Calibration System For Thermocouple Testing: January 2009

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Calibration System for Thermocouple Testing
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Sensors & Transducers Journal (ISSN 1726-5479) is a peer review international journal published monthly online by International Frequency Sensor Association (IFSA).
Available in electronic and CD-ROM. Copyright © 2009 by International Frequency Sensor Association. All rights reserved.
Sensors & Transducers Journal
Contents
Volume 100 www.sensorsportal.com ISSN 1726-5479
Issue 1
January 2009
Editorial
International Frequency Sensor Association (IFSA) Celebrates the 10th Anniversary ............. I
Sergey Y. Yurish
Research Articles
A Log Amplifier Based Linearization Scheme for Thermocouples

Nikhil Mondal, A. Abudhahir, Sourav Kanti Jana,Sugata Munshi and D. P. Bhattacharya................ 1
Uncertainty Analysis of Thermocouple Circuits

B. Vasuki, M. Umapathy, S. K. Velumani ........................................................................................... 11

Dragan R. Milivojevic, Visa Tasic, Marijana Pavlov, Zoran Andjelkovic ............................................. 16
Embedded Processor Based Automatic Temperature Control of VLSI Chips

Narasimha Murthy Yayavaram, Saritha Chappidi, Sukanya Velamakuri ........................................... 27
Field of Temperature Measurement by Virtual Instrumentation

Libor Hargaš, Dušan Koniar, Miroslav Hrianka, Jozef Čuntala .......................................................... 45
Analyzing Electroencephalogram Signal Using EEG Lab

Mukesh Bhardwaj and Avtar. K. Nadir ............................................................................................... 51
New Aspects in Respiratory Epithelium Diagnostics Using Virtual Instrumentation

Dušan Koniar, Libor Hargaš, Miroslav Hrianka, Peter Bánovčin........................................................ 58
A PC-based Technique to Measure the Thermal Conductivity of Solid Materials

Alety Sridevireddy, K. Raghavendra Rao........................................................................................... 65
A New Wide Frequency Band Capacitance Transducer with Application to Measuring Metal
Fill Time
Wael Deabes, Mohamed Abdelrahman, and Periasamy K. Rajan .................................................... 72
A Novel Hall Effect Sensor Using Elaborate Offset Cancellation Method

Vlassis N. Petoussis, Panos D. Dimitropoulos and George Stamoulis .............................................. 85
A Review of Material Properties Estimation Using Eddy Current Testing and Capacitor
Imaging
Mohd. Amri Yunus, S. C. Mukhopadhyay and G. Sen Gupta ............................................................ 92
Surface Plasmon Resonance Based Fiber Optic Sensor with Symmetric and Asymmetric
Metallic Coatings: a Comparative Study
Smita Singh, Rajneesh K. Verma and B. D. Gupta ............................................................................ 116
Increasing of Excursion Range of Absolute Optical Sensors Intended for Positioners
Igor Friedland, Ioseph Gurwich, Amit Brandes................................................................................... 125
Field-Effect-Transistor Behavior of a Multiwall Carbon Nano Fiber Directly Grown on Nickel

Electrodes
L. W. Chang, P. S. Wu, J. T. Lue and Z. P. Chen .............................................................................. 137
Classification of Fiber-Optic Pressure Sensors with Amplitude Modulation of Optical Signal

Vladyslav Kondratov, Vitalii Redko..................................................................................................... 146
New e-Book
Laboratories of Instrumentation for Measurement

Maria Teresa Restivo, Fernando Gomes de Almeida, Maria de Fátima Chouzal, Joaquim Gabriel
Mendes, António Mendes Lopes ........................................................................................................ 161
Authors are encouraged to submit article in MS Word (doc) and Acrobat (pdf) formats by e-mail: editor@sensorsportal.com
Please visit journal’s webpage with preparation instructions: http://www.sensorsportal.com/HTML/DIGEST/Submition.htm
International Frequency Sensor Association (IFSA).

