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Experimental Thermal and Fluid Science 34 (2010) 183189

Contents lists available at ScienceDirect

Experimental Thermal and Fluid Science


journal homepage: www.elsevier.com/locate/etfs

A fast response thermocouple for internal combustion engine surface


temperature measurements
Michael A. Marr, James S. Wallace *, Sanjeev Chandra, Larry Pershin, Javad Mostaghimi
Department of Mechanical and Industrial Engineering, University of Toronto, 5 Kings College Road, Toronto, Ontario, Canada M5S 3G8

a r t i c l e i n f o a b s t r a c t

Article history: A fast response thermocouple was developed for measuring surface temperatures of aluminum compo-
Received 11 June 2009 nents in ICE combustion chambers. The key features of the design are the use of the aluminum substrate
Received in revised form 23 September as one of the thermocouple metals and the use of a thick copper layer as the hot junction at the surface.
2009
The copper equalizes the hot junction temperature with the surrounding aluminum to correct for the dif-
Accepted 13 October 2009
ferences in thermal properties between the two materials. FEA determined the optimum thickness of the
copper layer to be between 100 and 125 lm. Under typical SI engine heat ux conditions, the thermocou-
ple should be able to measure average surface temperatures within 0.19 C and the magnitude of temper-
Keywords:
Internal combustion engine
ature swings within 6% of true values.
Surface thermocouple Following the FEA, the optimized thermocouple was tested in a SI engine. Experimental results dis-
Fast response thermocouple played the same trends as the FEA at measuring average temperatures and temperature swings, suggest-
Heat ux ing the thermocouple was performing as predicted.
2009 Elsevier Inc. All rights reserved.

1. Introduction mocouple element housed within a tube of a second element. A


thin metal junction forms the electrical connection between the
Measurement of combustion chamber surface temperatures is wire and tube at the thermocouple tip. Assanis and Badillos anal-
necessary for many areas of engine research. These authors require ysis found that type K and type J thermocouples overestimate the
surface temperature data for a study on thermal barrier coatings magnitude of true temperature swings by 59% and 69% respec-
(TBCs) in an aluminum alloy spark-ignition (SI) engine. For many tively. This difference is due to the substantially different thermal
years, the thermocouple has been the sensor most commonly used properties of the aluminum substrate compared to the thermocou-
to measure surface temperatures. However, there is no consensus ple materials. Aluminums thermal conductivity is at least three
about the optimal thermocouple design or even general congura- times greater than that of every metal in type K and type J thermo-
tion that best suits fast response engine applications. couples, and aluminums thermal diffusivity is at least four times
The primary consideration when selecting or designing a sur- greater than that of the thermocouple metals. As such, heat does
face thermocouple is accuracy at measuring true temperatures, not diffuse as readily through the thermocouple and its junction
being the temperatures that would exist if the thermocouple was experiences larger temperature swings than the more conductive
not present. Indeed, this criteria embodies the experimenters age aluminum substrate. This difference in thermal properties also
old challenge of taking measurements without changing what is introduces lateral heat conduction between the thermocouple
being measured. For the surface thermocouple, this includes accu- and the substrate. Similar coaxial thermocouples have been used
rate measurement of average temperatures and temperature in recent engine heat transfer studies [2,3].
swings, while minimizing delays in response time. Additionally, Furuhama and Enomoto developed a different coaxial thermo-
the thermocouple should be robust and simple to fabricate and in- couple which their analysis found to be very accurate at measuring
stall. Finally, it is necessary that it ts within a researchers budget. temperature swings [4]. The design featured a 3 mm aluminum
The accuracy issue was explored in 1989 by Assanis and Badillo cylinder with a 0.17 mm hole drilled through to house an insulated
[1], who used Finite Element Analysis (FEA) to model a 0.452 mm constantan wire. Interestingly, copper was used to form the
diameter coaxial thermocouple embedded in an aluminum piston. junction and its thickness was optimized to provide sufcient heat
A coaxial thermocouple is essentially an insulated wire of one ther- conduction from the wire tip to the aluminum to allow for temper-
ature equalization. The optimal copper thickness was found to be
710 lm. However, the 0.17 mm diameter hole is too small to be
* Corresponding author. Tel.: +1 416 978 4899; fax: +1 416 978 7753. drilled in a standard machine shop and therefore this exact design
E-mail address: wallace@mie.utoronto.ca (J.S. Wallace). was not feasible for the present study.

