Thermal Sensors for Device Performance Monitoring
ermal Sensors for Device Performance
Monitoring
By Samudrapom Dam Sep 21 2023
Reviewed by Megan Craig, [Link].
Thermal sensors can be used to ensure the optimal performance of industrial
devices, monitoring for changes in temperature that could limit function.
Image Credit: Yentafern/[Link]
Thermal Sensors and Device Performance Monitoring
A thermal sensor is primarily a device that can measure temperature variations in a
system/space by detecting the changes in the electrical properties of the sensor material. In
industrial settings, temperature control and measurement have become crucial for
monitoring industrial processes as several industrial applications require accurate and
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Thermal Sensors for Device Performance Monitoring
continuous temperature control, which can be effectively realized using thermal sensors.
Optimal operating temperature can improve the efficiency, reliability, and performance of
industrial processes and the quality of final products, ensure safety, and lead to substantial
cost savings. Thermocouples are used extensively as thermal sensors in different
applications, including industrial and automotive.
Thermal Sensor Types
Thermocouples
Thermocouples are nonlinear thermal sensors that operate based on the Seebeck effect
principle in which the difference in temperature between two different metal wires generates
a voltage difference, which is proportional to the changes in the temperature.
The voltage difference is converted to temperature measurements using a look-up table.
The temperature ranges and sensitivities of thermocouples vary depending on the types of
metals bound together. Although thermocouples have a low accuracy, they can operate
across an extensive temperature range from -200 ℃ to 1750 ℃.
Resistance Temperature Detectors (RTD)
RTDs measure the temperature variations based on the changes in the resistance of the
sensing material. Thus, these types of thermal sensors require materials with a well-defined
temperature-resistance relationship.
Platinum is the most suitable material for RTDs due to its linear relationship between
temperature variation and resistance change. Additionally, platinum RTDs are accurate,
stable, and have repeatability in measurements within -270 ℃ to 850 ℃ temperature range.
Although copper and nickel can be utilized in RTDs, the accuracy attained using these
materials is lower than platinum.
Thermistors
Thermistors also measure temperature based on the changes in the resistance. These
devices utilize ceramic or polymer materials in place of platinum, which makes them
cheaper than RTDs. However, the use of such materials also makes thermistors less
accurate than RTDs.
Negative temperature coefficient (NTC) thermistors and positive temperature coefficient
(PTC) thermistors are the key thermistor types. In NTC, the resistance change is inversely
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Thermal Sensors for Device Performance Monitoring
proportional to the temperature variation, while in PTC, the resistance change is directly
proportional to temperature variation. Thermistors can operate between -200 °C and 500 °C
temperatures.
Infrared (IR) Sensors
An IR sensor is primarily an electronic sensor that detects temperatures by emitting IR
radiations. These sensors are non-contacting type thermal sensors. Expensive IR sensors
typically display a higher accuracy compared to cheaper IR sensors.
Why is Temperature Monitoring Important in Industry?
Machinery and equipment will function the most optimally when kept within an acceptable
temperature range. Technicians can prevent performance issues in advance by monitoring
the temperature levels, as both underheating and overheating can significantly impact the
equipment/machinery efficiency, performance, and service life, and lead to expensive
repairs.
Chemical processing, power generation, food processing, pharmaceutical production, and
semiconductor manufacturing are some real-world industrial processes where temperature
control is a crucial requirement.
Integrating Thermal Sensors in Device Performance
Monitoring Systems
Thermal sensors can be integrated into device performance monitoring systems through
direct connection, wireless connection, network connection, and cloud-based connection. In
direct connection, a cable is used to directly connect the thermal sensor to the monitoring
system. Direct connection is the simplest method to integrate thermal sensors and is used
extensively to integrate thermal sensors.
Wireless connection involves connecting the thermal sensor with the monitoring system
using a Bluetooth or radio-frequency (RF) connection, which allows the installation of
thermal sensors in remote locations where direct connection cannot be used.
In network connection, the thermal sensor is connected to the system over a network, such
as a Wi-Fi or Ethernet network. This integration allows access to the thermal sensor from
any location.
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Thermal Sensors for Device Performance Monitoring
Cloud-based connection involves connecting thermal sensors to a cloud-based monitoring
system. Thus, the method enables remote monitoring of the thermal sensor. Modbus,
Ethernet, Wi-Fi, and Bluetooth are the communication protocols used for temperature data
transmission to the monitoring systems for analysis.
Thermal sensors are compatible with modern industrial Internet of Things (IIoT)
frameworks. These sensors can be integrated into the frameworks through direct
connection or by connecting to a gateway that transmits the data collected by the sensors
to the frameworks.
The data obtained from the sensor after connecting the sensor to the IIoT framework can
be utilized to monitor the target object's temperature and detect potential problems to avoid
equipment damage.
Image Credit: Dmitry Kalinovsky/[Link]
Benefits and Challenges of Thermal Sensor-Enabled
Performance Monitoring
Temperature monitoring can decrease the risk of costly equipment failure and downtime
through early fault detection by identifying temperature fluctuations that indicate a potential
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Thermal Sensors for Device Performance Monitoring
problem in an industrial device. Equipment breakdowns result in production delays, higher
maintenance expenses, and reduced output.
Thus, predictive maintenance using thermal sensor data is crucial to ensure the longevity,
performance, and efficiency of industrial devices. Moreover, expenses on energy can be
reduced substantially by minimizing energy expenditures and usage when the equipment is
kept at its optimal temperature.