Sensors & Transducers Journal, Vol. 100, Issue 1, January 2009, pp. 16-26
Sensors & Transducers

ISSN 1726-5479
© 2009 by IFSA
http://www.sensorsportal.com

1
Dragan R. MILIVOJEVIC, 1Visa TASIC, 1Marijana PAVLOV,
2
Zoran ANDJELKOVIC
1
Mining and Metallurgy Institute Bor, ZB 32, 19210 Bor, Serbia
2
Technical faculty of Bor, VJ 12, 19210 Bor, Serbia
Tel.: +381-30-435109, fax: +381-30-435175
E-mail: dane@ibb-bor.co.yu, visa@ibb-bor.co.yu, mary@ibb-bor.co.yu, jaz@eunet.rs
Received: 12 November 2008 /Accepted: 19 January 2009 /Published: 26 January 2009
Abstract: One of activities of the Mining and Metallurgy Institute is production of thermocouple
elements made of precious metals. Since this is a complex technological process and the quality
control of produced elements is performed by other institutions, sometimes the whole series of
products can happen to be bad and not useful. This is increasing costs and time of production, as well.
To prevent wasting of time and money, the special measuring system is developed. The kernel of the
system is already existing microprocessor measuring station - MMS. The MMS’s hardware
configuration, initially designed for industrial process control requirements with suitable input channel
characteristics and adequate response time is adapted for the purpose of thermocouple calibration.
Appropriate software solution is developed, as well. This article describes the practical solution for
thermocouple testing and calibration. Hardware interface, principles of system integration and
developed software are also included. Copyright © 2009 IFSA.
Keywords: Measuring system, Hardware interface, A/D conversion, Thermocouple examination
1. Introduction
Modern process engineering requires temperature control, measuring and regulation equipment in
order to satisfy the specified requirements for precision. The thermocouples are often in use as
temperature sensors. For an official application these sensors have to be calibrated and certificated [1].
Calibration systems are used to test temperature sensors by means of comparative measurements.
Using this method, the test specimens are inserted in a heat source together with the reference sensor
and the measurements are compared using the corresponding instruments. There are some defined
16
criteria for thermocouple validation. One way of determination of correctness is comparison with a
validated one, in this case called etalon. The measurement system is used for testing of temperature
sensors by means of comparative measurements [2]. The examination method is performed by
comparison of the voltage output of controlled sensors (specimens) and standard one (etalon) in a wide
temperature range [2]. The difference between results must not exceed 1 degree Celsius in whole
temperature area for official calibration and certification (the first class sensors). The spatial
environmental conditions have to be maintained for testing and validation process. In order to satisfy
the specified requirements, new measurement system was designed and realized (Fig. 1). Hardware of
the measuring system includes: electric tube furnace, measuring station with all interface modules and
subordinate PC computer. Two level software solutions are applied to support the appropriate
functions and to collect and process measurement data, interpret and store the results and make
different forms of reports.
INTERFACE
Furnace function control

Electric furnace
Thermocouple selection PC
and imput signal MMS
conditioning
A/D conversion
and data transfer
Fig. 1. Hardware configuration of the measurement system.
2. Hardware Base
Hardware of the measurement system includes two main parts: the tube electrical furnace with its
control functions (controlled subsystem) and MMS with subordinate PC (control units). The existing
electric furnace, type Heraeus – Hanau series ROK/F has acceptable performances: power of 3.6 kW,
and maximum temperature of 13000 C, Fig. 2. In the electric furnace body there is a massive metal
cylinder with 8 axial holes for eight specimens [2]. That homogenous cylinder is providing
approximately same temperature in the whole inner room. Furnace was initially designed for discrete
manual temperature control. In order to allow automatic or semiautomatic temperature control, a
digital electronic PID temperature regulation module is added to furnace. The electric furnace inner
temperature is measured by a separate precise digital thermometer [3]. The functions of temperature
controller can be performed with remote commands. The PC controls time-related constancy of
temperature via MMS.
Bi-directional hardware interface was designed and realized for a connection of furnace control
electronics and MMS, Fig. 1. It’s control functions are obtained by digital output signals for the
discrete actions: switch on and off (the standard output signal PA6 [4], with low level for switch off
and high for switch on), Fig. 2. The function of other PA signals will be explained later. The setting of
concrete measuring temperature is initiated by PC. The MMS translates received command with digital
value of selected temperature to the interface as an input to the D/A converter (DAC 1405), Fig. 3.
17
The process of assignment and reaching of every temperature measurement point is performed in the
following way: MMS command WR FB00 (write to address $FB00) starts conversion and output
analog voltage signal AUTO is led to temperature controller, Fig. 3. When the temperature is reached,
the autonomous temperature control module maintains it and sets the indicator diode.
Fig. 2. Heraeus Tube Furnace.
Ten measurement points are used for thermocouple testing in the range 0 to 1000 ºC. The MMS sends
to D/A converter one byte (discrete decade values in column three of Table 1) for temperature
selection (second column of Table 1). The values of analog voltage output for temperature control in
last column of Table 1 are empirically obtained.
Table 1. Measuring points, decade equivalent and D/A output voltages for heater control.
Digital value D/A output