0894-1777/$ - see front matter 2009 Elsevier Inc. All rights reserved.
doi:10.1016/j.expthermusci.2009.10.008
184 M.A. Marr et al. / Experimental Thermal and Fluid Science 34 (2010) 183189

The eroding thermocouple is another style of thermocouple that


is frequently used for engine measurements. The design utilizes
two thin ribbons of thermocouple element, insulated and housed
within a metal sheath. The electrical connection between the two
elements is formed by abrading the surface. Yet despite the small
size of the thermocouple elements, FEA by Buttsworth [5] shows
the temperature at the junction is signicantly higher than that
of the sheath during transient heat ux.
An alternative surface thermocouple (Fig. 1) was developed by
Heichal et al. [6] to measure temperatures of liquid droplets
impacting a metal surface. The steel substrate was used as one of
the thermocouple elements, and a 0.25 mm diameter constantan
wire was the second element. The wire was cemented in a
0.57 mm diameter hole through the steel, and the junction was
formed at the surface with an electrically conductive lm. Fig. 2. Thermocouple schematic.

As the substrate is one of the elements, the Heichal et al. design


has the potential to produce accurate true surface temperature
The ceramic cement (Omega product number CC HIGH TEMP) is
measurements. Additionally, it is simple enough to be fabricated
the same type used by Heichal et al.
in a typical machine shop. However, it was found that modica-
The second signicant modication was the addition of a
tions were required to improve its robustness and accuracy for en-
thick copper layer applied by a wire arc spray coating technique.
gine use.
The copper performs the same function as it did with the
This paper describes the modications made to the Heichal
Furuhama and Enomoto thermocouple [4], that being to conduct
et al. thermocouple to improve it for measuring temperatures of
heat away from the tip of the constantan wire to the aluminum
aluminum combustion chamber surfaces. The process included
substrate. Thus, the copper helps to equalize the temperature of
the use of FEA to optimize and evaluate the design. Ultimately,
the constantan and the aluminum substrate, allowing the ther-
the thermocouple was tested in an SI engine.
mocouple to measure true temperatures much more accurately.
The negative consequence of the copper layer is that it delays
the thermocouples response time. However, as will be shown
2. Thermocouple
in the Finite Element Analysis section, this delay is small and
acceptable when considering the accuracy improvements the
The modied thermocouple is illustrated in Fig. 2. The position
copper layer provides. The copper also forms the electrical
of the cold junction was chosen arbitrarily as an example; the po-
connection between the aluminum and the constantan. The
sition can be selected by the experimenter for convenience of mea-
thickness of the junction was optimized using FEA as described
suring its temperature. If possible the cold junction should be
in the next section.
positioned in an ice bath to eliminate the need for an additional
temperature sensor.
The rst change from the Heichal et al. design was the addition 3. Finite Element Analysis
of the Teon coating on the wire, which is simply the standard
insulator sold with the wire (Omega product number TFCI-010- COMSOL Multiphysics FEA software was used to model the
XX). The Teon coating was left on as otherwise electrical isolation thermocouple under typical SI engine heat transfer conditions.
between the wire and the substrate could not be achieved consis- The geometry and boundary conditions used for the analysis are
tently with cement alone. It should be noted that while Teons shown in Fig. 3, and relevant material properties are listed in Table
melting temperature is 327 C, it is only rated to 260 C and the 1. The model was two-dimensional axial symmetric in cylindrical
thermocouple may not be suitable for temperatures above this. coordinates to provide a three-dimensional equivalent output.

Fig. 1. Heichal et al. thermocouple [6].


