Thermo Couple

Thermo Couple

Edited By Vishal kumar | Updated on Jul 02, 2025 05:52 PM IST

A thermocouple is a simple yet powerful device used to measure temperature, which works on the principle of the Seebeck effect. It consists of two different metal wires joined at one end, forming a junction that generates a voltage when exposed to a temperature difference. This voltage is then used to determine the temperature at the junction. Thermocouples are widely used in various industries, from monitoring the temperature in furnaces to ensuring the correct functioning of home appliances like ovens and water heaters. In our daily lives, thermocouples play a critical role in maintaining safety and efficiency, such as in the engines of cars, where they help regulate fuel combustion by measuring exhaust gas temperatures. Their ability to operate in extreme environments makes thermocouples indispensable in both industrial and household settings. In this article, we will discuss the concept of thermocouples, the Seeback Effect, neutral temperatures and solved examples for better understanding.

This Story also Contains
  1. What is a Thermocouple?
  2. What is the Seeback Effect?
  3. Neutral Temperature
  4. Solved Examples Based on Thermo Couple
  5. Summary
Thermo Couple
Thermo Couple

What is a Thermocouple?

Two wires of different metals are connected at two points to form two junctions. This thermoelectric device used to measure the temperature is called a thermocouple. If one junction of the thermocouple is at lower temperature and the other is at a higher temperature then a current starts flowing through the thermocouple.

What is the Seeback Effect?

According to this when the two junctions of a thermocouple are kept and maintained at different temperatures, then a current starts flowing through the loop made by conductors known as thermo-electric current. Because of this potential differences will develop between the junctions which are called thermoelectric emf which is of the order of a few micro-volts per degree temperature difference.

Seebeck arranged different metals in the decreasing order of their electron density. A few metals forming the series are as below.

Sb, Fe, Cd, Zn, Ag, Au, Cr, Sn, Pb, Hg, Mn, Cu, Pt, Co, Ni, Bi

Neutral Temperature

Neutral temperature, in the context of a thermocouple, refers to the specific temperature at which the net electromotive force (EMF) generated by the thermocouple is zero, despite the two junctions being at different temperatures. This occurs because the thermoelectric effects of the two different metals cancel each other out at this particular temperature.

Keeping the temperature of the cold junction constant and increasing the temperature of the hot junction, the emf increases and becomes maximum at a particular temperature. This temperature of the hot junction is called neutral temperature$\left(\theta_n\right)$. If the temperature is further increased the thermal emf starts decreasing and at a particular temperature, thermal emf becomes zero. If the temperature is further increased the thermal emf starts reversing. The temperature of the hot junction at which the thermal emf starts reversing is known as inversion temperature $\left(\theta_i\right)$

$\begin{aligned} & \theta_n=\frac{\theta_i+\theta_c}{2} \\ & \theta_n=\text { Neutral Temperature } \\ & \theta_i=\text { Inversion Temperature } \\ & \theta_c=\text { Cold Temperature }\end{aligned}$

Thermoelectric emf is given by the equation

$E=\alpha t+\frac{1}{2} \beta t^2$

where $\alpha$ and $\beta$ are thermo electric constant ( t = temperature of the hot junction).

For E to be maximum at t=tn, we will differentiate the Electric field with respect to the temperature of the hot junction and we get

$\frac{d E}{d t}=0$ i.e. $\alpha+\beta t_n=0 \Rightarrow t_n=-\frac{\alpha}{\beta}$

If the temperature of the hot junction increases beyond the neutral temperature, then there is a decrease in the thermo emf and at a particular temperature it becomes zero, if heat is supplied further, the direction of emf is reversed. This temperature of the hot junction is called the temperature of inversion (ti).

$t_n=\frac{t_i+t_c}{2}$

Here, tc is the temperature of the cold junction.

We can understand better through video.

Solved Examples Based on Thermo Couple

Example 1: The thermo emf of a thermocouple varies with the temperature $\theta$ of the hot junction as $E=a \theta+b \theta^2$ in volt where the ratio a/b is 700°C. If the cold junction is kept at 0°C, then the neutral temperature is

1) 700°C

2) 350°C

3) 1400°C

4) no neutral temperature is possible for this thermocouple.

Solution:

Thermocouple

Current flow across the cold function from the later occurring metal in the series to the one occurring earlier in the thermoelectric series and reverse at the not junction.

