. Error caused by improper installation

For example, the installation position and insertion depth of thermocouples cannot reflect the
real temperature of furnace, in other words, thermocouples should not be installed too close to doors
and heating places, and the insertion depth should be at least 8-10 times of the diameter of the
protective tube; the gap between the protective sleeve and the wall of thermocouples is not filled
with insulation material, which causes the hot overflow or cold air intrusion in the furnace, so the
thermocouple protective tube and the wall holeThe gap between them shall be blocked with insulating
materials such as fire-resistant mud or asbestos rope to avoid the influence of cold and hot air
convection on the accuracy of temperature measurement; the cold end of thermocouple shall be too
close to the furnace body to make the temperature exceed 100 ℃; the installation of thermocouple
shall avoid strong magnetic field and strong electric field as far as possible, so the thermocouple
and power cable shall not be installed in the same conduit to avoid interference and error;
thermocouple cannot be installedIn the area where the measured medium rarely flows, when measuring
the gas temperature in the tube with thermocouple, the thermocouple must be installed against the
flow direction and fully contacted with the gas.

2. Error caused by insulation variation

For example, if the thermocouple is insulated, the dirt or salt slag between the protective tube
and the stay wire plate are too much, resulting in poor insulation between the thermal dipole and the
furnace wall, which is more serious under high temperature. This will not only cause the loss of the
thermal potential, but also introduce interference, resulting in errors sometimes up to Baidu.

3. Error introduced by thermal inertia

Because of the thermal inertia of the thermocouple, the indicating value of the instrument lags
behind the change of the measured temperature, especially in the rapid measurement.Therefore,
thermocouples with thin thermoelectric pole and small diameter of protective tube should be used as
far as possible.When the temperature measurement environment permits, the protective pipe can even be
taken away.Because of the measurement lag, the amplitude of temperature fluctuation detected by
thermocouple is smaller than that of furnace temperature fluctuation.The larger the measurement lag
is, the smaller the amplitude of thermocouple fluctuation is, and the greater the difference with the
actual furnace temperature is.When a thermocouple with a large time constant is used to measure or
control the temperature, although the temperature displayed by the instrument fluctuates very little,
the actual furnace temperature may fluctuate a lot.In order to measure temperature accurately,
thermocouple with small time constant should be selected.The time constant is inversely proportional
to the heat transfer coefficient and directly proportional to the diameter of the hot end of the
thermocouple, the density of the material and the specific heat. To reduce the time constant, in
addition to increasing the heat transfer coefficient, the most effective way is to minimize the size
of the hot end.In use, the protective casing with thin wall and small inner diameter is usually made
of materials with good thermal conductivity.In the more precise temperature measurement, the bare
wire thermocouple without protective sleeve is used, but the thermocouple is easy to be damaged, so
it should be corrected and replaced in time.

4. Thermal resistance error

In case of high temperature, if there is a layer of coal ash on the protective tube and dust is
attached to it, the thermal resistance will increase and block the heat conduction. At this time, the
temperature indication is lower than the true value of the measured temperature.Therefore, the
outside of the thermocouple protection tube should be kept clean to reduce the error.

 
 

Remember not to connect the thermocouple compensation wire reversely

Li Qiang (Longkou metrological verification and Measurement Institute)

All the comrades who are engaged in temperature measurement know the working principle of
thermocouples - two different conductors form a closed circuit. When the temperature at both ends of
the circuit is equal, the thermoelectric potential of the circuit is zero.When the temperature of the
working end and the overstock end of the thermocouple is not equal, the heat generated in the rebel
loop is potential.The thermoelectric potential is related to the temperature difference between the
two ends.The free end temperature of the thermocouple is not a constant value.All manufacturers use
thermocouple special wire compensation wire.By extending the thermocouple to a constant temperature,
the thermoelectric potential of the thermocouple is compensated.

In the process of daily inspection, many electricians do not know the function of compensation wire,
only know that compensation wire is the special wire connecting thermocouple and instrument.It is
wrong to connect the compensation wire with thermocouple and instrument at will, which will cause
great error.Take a machining factory in our city as an example. At that time, the process of
workpiece required 920 ℃.The operator also set the value according to the process requirements, and
the instrument indication is normal.After the liquid fire, the workpiece appears striation, which
makes a furnace of workpiece scrapped.In the analysis of the accident, it is found that the
compensation wire is connected reversely. After correction, the temperature in the furnace is 973
℃.At that time, the free end temperature of the mass transformer couple was 45 ℃, and the indoor
temperature was 18 ℃.The temperature error caused by reverse connection is as follows:

=1.817mV =0.718mV

Equivalent to 53.13 ℃.The above example shows that the

thermocouple compensation wire can cause considerable temperature error after being connected
reversely.Therefore, do not connect the compensation wire in reverse.
 