M.A. Marr et al. / Experimental Thermal and Fluid Science 34 (2010) 183189 185

1500 RPM. The lower boundary condition was set at 100 C, and
the aluminum side wall was modeled as thermally insulated.
The geometry was meshed by COMSOL with variable spacing
with the highest density around the hot junction. The time step
was set at 0.1 ms. Trials found that further renement of the mesh
or time step did not substantially alter the FEA output.
Fig. 5 shows FEA computed hot junction temperatures for a
range of copper thicknesses. The No Copper temperatures were
obtained by running the FEA model without the copper layer,
and the True temperatures were obtained by running the model
without the copper layer and with all other materials changed to
aluminum. The True results represent the surface temperatures
that would be measured by a perfectly accurate thermocouple.
Most striking about Fig. 5 is the No Copper curve, which has an
average temperature and temperature swing signicantly greater
than True values. This demonstrates the importance of the copper
layer for removing heat from the hot junction to equalize its tem-
perature with the substrate.
The thermocouple is highly accurate at measuring cycle aver-
aged temperatures over a wide range of copper layer thicknesses.
The range of thicknesses shown in Fig. 5, 75400 lm, all measure
the average temperature within 0.23 C of the True average tem-
Fig. 3. FEA model geometry and boundary conditions (all dimensions in mm, not to perature. If copper thickness is reduced to 10 lm, the thermocou-
scale). ple would still measure an average temperature within 0.8 C of
the True value.
When measuring the magnitude of surface temperature swings,
Table 1
Material properties.
the specic thickness of the copper layer is more important. In
Fig. 5, the 75 lm case overestimates the True temperature swing
Material k (W/m K) qkg=m3 C (J/kg K) by 11% while the 400 lm case underestimates it by 44%. The opti-
Constantan 19.5 8900 390 mal thickness of the copper layer was found to be between 100 and
Teon 0.23 2190 1010 125 lm, as shown in Fig. 6. These thicknesses will measure the
Ceramic cement 1.2 2260 1000
True temperature swing within 2% and 6% accuracy respectively.
Aluminum 155 2750 915
Copper 400 8700 385 Furthermore, in this thickness range the delay in peak temperature
occurrence from the True value is less than 5 Crank Angle (CA).
This delay is on the order of 10% of combustion duration, but is a
necessary trade-off for improved temperature measurement accu-
In the analysis, the thermocouple output was assumed to be the
racy. If desired, temperature data could be shifted by a processing
temperature at the hot junction marked in Fig. 3. This assumption
algorithm to offset the delay. Table 2 provides a numerical sum-
therefore ignores the temperature difference across the copper be-
mary of FEA results shown in Figs. 5 and 6.
tween the hot junction and the aluminumcement interface. This
To conrm the thermocouples accuracy over a range of heat
is a reasonable assumption because the temperature difference
transfer conditions, the analysis was repeated twice using different
was generally small, and copper and aluminum have similar ther-
convective heat transfer boundary conditions. First, the model was
moelectric powers which are considerably smaller in magnitude
run using twice the Alkidas and Myers convective heat ux, the
than constantans. For example, at 100 C the thermoelectric volt-
results of which are shown in Fig. 7. Second, the analysis was per-
ages of copper, aluminum and constantan are approximately 1.0,
formed with heat ux calculated from in-cylinder gas tempera-
0.5 and 4.0 mV respectively when paired with platinum with
tures and a heat transfer coefcient. Gas temperatures were
the reference junction at 0 C [7].
taken from previous SI engine work by Enomoto and Furuhama
The time varying boundary condition for the upper surface was
[9], and the heat transfer coefcient was calculated with the
convective heat ux as shown in Fig. 4. These data were taken from
Woschni equation [10] using temperature and pressure data from
measurements by Alkidas and Myers [8] in the cylinder head of a
Enomoto and Furuhama. Hot junction temperatures from the anal-
propane-fueled SI engine running slightly lean at part load and
ysis with the Woschni equation are shown in Fig. 8.

Fig. 4. Convective heat ux data taken from Alkidas and Myers [8]. Fig. 5. Hot junction temperature with varied copper thickness.
186 M.A. Marr et al. / Experimental Thermal and Fluid Science 34 (2010) 183189

Fig. 6. Hot junction temperature with 100 and 125 lm copper layers. Fig. 9. Hot junction temperature with 0.5 mm YSZ TBC.