Temperature [ºC]
[0-255] [mV]
temp0 200 39 117
temp1 250 49 153
temp2 330 65 210
temp3 420 83 275
temp4 480 95 318
temp5 540 108 362
temp6 610 122 412
temp7 750 150 513
temp8 850 170 585
temp9 970 194 671
Option ‘Start merenja’ (Start measuring) on interactive PC program generates appropriate command to
MMS and it continues with a measurement sequence. The furnace can contain up to 8 thermocouples
(seven specimens and etalon-standard), as mentioned. Selection of one of them is performed by using
of three digital MMS output signals PA3, PA4 and PA5 via two multiplexers 4051 (left part of Fig. 4).
The selected voltage output, (both poles, plus and minus) is led to preamplifier and amplifier (OP07-1
and OP07-2). The amplified signal is checked by three pairs of comparators LM339 and logic gates, to
determine the voltage range between 0 and 4 V (right part of Fig. 4).
18
MMS
Fig. 3. Electrical schema of temperature assignment.
The two level operational amplifiers OP07-3 and OP07-4 from the same signal generate Uout ADconv,
(as shown on Fig. 4, Ui in Table 2), as the ADC input. The output of discrete comparator (Fig. 4)
directly determinates values of two most significant bits of digital value: D12 and D13, accordingly to
Table 2.
Table 2. The definition of A/D conversion most significant bits.
Ui D13 D12
0 < Ui < 1 V 0 0
1 < Ui < 2 V 0 1
2 < Ui < 3 V 1 0
3 < Ui < 4 V 1 1
The voltage signal Vout to ADconv is connected to input of A/D converter ICL7109, pins 34 and 35, as
shown on Fig. 5. This 12-bit converter is driven by free running oscillator 4060. The A/D conversion is
performed cyclically and after every completion the status conversion complete is set. The MMS is
permanently testing the input signal PA0 in order to detect the end of A/D conversion. When the status
bit is high, the reading data (digital value) occurs. This is realized in two steps: for high order and low
order byte. Higher four data bits (D8 – D11) with associated two D12 and D13 (determined in the
19
described way) and two most significant bits (D14 and D15 are always zero) are read in the first, and
last eight significant bits (D0 – D7) in the second step. The MMS forms two-bytes number as a 14-bit
digital representation of analog input signal.
Fig. 4. The thermocouple output signal selection and conditioning.
The described way of amplification, comparison and conversion of thermocouple output signal allows
increasing the resolution of 12-bit A/D converter to 14 bits. Although that is desirable, there are some
disadvantages. One of them is the occurrence a small zone near every round Volt of the amplified
input signal (‘dead zones’), shaded part on Fig. 6. It is not possible to make measuring in small areas
near these points.
The thermocouple working curve is rather linear and can be approximated by a straight line in the
whole temperature range. The choice of measurement points is not dictated by any strict regulation; it
is necessary just to make appropriate number of samples in uniform distances. This circumstance
makes the task much easier with possibility of skipping those three small areas, which are shown as
shaded parts of diagram on the Fig. 6.
20
Fig. 5. Analog to digital conversion.
4500
Voltages [mV]
4000
3500
Preamplifier output
3000
2500
D13=0 D13=0 D13=1 D13=1
2000
D12=0 D12=1 D12=0 D12=1
1500
A/D input A/D input A/D input A/D input