$
\begin{aligned}
E & =a \Theta+b \Theta^2 \\
\frac{d E}{d \Theta} & =a+2 b \Theta \quad\left(\frac{a}{b}=700^{\circ} c\right)
\end{aligned}
$

At neutral temperature
$
\begin{aligned}
& \frac{d E}{d \Theta}=0 \\
& 0=a+2 b \Theta_n \\
& \Rightarrow \Theta_n=\frac{-a}{2 b} \\
& \Theta_n=\frac{-1}{2} \times(700) \\
& =-350^{\circ} \mathrm{c}
\end{aligned}
$

Neutral temperature is calculated to be $-350^{\circ} \mathrm{C}$ i.e. no neutral temperature is possible in this thermocouple.

Hence, the answer is the option (4).

Example 2: For a thermocouple, the neutral temperature is 270o C and the temperature of its cold junction is 20o C. If there is no deflection in the galvanometer, the temperature (in $^\circ C$ ) of the hot junction should be

1) 520

2) 540

3) 210

4) 209

Solution:

If the temperature of the hot junction increases beyond the neutral temperature, then there is a decrease in the thermo emf, and at a particular temperature it becomes zero, if heat is supplied further, the direction of emf is reversed. This temperature of the hot junction is called the temperature of inversion (ti).

$
t_n=\frac{t_i+t_c}{2}
$

When there is no deflection, then this temperature is called inversion temperature. It is given by the relation $\theta_n=\frac{\theta_i+\theta_c}{2}$ Where $\theta_c$ is temperature of cold junction $=20^{\circ} \mathrm{C}$ and neutral

Here, tc is the temperature of the cold junction.

temperature $\theta_n=270^{\circ} \mathrm{C} \therefore \theta_i=2 \theta_n-\theta_c=540-20=520^{\circ} \mathrm{C}$

Hence, the answer is the option (1).

Example 3: If $\theta_i$ is the inversion temperature, $\theta_n$ is the neutral temperature, $\theta_c$ is the temperature of the cold junction, then

1) $\theta_i+\theta_c=\theta_n$
2) $\theta_i-\theta_c=2 \theta_n$
3) $\frac{\theta_i+\theta_c}{2}=\theta_n$
4) $\theta_c-\theta_i=2 \theta_n$

Solution:

$\begin{aligned} & \theta_c+\theta_i=2 \theta_n \\ & \Rightarrow \theta_n=\frac{\theta_c+\theta_i}{2}\end{aligned}$

Hence, the answer is the option (3).

Example 4:A thermocouple is made from two metals, antimony and bismuth. If one junction of the couple is kept hot and the other is kept cold then, an electric current will

1) flow from antimony to bismuth at the cold junction

2) flow from antimony to bismuth at the hot junction

3) flow from bismuth to antimony at the cold junction

4) not flow through the thermocouple.

Solution:

At cold junction, current flows from Antimony to Bismuth (because current flows from metal occurring later in the series to metal occurring earlier in the thermoelectric series).

Hence, the answer is the option (1).

Summary

Thermocouples are essential devices for measuring temperature, operating on the Seebeck effect, where different metal junctions generate an electromotive force (EMF) when exposed to temperature differences. Key concepts include the neutral temperature, where EMF is zero, and the inversion temperature, where EMF reverses direction. Understanding these principles is crucial for accurate temperature measurement in various applications, from industrial processes to everyday appliances.

Frequently Asked Questions (FAQs)