Table 2 (k = 2 W/m K, q = 5100 kg/m3, C = 590 J/kg K) was added on top of


Numerical summary of FEA results shown in Figs. 5 and 6.
the copper layer. The TBC results are shown in Fig. 9. Without
Copper thickness Average Temp Peak temp delay the copper layer, the thermocouple overestimates true tempera-
(lm) temp (C) swing (C) (CA) tures by 45 C. However, with copper layers between 125 and
True values 107.22 6.01 32.4
400 lm thick, hot junction temperatures are within 0.2 C of True
Difference at hot junction from true values values. With a thickness of 400 lm, hot junction temperatures are
0 (No Copper) +7.87 +12.77 +1.8 only 0.09 C above True values. Temperature swings are minimal
75 +0.23 +0.69 +0.9
100 +0.19 +0.09 +2.7
under the TBC, and therefore a wide range of copper thicknesses
125 +0.16 0.37 +4.5 can be used while still producing accurate measurements.
400 +0.09 2.65 +13.5

4. Engine testing

A single cylinder, gasoline-fueled, Cooperative Fuels Research


(CFR) engine was used for testing the optimized thermocouple.
This engine was chosen because it features three threaded access
ports around the upper cylinder perimeter as illustrated in
Fig. 10. All three ports are fully in the clearance volume and there-
fore continuously exposed to in-cylinder gases. Three thermocou-
ples were built in a single aluminum plug that could be threaded
into either Port B or Port C. The thermocouples were spaced
4.5 mm apart along a line that oriented vertically when the plug
was installed in the engine. To label the thermocouples, Thermo-
couple 1 was highest (closest to the cylinder head), Thermocouple
2 was in the middle and Thermocouple 3 at the lowest. To com-
plete the thermocouple loop, an aluminum wire was clamped to
Fig. 7. Hot junction temperature with 2 Alkidas and Myers convective heat ux. the plug and joined with another constantan wire in an ice bath
to form the cold junction. A schematic of the thermocouple setup
used for the engine testing is shown in Fig. 11. A control plug
was fabricated with a type K thermocouple embedded 3 mm from
the face. The control plug was installed in port A for all tests to pro-
vide an indication of the consistency of test conditions.

Fig. 8. Hot junction temperature with Woschni heat transfer coefcient.

Figs. 7 and 8 conrm that, with a 125 lm copper layer, the ther-
mocouple should produce highly accurate temperature
measurements.
Finally, as the authors intend to use the thermocouple to study
TBCs, the FEA was performed with the thermocouple behind a
layer of Yttria-Stabilized Zirconia (YSZ). The geometry shown in
Fig. 3 was again used, except a 0.5 mm thick layer of YSZ Fig. 10. Cylinder wall access port conguration. Adapted from [11].
M.A. Marr et al. / Experimental Thermal and Fluid Science 34 (2010) 183189 187

recording. Instantaneous temperatures were measured intermit-


tently in packets of 10 consecutive cycles with a sampling rate of
0.2 CA. An optical encoder (BEI model number H25D-SS-1800-
ABZ) coupled to the crank shaft provided the timing signal for
the instantaneous measurements.
MATLAB code was used to further process the instantaneous
temperature measurements. A 25 point (5 CA) moving average
smoothing algorithm was applied to damp remaining random
noise, and temperatures were shifted 0.001 s to offset the delay
introduced by the analog lter. Additionally, the code removed
the occasional large noise spike transmitted through the analog l-
ter. These spikes were only found around spark and exhaust valve
closure. Finally, the code identied the minimum and maximum
temperatures of each cycle and the crank angle position of the
maximum.
The thermocouple plug was tested with ve surface conditions
applied in the following sequence as described:

1. 400 lm A coating of copper was applied by wire arc spray to


the face of the surface thermocouple plug. The copper was
Fig. 11. Thermocouple setup for engine testing. machined on a lathe to a thickness of 400 lm.
2. YSZ The copper layer was removed and a new copper layer
approximately 400 lm thick was applied. A 400 lm coating of
The constantanaluminum thermocouple combination was cal- YSZ was applied by plasma spray on top of the copper.
ibrated against a type J thermocouple in an oven. Both pairs of 3. 237 lm The YSZ was removed and the copper underneath was
thermocouple wires were embedded in an aluminum block to machined to a thickness of 237 lm.
avoid fast temperature changes. Calibration voltage data were re- 4. 125 lm The copper was further machined to a thickness of
corded from room temperature to 250 C during both heating 125 lm.
and cooling. A third-order polynomial was t to the data to nd 5. 75 lm The copper was removed and a new layer was applied
the temperaturevoltage relationship, which averaged 44 lV/C and machined to a thickness 75 lm.
over that temperature range.
Due to the noisy test environment and the low magnitude of the It should be noted that copper was applied three times in the
output, analog signal conditioning was required prior to measure- above sequence, and being that there were three thermocouples
ment by the data acquisition board. First the raw voltages were in the plug, the thermocouple was essentially fabricated nine
amplied by a factor of 100 by a differential amplier (Analog De- times. The thickness of the copper layer was determined by mea-
vices product number AD626). Subsequently the amplied signals suring the overall length of the plug with a micrometer before
were passed through an active two-pole low-pass Butterworth l- coating and then after coating and machining. Thicknesses were
ter with a cut-off frequency of 200 Hz. This cut-off frequency pro- veried after engine testing by measuring before and after remov-
vided high noise reduction with minimal damping of the signal. ing the coating with the lathe. It is estimated that the thickness
The lters were built following the modied Sallen-Key circuit de- values listed are accurate within 25 lm.
sign [12]. Three parallel amplierlter modules were built to per- For all tests 87 octane regular pump gasoline was used and the
mit sampling of all three surface thermocouples simultaneously. compression ratio was set to approximately 8.7:1. The crank shaft
The conditioned thermocouple signals were acquired with a Na- was coupled to a DC dynamometer to maintain the engine speed at
tional Instruments PCI-6251 data acquisition board through a SCB- 1500 RPM at wide open throttle with a stoichiometric air-fuel mix-
68 termination block. LabVIEW software was used to convert volt- ture. Spark timing was set at 20 CA before top center for maxi-
age readings to temperatures. mum brake torque. A 12 min warm-up was performed before
During testing, average temperatures were measured at a fre- measurements were taken. By this time, the cooling water temper-
quency of 1000 Hz and averaged into one second intervals for ature had stabilized at its boiling point and plug temperatures

Table 3
Engine test results.

Port Copper thickness Control temp Thermocouple 1 Thermocouple 2 Thermocouple 3


(lm) (C)
Avg tempa Temp Peakb Avg tempa Temp Peakb Avg tempa Temp Peakb
(C) swingb,c (C) (CA) (C) swingb,c (C) (CA) (C) swingb,c (C) (CA)
B 400 131.4 157.5 2.8 (0.31) 146.4 156.4 3.5 (0.33) 137.4 155.0 2.9 (0.32) 145.5
237 130.0 152.2 5.2 (0.62) 85.0 151.7 5.1 (0.46) 95.1 151.0 4.3 (0.46) 93.5
125 129.6 153.9 6.8 (0.95) 63.5 153.7 6.2 (0.69) 69.6 153.2 5.0 (0.59) 69.7
75 129.7 154.2 5.9 (0.93) 62.6 154.5 7.9 (1.01) 53.6 154.1 6.2 (0.75) 69.8
C 400 131.2 153.4 2.3 (0.26) 152.6 153.1 2.8 (0.31) 147.1 151.9 2.3 (0.27) 148.4
237 129.5 150.0 4.1 (0.49) 94.0 149.3 4.0 (0.44) 101.4 148.2 3.5 (0.45) 95.4
125 129.9 150.7 5.1 (0.66) 69.7 150.2 5.0 (0.60) 73.9 149.4 3.9 (0.45) 70.2
75 129.8 152.7 4.5 (0.60) 70.5 152.3 6.3 (0.81) 59.0 151.4 5.2 (0.64) 74.0
a
Results are averages from at least 12 min of testing with sampling frequency of 1000 Hz.
b
Results are averages from at least 300 engine cycles sampled every 0.2 CA.
c
Standard deviations shown in brackets.
188 M.A. Marr et al. / Experimental Thermal and Fluid Science 34 (2010) 183189