1000
500
Temperature [єC]
0
0 3000 6000 9000 12000
-500
Fig. 6. The A/D converter input voltage.
21
3. Software Solutions
A two-level software solution is realized for the support and maintenance of system measurement
functions: PC based applications and MMS executive system [7]. MMS is an industrial programmable
logic controller (PLC) with some adaptations for concrete purposes.
All functions of measurement system are controlled via PC. The software is Windows compatible
(Windows 98/2000/XP). Two different applications are developed. The first one is created for on-line
system operation, as an interactive real-time program. An off-line application is developed for data
collection, processing and analyses, and report presentation.
The main tasks of interactive on-line program are:

- control of electric furnace heating;
- measuring of the electrical signal on input as an output of selected thermocouple.
Application is developed in Visual C++ 6.0 development environment and interacts with the user on
menu principles [7]. It is user friendly, giving the possibilities of easy choice of system functions: type
of thermocouple selection, temperature selection (measurement points), commands to furnace and start
and stop of measuring commands, as shown in Fig. 7.
Fig. 7. Main on-line application menu.
The measurement procedure starts with the type of thermocouple selection – once per experiment
(‘Izbor termopara’ (Thermocouple selection) in upper command line), then the measurement
temperature is set using dialog box ‘Izbor temperature’ (Temperature selection). These two commands
are transferred to MMS, controlling the electrical furnace heating. When the desired temperature is
reached (the LED light is on), start of measuring is performed by acknowledgement on the appearing
window: ‘Start merenja’ (Start measuring). This remote PC command activates the MMS sampling
function which is a complex procedure performed by executive system contained in EPROM of the
MMS.
22
The first measurement procedure stage is thermocouple selection. The MMS sets the appropriate
digital state on its own output port A. Combination of PA signals states (PA3, PA4 and PA5) is
decoded as an address, connecting one of 8 thermocouple outputs to input of double amplifier, Fig. 4.
After every address change there is a program delay of 150 ms before a real measuring starts. This is
necessary because of input signal stabilization. The duration is empirically determined. After that time
MMS is starting an input operation by testing of its own input signal PA0 in order to detect the end of
A/D conversion. Reading two bytes, described at the end of section 2, performs data collection.
After logical control of data, the MMS forms a data record of two-byte numerical values for all
thermocouples and etalon as well, as shown in Fig. 8. The first field is date and time followed by
numerical value of etalon voltage output (2512), than thermocouple 1 (2527), etalon again (2512),
thermocouple 2 (2528) and so on, until the last thermocouple 7 (2528) and ended by etalon (2512).
12 10 10:15:00 2512 2527 2512 2528 2511 2514 2511 2518 2513 2516 2512 2515 2512 2516 2512
Fig. 8. The MMS message format.
Prepared measurement results are transferred to subordinated PC in the described form (Fig. 8).
Function of the interactive PC application completes by receiving of the messages and writing of the
measurement data in the database. After enough number of sampling (six in this experiment), the
textual (ASCII) file is produced as a final result. In Fig. 9 only the records with values are presented,
time is omitted, since it is not important for the analyses.
1805 1822 1804 1867 1804 1806 1805 1809 1806 1808 1806 1811 1806 1806 1808
2494 2524 2493 2597 2492 2493 2494 2498 2493 2500 2495 2496 2493 2498 2494
2512 2527 2512 2528 2511 2514 2511 2518 2513 2516 2512 2515 2512 2516 2512
3023 3034 3024 3034 3024 3026 3024 3040 3025 3037 3026 3030 3026 3027 3027
4800 4806 4798 4805 4798 4800 4799 4901 4798 4805 4797 4806 4797 4805 4798
7237 7236 7237 7236 7236 7235 7237 7365 7237 7235 7236 7234 7235 7234 7235
Fig. 9. The part of measurement data file.
4. Data Analyses and Results Interpretation