1. Can a thermocouple measure absolute temperature?
No, a thermocouple cannot measure absolute temperature directly. It measures the temperature difference between the measuring junction (hot junction) and the reference junction (cold junction). To determine absolute temperature, the reference junction temperature must be known or compensated for.
2. What is cold junction compensation in thermocouples?
Cold junction compensation is a technique used to account for the reference junction temperature in thermocouple measurements. It involves measuring the temperature at the reference junction and using this information to calculate the actual temperature at the measuring junction.
3. How can the output of a thermocouple be amplified?
The output of a thermocouple can be amplified using specialized amplifiers designed for low-level DC signals, such as instrumentation amplifiers or thermocouple amplifiers. These amplifiers boost the small thermocouple voltage to a more easily measurable level while minimizing noise and maintaining accuracy.
4. How does temperature affect the accuracy of a thermocouple?
Temperature can affect thermocouple accuracy in several ways. The Seebeck coefficient of metals can change with temperature, affecting the voltage-temperature relationship. Additionally, extreme temperatures can cause physical changes in the thermocouple materials, leading to calibration drift or failure.
5. How do you calibrate a thermocouple?
Thermocouple calibration involves exposing the thermocouple to known temperatures and comparing its output to a standard. This can be done using calibration baths, dry block calibrators, or fixed-point cells. The calibration data is then used to create a correction curve or to verify the thermocouple's accuracy.
6. What is a thermocouple and how does it work?
A thermocouple is a temperature-measuring device consisting of two different metal wires joined at one end. It works based on the Seebeck effect, where a temperature difference between the junction and the free ends of the wires generates a small voltage. This voltage can be measured and used to determine the temperature at the junction.
7. What is a thermocouple junction?
A thermocouple junction is the point where two dissimilar metal wires are joined together in a thermocouple. There are typically two junctions: the measuring (or hot) junction, which is exposed to the temperature being measured, and the reference (or cold) junction, which is kept at a known temperature.
8. What is the difference between a thermocouple and an RTD?
A thermocouple measures temperature using the Seebeck effect, while an RTD (Resistance Temperature Detector) measures temperature based on the change in electrical resistance of a metal with temperature. Thermocouples are generally less accurate but can measure a wider temperature range and respond faster than RTDs.
9. Can thermocouples measure very high temperatures?
Yes, certain types of thermocouples can measure very high temperatures. For example, tungsten-rhenium thermocouples can measure temperatures up to 2300°C (4172°F). The choice of thermocouple type depends on the temperature range and the specific application requirements.
10. What is thermoelectric EMF?
Thermoelectric EMF (electromotive force) is the voltage generated by a thermocouple due to the Seebeck effect. It's the potential difference created when two dissimilar metals are joined and their junctions are at different temperatures.
11. Why are two different metals used in a thermocouple?
Two different metals are used because they have different electron densities and respond differently to temperature changes. This difference in behavior creates a potential difference (voltage) between the two metals when there's a temperature gradient, allowing for temperature measurement.
12. What is the Seebeck effect and how is it related to thermocouples?
The Seebeck effect is the phenomenon where a temperature difference between two different electrical conductors produces a voltage difference between them. In thermocouples, this effect is utilized to generate a small voltage proportional to the temperature difference, enabling temperature measurement.
13. What is the Seebeck coefficient?
The Seebeck coefficient, also known as thermoelectric power or thermopower, is a measure of the magnitude of an induced thermoelectric voltage in response to a temperature difference across a material. In thermocouples, it represents the voltage generated per degree of temperature difference between the junctions.
14. How does the choice of metals affect thermocouple performance?
The choice of metals affects the thermocouple's sensitivity, temperature range, and output voltage. Different metal combinations have varying Seebeck coefficients, which determine the voltage produced per degree of temperature difference. Some combinations are better suited for specific temperature ranges or environments.
15. What is the Thomson effect and how does it relate to thermocouples?
The Thomson effect is the generation or absorption of heat when an electric current flows through a conductor with a temperature gradient. In thermocouples, the Thomson effect can cause small deviations from the ideal Seebeck effect, particularly at high temperatures or with large temperature gradients.
16. Why don't thermocouples produce a large voltage output?
Thermocouples produce small voltages (typically in the millivolt range) because the Seebeck effect is relatively weak. The voltage generated depends on the temperature difference and the specific metals used, but it's usually in the order of microvolts to millivolts per degree Celsius.
17. How do self-powered thermocouples work?
Self-powered thermocouples generate their own electrical signal without requiring external power, based solely on the Seebeck effect. This makes them useful in applications where external power is unavailable or undesirable. However, the signal is very small and usually requires amplification for practical use.
18. What is the significance of the Kelvin double bridge in precise thermocouple measurements?