However, challenges related to sensor calibration, sensor placement optimization, and the
ability of the sensors to withstand severe industrial environments are the main problems
thermal sensor-enabled monitoring faces.
Although thermal sensor calibration is crucial to ensure measurement accuracy, the
calibration is difficult due to the intangibility of temperature, which necessitates repeated
calibration of the sensor.
Similarly, sensor placement optimization is also challenging as several factors, such as
sensor accuracy and cost and observability of the system, must be considered while
deciding on the sensor positions, specifically when the sensors are used for condition-
based maintenance.
Recent Developments
In a paper recently published in the journal Sensors, researchers developed a high-
temperature probe using silicon carbide (SiC) Schottky diodes as a sensing element for the
cement industry.
Four-hexahedral SiC (4H-SiC) devices with annealed nickel (Ni)/4H-SiC Schottky contacts
were synthesized, packaged, and measured up to 400 °C, and fully parameterized to
evaluate temperature-sensing properties and detect the best-performing devices in
industrial environments.
Exceptional diode temperature sensitivities were observed between 1.8 mV/°C and 2.54
mV/°C for 100 nA–100 µA bias currents. Additionally, excellent sensing linearity was
displayed within this current interval.
Moreover, a high response time of 117 °C/µs was achieved for the processing circuit, which
was much higher than the speed of the temperature variation in the operation environment.
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Low and high-temperature points in a raw meal mill were selected for temperature
monitoring using the high-temperature probe and thermocouple-based alternatives. A very
close agreement was observed between the conventional and proposed temperature
sensing solutions between 40 °C and 400 °C, with the lifetime of the best probe being six
months, which was significantly higher than conventional solutions.
Thus, the study demonstrated the feasibility of using the proposed high-temperature probe
in industrial settings, specifically in the cement industry, to increase the efficiency of raw
meal mills and reduce their energy consumption.
Future Trends
Recently, a team from the University of Tokyo investigated the behavior of a heat flux
sensor containing special magnetic materials and electrodes during complex heat flow
patterns. The magnetic material based on gallium and iron demonstrates an anomalous
Nernst effect (ANE) phenomenon in which the heat energy is converted to an electrical
signal.
Flexible, easy-to-produce, cheap, and robust microscopic circuits were developed by
identifying the proper electrode and magnetic materials and then applying them in a
repeating pattern.
Specifically, the team designed the circuits to increase the ANE while suppressing the
Seebeck effect, which interferes with the ANE data-gathering potential. Most circuits
displayed their effectiveness in providing heat flux data in real-time.
To summarize, thermal sensors play a critical role in ensuring optimal efficiency and
performance of industrial equipment and the safety of workers while reducing energy usage
and equipment failures. Proactive temperature management using these sensors can
improve industrial process efficiency.
See more: Reliable Results with Self-Service Thermal Scanning.
References and Further Reading
Thermal Sensors. [Online] Available at:
[Link]
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IIoT sensors – The foundation of digital industry. [Online] Available at:
[Link]
components/iiot-sensors-the-foundation-of-digital-industry/
Sensor Placement Optimization. [Online] Available at: [Link]
integrity-health-monitoring/research/life-cycle-assessment-of-complex-structures/structural-
health-monitoring/sensor-placement-optimization-/
Schweber, B. (2021). The challenge of temperature measurement and sensor calibration,
Part 1. Available at: [Link]
measurement-sensor-calibration-part-1-faq/
Jansen, J. & Merwe, A.V.D. (2020). A Framework for Industrial Internet of Things.
Responsible Design, Implementation and Use of Information and Communication
Technology, 12066, pp. 138-150. [Link]/10.1007/978-3-030-44999-5_12
Implementing a Cloud based Temperature Monitoring System. [Online] Available at:
[Link]
Novel thermal sensor could help drive down the heat. [Online] Available at:
[Link]
Draghici, F., et al. (2018). 400 °C Sensor Based on Ni/4H-SiC Schottky Diode for Reliable
Temperature Monitoring in Industrial Environments. Sensors, 19(10), p. 2384.
[Link]/10.3390/s19102384
Industrial Temperature Sensor Technology. [Online] Available at:
[Link]
Significance of Temperature Sensor Probes in Industrial Applications. [Online] Available at:
[Link]
applications/
The Different Types of Thermal Sensors. [Online] Available at: [Link]
[Link]/blog/msa2021-the-different-types-of-thermal-sensors
Benefits of temperature control in industry. [Online] Available at:
[Link]
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Why temperature control is essential to the manufacturing sector. [Online] Available at:
[Link]
sector/
Benefits of Temperature Monitoring in Industrial Settings. [Online] Available at:
[Link]
[Link]
Constructing a Monitoring System Using Existing Sensors. [Online] Available at:
[Link]
system-using-existing-sensors/
Fan, G., et al. (2015). Large-Scale Wireless Temperature Monitoring System for Liquefied
Petroleum Gas Storage Tanks. Sensors, 15(9), pp. 23745-23762.
[Link]/10.3390/s15092374
Disclaimer: The views expressed here are those of the author expressed in their private
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Written by
Samudrapom Dam
Samudrapom Dam is a freelance scientific and business writer based in Kolkata, India. He has
been writing articles related to business and scientific topics for more than one and a half years.
He has extensive experience in writing about advanced technologies, information technology,
machinery, metals and metal products, clean technologies, finance and banking, automotive,
household products, and the aerospace industry. He is passionate about the latest developments
in advanced technologies, the ways these developments can be implemented in a real-world
situation, and how these developments can positively impact common people.
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