were approximately steady. At least 300 cycles of instantaneous


data were collected for each surface condition.
The results from the engine tests are summarized in Table 3.
The engine featured a masked intake valve to generate swirl, which
is the likely reason for Port B having higher average temperatures
and larger temperature swings than Port C. Examples of represen-
tative instantaneous temperature proles are shown in Figs. 12
and 13. To allow for direct comparison of the shapes of the temper-
ature proles, the curves were shifted to have average tempera-
tures of 0 C.
For all but one copper thickness and port combination in Table 3
(75 lm in Port B being the exception), Thermocouple 1 has the
highest average temperature, followed by Thermocouples 2 and 3
Fig. 14. Ratios of average temperature swing to average temperature swing at
respectively. This consistency supports the accuracy of the thermo-
400 lm copper layer thickness black lines indicate FEA ratios.
couple at reading averages temperatures.
The temperature swing values in Table 3 and the temperature
proles in Figs. 12 and 13 generally show the same trends as sug- one in nine occurrence. Additional care during fabrication could re-
gested by the FEA. To make this clearer, Fig. 14 shows the ratios of duce this frequency.
average temperature swing to the average temperature swing at The errors associated with this thermocouple measurement
400 lm copper layer thickness. The FEA computed ratios are indi- system can be divided into three components. First, a component
cated with black lines. Thermocouples 2 and 3 follow the FEA trend of the error is due to the design of the thermocouple. This error
with all copper thicknesses, but Thermocouple 1 has a substan- component is illustrated by the FEA, which found that the thermo-
tially higher ratio with both 125 and 237 lm copper layer thick- couple could not measure the True surface temperatures with
nesses. These thicknesses had the same copper application, any copper layer thickness. Second, a component of the error can
suggesting possibility of an irregularity during coating or pre-coat- be attributed to thermocouple fabrication, and primarily to fabrica-
ing preparation resulted in an imperfect copper layer around Ther- tion of the copper layer. Deviations in the thickness and thermal
mocouple 1s hot junction. properties of the actual copper layer from that of the FEA modeled
It is impossible to know the true magnitude of the temperature thermocouple would affect accuracy. Finally, the third component
swings the thermocouples were measuring. The consistency be- includes the errors that are present in any thermocouple measure-
tween the FEA and experimental results suggests the thermocou- ment system. These errors include imperfect calibration and data
ples were accurate. The irregularities displayed by Thermocouple acquisition system inaccuracies.
1 with 125 and 237 lm copper layer thickness were effectively a The FEA found that the thermocouple could measure average
temperatures within 0.19 C and the magnitude of temperature
swings within 6% when copper layer thickness was between 100
and 125 lm. These accuracy values include the rst error compo-
nent and part of the second, as it is assumed that the 25 lm thick-
ness window is within fabrication capabilities. However, as
demonstrated by Thermocouple 1 with 125 and 237 lm copper
thicknesses, care must be taken during fabrication to ensure errors
are not larger. New copper application techniques, such as electro-
plating, could reduce fabrication errors. The third error component
would vary from experiment to experiment depending on the
quality of data acquisition system equipment used for calibration
and subsequent test measurements.
While the results of the YSZ coated tests were not explored in
detail, a sample temperature prole is presented in Fig. 15. The
coating damps the temperature swing to the point where it is no
Fig. 12. Representative cycles of Thermocouple 2 in Port B (temperatures shifted to longer visible to the human eye. This level of damping is consistent
provide average temperature of 0 C).
with the results of the FEA run with the YSZ coating, as shown in
Fig. 9.

Fig. 13. Representative cycles of Thermocouple 3 in Port C (temperatures shifted to Fig. 15. Sample cycle of Thermocouple 2 with YSZ coating in Port B (temperatures
provide average temperature of 0 C). shifted to provide average temperature of 0 C).
M.A. Marr et al. / Experimental Thermal and Fluid Science 34 (2010) 183189 189

5. Conclusions References

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