 
 
 
 
 
1. Principle of thermocouple temperature measurement

   Two conductors (or semiconductors) of different materials form a closed

circuit. When the temperature of two contacts is different from 0,

electromotive force will be generated in the circuit. This phenomenon is called

thermoelectric effect, and the electromotive force is called thermoelectric

potential.The combination of conductors or semiconductors of these two

different materials is called thermocouple, and conductors A and B are called

thermoelectric poles.Two contacts, one is called hot end, also known as

measuring end or working end. When measuring temperature, it is placed in the

measured medium; the other is called cold end, also known as reference end or

free end, which is connected with display instrument through wire.TT

Contact potential is the electromotive force formed at the contact due to the

different free electron density of two different conductors.When two kinds of

conductors contact, the free electron diffuses from the conductor with high density

to the conductor with low density, and one side of the free electron loses positive

charge at the contact, and the other side of the free electron has negative charge.

When the diffusion reaches dynamic balance, a stable contact potential is formed at

both sides of the contact surface.The value of contact potential depends on the

properties of two different conductors and the temperature of the contact point.The

contact potentials AB (T) and ab (0) of the two contacts can be expressed asEET

Where: K - Boltzmann constant;  - electric quantity per unit charge; NAT, and

at0, BT0 - electronic density of the two materials when the temperature is and 0,

respectively.ENBTNNTTA, B

 
Thermoelectric potential is a kind of electromotive force produced by the

difference of temperature between two ends of the same conductor.When the

temperature at both ends of the same conductor is different, the electronic energy

at the high temperature end is greater than that at the low temperature end, so the

number of electrons from the high temperature end to the low temperature end is

more than that from the low temperature end to the high temperature end. As a

result, the high temperature end is positively charged due to the loss of

electrons, and the low temperature end is negatively charged due to the gain of
redundant electrons. Therefore, the contact potential is formed at both ends of the

conductor, and its size is determined by the following factorsThe formula is:

Where, NAT and are the electronic density of conductor and conductor respectively,

which are functions of temperature.NBtAB

The total thermal potential generated in the thermocouple loop is

EAB(T, T0)=eAB(T)+eB(T,T0)-eAB(T0)-eA(T,T0)

In the total thermal potential, the thermoelectric potential of the

thermocouple is much smaller than that of the contact potential, which can be

ignored. Then the thermoelectric potential of the thermocouple can be expressed

as: (T, t0) = EAB (T) - EAB (T0)EAB

For the selected thermocouple, when the reference terminal temperature is

0 constant, (t0 = C) is constant, then the total thermoelectric EMF is only a

function of temperature, that is, (T, t0 = EAB (T) - C = f (T)TEABTEAB

This relation is very useful in practical measurement, that is, as long as the

magnitude of (, t0) is measured, the measured temperature can be obtained, which is

the principle of using thermocouple to measure temperature.EABTT

2、 Basic law of thermocouple

1Law of homogeneous Conductor: The thermoelectric EMF of a thermocouple

composed of two kinds of homogeneous conductors is only related to the

temperature of two materials and two contacts, but not to the size, shape and

temperature distribution along the electrode.That is, if the material is not

uniform, when there is a temperature gradient on the conductor, there will be

additional electromotive force.This theorem shows that thermocouples must be

composed of two homogeneous materials with different properties.Inside

2, law of intermediate conductor:When using thermocouple to measure

temperature, it is necessary to introduce connecting wires and instruments into

the circuit. Will the connecting wires and instruments affect the

thermoelectric potential in the circuit?The law of intermediate conductor

states that when the third conductor is connected in the thermocouple

temperature measuring circuit, as long as the temperature at both ends of the

third conductor is the same, there is no effect on the total thermal potential

of the circuit.

3, law of intermediate temperatureIn the thermocouple temperature measuring

circuit, C is the temperature of a certain point on the thermoelectric pole.

The thermoelectric potential (T, t0) of the thermocouple at the contact

temperature of 0 is equal to the algebraic sum of the thermoelectric potential

(T, TC) and (T, t0) of the thermocouple at the contact temperature of C and 0,

that is, EAB (T, t0) = EAB (T, TC) + EAB (TC, t0)TABT, tEABABT, tTCTEABEAB

This law is the theoretical basis of the reference terminal temperature

calculation correction method. In the actual thermocouple temperature measuring

circuit, the thermoelectric potential with the reference terminal temperature not 0

℃ can be corrected by using the thermocouple property.

3、 Structure of thermocouple

In order to meet the temperature measurement requirements and conditions

of different production objects, the structure of thermocouples includes common

type thermocouple, armored type thermocouple and thin film thermocouple.Inside

1. ordinary thermocouple: the common structure thermocouple is the most widely

used in the industry. It is generally composed of thermal electrode, insulating

sleeve, protective tube and junction box.Common thermocouple can be divided

into fixed thread connection, fixed flange connection, movable flange

connection, no fixed device and other forms according to the connection form

when it is installed.

2Armored thermocouple: armored thermocouple is also called thermowell.It is a

solid combination of thermocouple wire, insulating material and metal sleeve.