Main functions of off-line application are data processing, presentation and analyses. MS Excel is used
for off-line data manipulation, since it is open for many data formats, giving lots of possibilities for
numerical calculations and graphical presentations of data. As a result of these manipulations
appropriate tables and diagrams can be generated, as shown in Table 3 and Fig. 8.
The quick look at Table 3 shows that the thermocouple 3 is the best one, because of very low errors
(difference) at all of measurement temperatures. The conclusion is that the thermocouples 5, 6 and 7
could be used, while the first two (1 and 2) have very bad performances.
23
Table 3. The absolute and relative difference between thermocouples and etalon1.
Thermocouple Thermocouple Thermocouple Thermocouple Thermocouple Thermocouple Thermocouple

Temp. 1 2 3 4 5 6 7
∆ δ [%] ∆ δ [%] ∆ δ [%] ∆ δ [%] ∆ δ [%] ∆ δ [%] ∆ δ [%]
104ºC 16.50 0.0091 61.50 0.0341 0.50 0.0003 3.50 0.0019 2.50 0.0014 5.50 0.0030 0.50 0.0003
215ºC 30.50 0.0122 103.50 0.0415 -0.50 0.0002 4.50 0.0018 6.50 0.0026 2.50 0.0010 4.50 0.0018
310ºC 15.13 0.0060 16.13 0.0064 2.13 0.0008 6.13 0.0024 4.13 0.0016 3.13 0.0012 4.13 0.0016
420ºC 9.13 0.0030 9.13 0.0030 1.13 0.0004 15.13 0.0050 12.13 0.0040 5.13 0.0017 2.13 0.0007
560ºC 7.88 0.0016 6.88 0.0014 1.88 0.0004 102.88 0.0214 6.88 0.0014 7.88 0.0016 6.88 0.0014
655ºC -0.25 0.0000 -0.25 0.0000 -1.25 0.0002 128.75 0.0178 -1.25 0.0002 -2.25 0.0003 -2.25 0.0003
800ºC 16.50 0.0091 61.50 0.0341 0.50 0.0003 3.50 0.0019 2.50 0.0014 5.50 0.0030 0.50 0.0003
Practical measurement results give very often a nonlinear working curve, although theoretically it
should be a straight line, see Fig. 10.
S - Thermocouple Pt10%-RhPt10%
20
Voltages [mV]
15
10
0
-50 150 350 550 750 950 1150 1350 1550 1750
Temperature [єC]
-5
Fig. 10. The linearity of experimental working curve for thermocouple S-type 2.
For the strict requirements of linearity it is possible to use some mathematical tools for polynomial
approximations, see Fig. 11. The program packet ORIGIN is suitable for this purpose [8]. The
polynomial regression for thermocouple type R3 gives the best approximation with polynomial of
order seven:
y = A + B1 x + B2 x2 + B3 x3 + B4 x4 + B5 x5 + B6 x6 + B7 x7, (1)
with coefficients: A = 0.10688, B1 = -0.25295, B2 = 0.00595, B3 , B4 , B5 , B6 , and B7 are very

small values from –1.47 x 10-6 to –2.8 x 10-19.
1
For Etalon is taken average value of eight consecutive values-digital filtering [11].
2
Type S thermocouples use a platinum–rhodium alloy containing 10% rhodium for one conductor and pure platinum for the
other conductor. Like type R, type S thermocouples are used up to 1600 °C. In particular, type S is used as the standard of
calibration for the melting point of gold (1064.43 °C).
3
Type R thermocouples use a platinum–rhodium alloy containing 13% rhodium for one conductor and pure platinum for
the other conductor. Type R thermocouples are used up to 1600 °C [10].
24
2.50
Relative Error [%]

Pol. 5
2.00 Pol. 6
Pol. 7
1.50
Pol. 8
1.00 Pol. 5S
0.50
0.00
20 120 220 320 420 520 620 720 820 920 1020 1120
-0.50
-1.00
Temperature [єC]
-1.50
-2.00
-2.50
Fig. 11. The polynomial approximation errors of working curve.
In this concrete case the approximation with polynomial order seven is the most accurate (pink line),
because the absolute error is significantly less than 0.5º C in the wide temperature range (120 to
1120 ºC), as shown in Fig. 11.
5. Summary and Conclusion

