OPTIMIZED THERMOCOUPLE SYSTEM AND METHOD
An optimized thermocouple system and a method of optimizing a thermocouple system having a plurality of thermocouple probes and a junction box is provided and includes examining the thermocouple system to identify a first thermocouple probe of the plurality of thermocouple probes, wherein the first thermocouple probe includes a first positive leg and a first negative leg and is located electrically farthest from the junction box. The method includes calculating a first loop resistance between the first thermocouple probe and the junction box and configuring a second thermocouple probe of the plurality of thermocouple probes having a second positive leg, a second negative leg and a second loop resistance such that the second loop resistance is substantially equal to the first loop resistance.
1 . A thermocouple wire harness comprising:
at least two first wire legs of a first material having a first resistivity, each first wire leg having a total wire length from a first end to a second end configured to connect to a respective thermocouple; and
at least two second wire legs of a second material having a second resistivity different than the first resistivity, each second wire leg having a total wire length from a first end to a second end configured to connect to one of the respective thermocouples,
wherein the total wire length of at least one of the second wire legs is greater than the total wire length of each of the at least two first wire legs, or wherein the total wire length of at least one of the first wire legs is shorter than the total wire length of each of the at least two second wire legs, and
wherein the lengths of the at least two first wire legs and the at least two second wire legs are configured to balance series resistance between the thermocouples.
2 . The thermocouple wire harness according to claim 1 , wherein the at least one second wire leg having the total wire length greater than the total wire length of each of the at least two first wire legs is looped.
3 . The thermocouple wire harness according to claim 1 , further comprising:
at least two third wire legs of the first material having the first resistivity, each third wire leg being configured to connect to a respective one of the plurality of thermocouples; and
at least two fourth wire legs of the second material having the second resistivity, each fourth wire leg being configured to connect to a respective one of the plurality of thermocouples.
4 . The thermocouple wire harness according to claim 3 , wherein at least one of the at least two fourth wire legs has a total wire length from a first end to a second end greater than a total wire length from a first end to a second end of each of the at least two third wire legs.
5 . The thermocouple wire harness according to claim 4 , wherein the total wire length of at least one of the at least two second wire legs and at least one of the at least two fourth wire legs is greater than the total wire length of each of the at least two first wire legs and at least two third wire legs.
6 . The thermocouple wire harness according to claim 5 , wherein the at least one second wire leg having the total wire length greater than the total wire length of each of the at least two first wire legs is looped, and the at least one fourth wire leg having the total wire length greater than the total wire length of each of the at least two third wire legs is looped.
7 . The thermocouple wire harness according to claim 3 , wherein at least one of the at least two fourth wire legs has a total wire length from a first end to a second end greater than a total wire length from a first end to a second end of each of the at least two third wire legs, and wherein the total wire length of at least one of the at least two second wire legs and at least one of the at least two fourth wire legs is greater than the total wire length of each of the at least two first wire legs and at least two third wire legs.
8 . The thermocouple wire harness according to claim 3 , wherein at least one of the at least two third wire legs has a total wire length from a first end to a second end shorter than a total wire length of each of the at least two fourth wire legs.
9 . The thermocouple wire harness according to claim 8 , where the total wire length of at least one of the at least two first wire legs and at least one of the at least two third wire legs is shorter than the total wire length of each of the at least two second wire legs and at least two fourth wire legs.
10 . There thermocouple wire harness according to claim 3 , wherein the at least two first wire legs, the at least two second wire legs, the at least two third wire legs, and the at least two fourth wire legs are the same wire gage.
11 . A thermocouple wire harness comprising:
a first wire leg of a first material having a first resistivity and being configured to connect to a first thermocouple;
a second wire leg of the first material having the first resistivity and being configured to connect to a second thermocouple;
a third wire leg of a second material having a second resistivity different from the first resistivity and being configured to connect to the first thermocouple; and
a fourth wire leg of the second material having the second resistivity and being configured to connect to the second thermocouple,
wherein at least one of the third and fourth wire legs has a length greater than a length of each of the first and second wire legs, or wherein at least one of the first and second wire legs has a length shorter than the length of each of the third and fourth wire legs, and
wherein the lengths of the wire legs are configured to balance series resistance between the first and second thermocouples.
12 . The thermocouple wire harness according to claim 11 , wherein the length of at least one of the third and fourth wire legs is greater than the length of each of the first and second wire legs, and wherein the length of at least one of the first and second wire legs is shorter than the length of each of the third and fourth wire legs.
13 . The thermocouple wire harness according to claim 12 , wherein the length of the third wire leg is greater than the length of each of the first and second wire legs, and wherein the third wire leg is looped.
14 . The thermocouple wire harness according to claim 12 , further comprising:
a fifth wire leg of the first material having the first resistivity and being configured to connect to a third thermocouple;
a sixth wire leg of the first material having the first resistivity and being configured to connect to a fourth thermocouple;
a seventh wire leg of the second material having the second resistivity and being configured to connect to the third thermocouple; and
an eighth wire leg of the second material having the second resistivity and being configured to connect to the fourth thermocouple,
wherein at least one of the seventh and eighth wire legs has a length greater than a length of each of the fifth and sixth wire legs, and wherein at least one of the fifth and sixth wire legs has a length shorter than the length of each of the seventh and eighth wire legs.
15 . The thermocouple wire harness according to claim 11 , wherein harness includes a total resistance including a first channel loop resistance being the loop resistance of the first and third wire legs, and a second channel loop resistance being the loop resistance of the second and fourth wire legs.
16 . A thermocouple wire harness comprising:
at least two first wire legs of a first material having a first resistivity, each wire leg being configured to connect to a respective one of a plurality of thermocouples; and
at least two second wire legs of a second material having a second resistivity different than the first resistivity, each wire leg being configured to connect to a respective one of the plurality of thermocouples,
wherein at least one of the at least two second wire legs has a length greater than a length of each of the at least two first wire legs, the at least one second wire leg having the length greater than the length of each of the at least two first wire legs being looped, and
wherein the lengths of the wire legs are configured to balance series resistance between the plurality of thermocouples.
17 . The thermocouple wire harness according to claim 16 , further comprising:
at least two third wire legs of the first material having the first resistivity and being of the first wire gage, each wire leg being configured to connect to a respective one of the plurality of thermocouples; and
at least two fourth wire legs of the second material having the second resistivity and being of the first wire gage, each wire leg being configured to connect to a respective one of the plurality of thermocouples,
wherein at least one of the at least two fourth wire legs has a length greater than a length of each of the at least two third wire legs, and the at least one fourth wire leg having the length greater than the length of each of the at least two third wire legs is looped.
18 . The thermocouple wire harness according to claim 17 , wherein the length of at least one of the at least two second wire legs and at least one of the at least two fourth wire legs is greater than the length of each of the at least two first wire legs and at least two third wire legs.
19 . The thermocouple wire harness according to claim 17 , wherein at least one of the at least two first wire legs has a length shorter than the length of each of the at least two second wire legs, and wherein at least one of the at least two third wire legs has a length shorter than the length of each of the at least two fourth wire legs.
20 . The thermocouple wire harness according to claim 19 , where the length of at least one of the at least two first wire legs and at least one of the at least two third wire legs is shorter than the length of each of the at least two second wire legs and at least two fourth wire legs.