The main advantages of armored thermocouple are small thermal capacity, fast

dynamic response, high mechanical strength and good flexibility. It can be

installed on the device with complex structure, so it is widely used in many

industrial sectors.
3Membrane thermocoupleThin film thermocouple is a kind of special thermocouple

made of two kinds of thin film thermoelectric materials, which are evaporated

to the insulating substrate by vacuum plating and chemical coating,The thermal

contact of thin film thermocouple can be made very small (can be thin to 0.01-

0.1 μ m), has the characteristics of small thermal capacity, fast reaction

speed and so on. The thermal response time reaches the microsecond level, which

is suitable for the surface temperature of small area and the dynamic

temperature measurement with rapid change.

4、 Compensation wire of thermocouple and compensation method of cold end

temperature

When the thermocouple material is selected, the thermoelectric EMF is only

related to the temperature of the hot end and the cold end.Therefore, only when

the cold end temperature is constant, the thermoelectric potential of the

thermocouple has a single value function relationship with the hot end

temperature.The graduation table of thermocouple is based on the cold end

temperature of 0 ℃, but in the actual use process, the cold end temperature is

often not 0 ℃, so the cold end temperature must be treated to eliminate the

influence of cold end temperature.

Then, when the hot end temperature is, the relationship between the

thermoelectric potential (T, 0) corresponding to the graduation table and the

thermoelectric potential (T, t0) actually generated by the thermocouple can be

obtained according to the intermediate temperature law as follows: (T, 0) = EAB (T,

t0) + EAB (T0, 0)TEABEABEAB

It can be seen that (T0, 0) is a function of cold junction temperature 0, so

it is necessary to treat the cold junction temperature of thermocouple.EABT

1. thermocouple compensation wire: In the actual temperature measurement, it is

necessary to transmit the potential signal output by the thermocouple to the

display instrument or control instrument in the control room tens of meters

away from the site, so that the cold end temperature 0 is relatively

stable.Thermocouples are generally made short, generally 350-2000mm, and wires

are needed to extend the cold end of the thermocouple.In the project, a kind of

compensation wire is used, which is usually made of two kinds of cheap metal

wires with different properties. In the temperature range of 0-100 ℃, the

compensation wire and the matched thermocouple are required to have the same

thermoelectric characteristics.T

2. cold end temperature correction method: The cold end of the thermocouple can

be extended to the place where the temperature is relatively stable by using

the compensation wire, but as long as the cold end temperature 0 is not equal

to 0 ℃, the measured potential value (0) of the thermocouple loop needs to be

corrected.When the working end temperature is, the relationship between the

thermoelectric potential (T, 0) corresponding to the graduation table and the

thermoelectric potential (T, t0) actually generated by the thermocouple can be

obtained according to the intermediate temperature law as follows: (T, 0) = EAB

(T, t0) + EAB (T0, 0)TEABTTTEABEABEAB

It can be seen that the corrected value of the measured potential value

(T, t0) is (T0, 0).(T0, 0) is a function of the reference end temperature 0,

the corrected thermoelectric potential is (, 0), and the actual temperature

value to be measured can be found out from the graduation table.In the

worldEABEABEABTEABTT

For example, a nichrome nickel silicon thermocouple is used to measure the

furnace temperature.It is known that the cold end temperature is 0 = 30 ℃, and the

measured thermal potential (0) is 33.29mv, and the temperature of the heating

furnace is calculated.TEABT,T

solution(30,0) 1.203 MV was obtained by checking the graduation table of

Ni Cr Ni Si thermocouple.According to equation (15-13), EAB (, 0) = EAB (T, t0)

+ EAB (T0, 0) = 33.29 + 1.203 = 34.493mv, and from the graduation table of Ni

Cr Ni Si thermocouple = 829.5 ℃.EABTT

3Cold end 0Constant temperature method at constant temperature:  In laboratory

and precise measurement, the cold end is usually put into a 0 ℃ thermostat or
a container filled with ice water mixture to keep the cold end temperature at 0

℃, which is also called ice bath method.This is an ideal compensation method,

but it is very inconvenient to use in industry.

4. cold end temperature automatic compensation method (compensation bridge

method):    The compensation bridge method uses the unbalanced voltage generated

by the unbalanced bridge as the compensation signal to automatically compensate

the change value of the thermal potential caused by the temperature of the cold

end not being 0 ℃ or the change in the measurement process of the

thermocouple.The compensation bridge is composed of three resistances 1, 2, 3

which are wound by manganese copper wire with smaller temperature coefficient

of resistance, and the resistances Cu which are wound by copper wire with

larger temperature coefficient of resistance and the regulated power supply.The

compensation bridge and the cold end of the thermocouple are in the same

ambient temperature. When the thermoelectric potential (T, t0) changes due to

the change of the cold end temperature, the resistance value of Cu changes with

the change of the cold end temperature. If the resistance of the bridge arm and

the bridge current are properly selected, the unbalanced voltage AB generated

by the bridge can compensate the thermoelectric potential change due to the

change of the cold end temperature 0, so as to achieve the purpose of automatic

compensation.UabRRRREABRUT