The practical usage of described hardware with developed software solutions has shown very good
results. At the moment it is working as a prototype, Fig. 12, but there is an intention to integrate it into
laboratories equipment for the permanent thermocouple testing and calibration.
MMS CPU Interface
Fig. 12. The realized MMS and interface module in the same cabinet.
The system has been tested with different sets of thermocouples in the different temperature
measurement points. All the tests showed remarkably well behavior of the system, that is: a very good
stability and correctness [10, 11]. It is possible to make very good estimate of thermocouples quality
25
and do a selection with great probability of correctness. The use of described system in practice rapidly
decreased the costs and time for bad thermocouples testing and validation performed by official
institutions. The thermocouple production process is now more efficient and productive, thanks to
short response time for alloy testing.
Acknowledgements
This paper is supported by the Grant of the Ministry of Science of Republic of Serbia, as a part of a
project EE18016 within the framework of Technological development programme.
References
[1]. Sluzbeni list SCG, 44/2005, Zakon o metrologiji, Beograd Serbia, 2005.
[2]. Heraeus Sensor GMBH, Calibration System for Temperature Sensors, D-6450 Hanau, 2001.
[3]. Endress+Hauser, General Specifications Catalogue, Endress+Hauser GmbH+Co Instruments
International, D-79574 Weil am Rhein, 2001.
[4]. BUR-BROWN COMPANY, Master Link Software Libraries, Intelligent Instrumentation Inc., Tucson,
USA, 2000.
[5]. M68HC11 Reference Manual, Motorola Inc, 1990.
[6]. Milivojević D.R, Tasić V., Some Software Elements of the Microprocessor Measuring Station, Acta
Electrotechnica et Informatica_files, No. 2, Vol. 7, 2007.
[7]. Barney G. C. Intelligent instrumentation, Prentice Hall International, UK, 1988.
[8]. MicrocalTMOriginTM, Version: 5.0, Microcal Software, Inc, Northampton, MA01060 USA, 2004.
[9]. General Specifications Catalogue, Endres+Hauser, 2003.
[10].Smart Sensors Web Portal (http://www.smartsensors.com/tcouples.htm)
[11].Chao Hu, Max Q.-H Meng, Mrinal Mandal, Peter Xiaoping Liu, Xiangguang, Hua-Wei Liang, The
Development of High-Accuracy Microprocessor Based Thermocouple Calibrator, International Conference
on Information Acquisition, June 27-july 3, 2005, Hong Kong and Macau, China.
___________________
2009 Copyright ©, International Frequency Sensor Association (IFSA). All rights reserved.
(http://www.sensorsportal.com)
Universal Frequency-to-Digital
Converter (UFDC-1)
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difference and ratio, duty-cycle, duty-off factor, time
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Calibration System for Thermocouple Testing

Article · January 2009

Dragan Milivojevic Visa M Tasic

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Calibration System for Thermocouple Testing

Received: 12 November 2008 /Accepted: 19 January 2009 /Published: 26 January 2009

Keywords: Measuring system, Hardware interface, A/D conversion, Thermocouple examination

Furnace function control

Fig. 1. Hardware configuration of the measurement system.

Fig. 2. Heraeus Tube Furnace.

Digital value D/A output

Fig. 3. Electrical schema of temperature assignment.

Table 2. The definition of A/D conversion most significant bits.

Fig. 4. The thermocouple output signal selection and conditioning.

Fig. 5. Analog to digital conversion.

A/D input A/D input A/D input A/D input

Fig. 6. The A/D converter input voltage.

The main tasks of interactive on-line program are:

Fig. 7. Main on-line application menu.

Fig. 8. The MMS message format.

Fig. 9. The part of measurement data file.

4. Data Analyses and Results Interpretation

Thermocouple Thermocouple Thermocouple Thermocouple Thermocouple Thermocouple Thermocouple

with coefficients: A = 0.10688, B1 = -0.25295, B2 = 0.00595, B3 , B4 , B5 , B6 , and B7 are very

Relative Error [%]

Fig. 11. The polynomial approximation errors of working curve.

5. Summary and Conclusion

MMS CPU Interface

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