The Kelvin double bridge is a circuit configuration used for precise resistance measurements. In thermocouple applications, it can be used to accurately measure the resistance of thermocouple wires, which is important for compensating for lead wire resistance and improving overall measurement accuracy, especially in long-distance thermocouple installations.
19. Can thermocouples be used to generate electricity?
While thermocouples can generate small amounts of electricity, they are not typically used for power generation due to their low efficiency. However, the same principle is used in thermoelectric generators, which are designed specifically for power generation from temperature differences.
20. What is thermocouple drift and what causes it?
Thermocouple drift is a gradual change in the thermocouple's output over time, leading to inaccurate temperature measurements. It can be caused by various factors, including chemical changes in the thermocouple materials, physical strain, or contamination. Regular calibration can help detect and correct for drift.
21. How does wire length affect thermocouple performance?
Wire length can affect thermocouple performance by increasing resistance and potentially introducing noise. Longer wires can also be more susceptible to electromagnetic interference. However, if the wires are of the correct type and properly installed, the effect on measurement accuracy is usually minimal.
22. What is the law of intermediate metals in thermocouples?
The law of intermediate metals states that inserting a third metal into a thermocouple circuit will not affect the net EMF, provided that both ends of the third metal are at the same temperature. This principle allows for the use of connection terminals and extension wires in thermocouple systems.
23. How do thermocouples compare to other temperature sensors in terms of response time?
Thermocouples generally have faster response times compared to many other temperature sensors, such as RTDs or thermistors. This is due to their small size and low thermal mass, allowing them to quickly respond to temperature changes. This makes them suitable for applications requiring rapid temperature measurements.
24. What is a thermocouple extension wire?
A thermocouple extension wire is a cable made of the same alloy combination as the thermocouple itself, used to extend the thermocouple's reach without affecting its accuracy. It allows the reference junction to be located far from the measuring point while maintaining the thermoelectric properties of the original thermocouple.
25. Can thermocouples be used in corrosive environments?
Yes, certain types of thermocouples can be used in corrosive environments. For example, platinum-rhodium thermocouples are resistant to many corrosive substances. Additionally, thermocouples can be protected using special sheaths or wells made of corrosion-resistant materials to extend their lifespan in harsh environments.
26. What is the difference between grounded and ungrounded thermocouples?
In a grounded thermocouple, the junction is physically connected to the protective sheath, allowing faster response times but potentially introducing electrical noise. An ungrounded thermocouple has its junction electrically isolated from the sheath, providing better electrical isolation but slower response times.
27. How does polarity affect thermocouple measurements?
Polarity is crucial in thermocouple measurements. Reversing the polarity of the thermocouple leads will result in an incorrect reading, typically showing a temperature lower than the actual temperature. It's essential to connect the positive and negative leads correctly to ensure accurate measurements.
28. What is the cold finger effect in thermocouples?
The cold finger effect occurs when a thermocouple probe acts as a heat sink, drawing heat away from the point being measured and causing an inaccurate (usually lower) temperature reading. This effect is more pronounced with larger diameter probes or when measuring small objects or volumes.
29. How do thermocouples behave in parallel and series connections?
When thermocouples are connected in parallel, the output voltage is an average of the individual thermocouple voltages, weighted by their respective resistances. In series, the voltages add up, but this configuration is rarely used due to practical difficulties and potential errors.
30. What is thermocouple burnout detection?
Thermocouple burnout detection is a safety feature in temperature controllers that detects when a thermocouple has failed open-circuit. It typically works by passing a small current through the thermocouple and monitoring for an abnormally high resistance, indicating a break in the circuit.
31. How does the Peltier effect relate to thermocouples?
The Peltier effect is the inverse of the Seebeck effect: when a current is passed through a thermocouple junction, it causes heating or cooling depending on the direction of the current. While not directly used in temperature measurement, understanding the Peltier effect is important for comprehending thermocouple behavior and potential sources of measurement error.
32. What is the importance of wire gauge in thermocouple construction?
Wire gauge affects thermocouple performance in several ways. Thicker wires (smaller gauge numbers) have lower resistance, which can improve accuracy over long distances. However, thicker wires also have more thermal mass, which can slow response times. The choice of wire gauge depends on the specific application requirements.
33. What is thermocouple aging and how does it affect measurements?
Thermocouple aging refers to changes in the thermoelectric properties of the thermocouple materials over time, often due to exposure to high temperatures or corrosive environments. This can lead to drift in the thermocouple's calibration, affecting measurement accuracy. Regular calibration checks can help detect and compensate for aging effects.
34. How do thermocouples behave in alternating magnetic fields?
Alternating magnetic fields can induce voltages in thermocouple circuits, potentially causing measurement errors. This effect, known as magnetic pickup, is more pronounced in larger loops formed by the thermocouple wires. Proper shielding and minimizing loop areas can help reduce this interference.
35. What is the significance of the reference tables in thermocouple measurements?
Reference tables, also known as thermocouple tables, provide standardized voltage-to-temperature conversion data for different thermocouple types. These tables are essential for accurate temperature determination, as they account for the non-linear relationship between temperature and thermoelectric voltage.
36. How does thermal shunting affect thermocouple measurements?
Thermal shunting occurs when the thermocouple itself conducts heat away from the measurement point, causing an inaccurate reading. This effect is more significant when measuring small objects or in situations with large temperature gradients. Using smaller diameter probes or non-contact methods can help minimize thermal shunting.
37. What is the difference between intrinsic and extrinsic thermocouples?
Intrinsic thermocouples are made from pure metals or alloys with well-defined compositions, ensuring consistent thermoelectric properties. Extrinsic thermocouples use less pure materials or alloys with more variable compositions, which can lead to slight variations in performance but are often more cost-effective.
38. How do thermocouples perform in vacuum environments?
Thermocouples can generally perform well in vacuum environments, as they don't require a medium for heat transfer. However, in high vacuum conditions, some thermocouple materials may outgas or sublimate, potentially affecting accuracy or lifespan. Special consideration should be given to material selection for vacuum applications.
39. What is the importance of insulation resistance in thermocouple circuits?
Insulation resistance is crucial in thermocouple circuits to prevent current leakage, which can cause measurement errors. High insulation resistance ensures that the small thermoelectric voltages are accurately measured without interference. This is particularly important at high temperatures, where insulation materials may become less effective.
40. How do thermocouples behave near their Curie point?
The Curie point is the temperature at which a material's magnetic properties change. For thermocouple materials that exhibit magnetic properties, approaching the Curie point can cause non-linear behavior in the thermoelectric response. This can lead to measurement inaccuracies if not properly accounted for.
41. What is the effect of strain on thermocouple performance?
Mechanical strain on thermocouple wires can alter their thermoelectric properties, leading to measurement errors. This effect, known as the elastic strain effect or piezoelectric effect in thermocouples, is more pronounced in certain thermocouple types and can be significant in applications involving vibration or thermal cycling.
42. How do thermocouples compare to pyrometers for high-temperature measurements?
Thermocouples can measure high temperatures through direct contact, while pyrometers measure temperature remotely using thermal radiation. Thermocouples are often more accurate and can be used in confined spaces, but pyrometers have the advantage of non-contact measurement, which is useful for moving objects or very high temperatures where direct contact is impractical.
43. What is the principle behind differential thermocouples?
Differential thermocouples measure the temperature difference between two points rather than absolute temperature. They consist of two measuring junctions connected in opposition, so the output voltage represents the temperature difference between the two points. This configuration is useful for applications requiring precise temperature difference measurements.
44. How does the chemical composition of thermocouple materials affect long-term stability?
The chemical composition of thermocouple materials significantly impacts their long-term stability. Impurities or slight variations in alloy composition can lead to changes in thermoelectric properties over time, especially at high temperatures. High-purity materials and precise alloy compositions are used in premium thermocouples to ensure better long-term stability.
45. What is the significance of the inhomogeneity effect in thermocouples?
The inhomogeneity effect occurs when the composition or structure of the thermocouple wires varies along their length, often due to temperature gradients or manufacturing variations. This can create additional thermoelectric junctions along the wire, leading to measurement errors. Minimizing inhomogeneity is crucial for maintaining thermocouple accuracy.
46. How do thermocouples behave in strong electric fields?
Strong electric fields can induce voltages in thermocouple circuits, potentially causing measurement errors. This effect is more pronounced with longer wire lengths and larger loop areas. Proper shielding and grounding techniques can help minimize the impact of electric fields on thermocouple measurements.
47. What is the role of the law of successive temperatures in thermocouple theory?
The law of successive temperatures states that the EMF generated by a thermocouple with its junctions at temperatures T1 and T3 is equal to the sum of the EMFs generated by the same thermocouple with junctions at T1 and T2, and T2 and T3. This principle is fundamental to understanding thermocouple behavior and calibration.
48. How does the thermal conductivity of the thermocouple materials affect measurement accuracy?
The thermal conductivity of thermocouple materials can affect measurement accuracy, particularly in situations with large temperature gradients. Materials with high thermal conductivity may conduct heat along the wire, creating a temperature distribution that differs from the environment being measured. This effect is more significant in bare wire thermocouples and at high temperatures.
49. How do thermocouples perform in radioactive environments?
Thermocouples can generally withstand moderate levels of radiation, making them suitable for some nuclear applications. However, prolonged exposure to high radiation levels can cause transmutation of the thermocouple materials, altering their thermoelectric properties and leading to measurement

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