What are the biggest technological challenges in manufacturing wired temperature sensors for the HVAC industry? The customer's problem

The customer, operating in the HVAC industry, faced the challenge of creating a new generation of cable temperature sensors for heating systems that had to be both reliable, precise and affordable. He needed sensors that could operate at high temperatures. He also required that they operate in dry ambient conditions. What's more, the accuracy of the measurements had to meet stringent standards, which meant the use of Pt100 and Pt1000 platinum resistors with an accuracy class of F0.3. In addition, the design had to be extremely compact, which raised the difficulty of miniaturization, while it was necessary to provide an axial design where the sensor would be in the center and the cable outputs on either side. The customer needed a solution that would meet these requirements and at the same time allow cost-effective large-scale production.

How did the use of SMD temperature sensor inserts on PCBs help optimize the cost of manufacturing wired temperature sensors?

When our team started working on a solution for a customer, we knew we needed something that would combine precision and compactness with manufacturing economy. The customer was looking for measurement modules that could be integrated into their cable temperature sensors, which are used in heating systems. The requirements were clear - we needed to provide a solution that could handle temperatures up to 150 °C while maintaining full functionality and reliability, but in a much smaller size than traditional sensors.

We proposed a temperature measurement module based on Pt100 and Pt1000 platinum chips, mounted on a PCB in an extremely compact form factor. This allowed the customer to produce cost-effective sensors that fit perfectly into their systems, while providing a cheaper alternative to traditional sensors with connecting wires. What's more, the board's design not only met space constraints, but also facilitated the installation of an axial cable sensor, where the sensor is centrally located and the connection wires exit at the sides.

Knowing that the customer values flexibility, we tailored our product to meet different production needs. Our modules can be supplied in strip form or individually, depending on order specifications. The choice of SMD assembly technology on the board brought additional benefits - the handling process became simpler, and further processing of the board into finished cable sensors was much easier to automate, allowing the customer to increase production efficiency and reduce costs.

How have our temperature sensor measuring inserts contributed to manufacturing cost savings? Customer benefits

Thanks to our solution, the customer gained a significant cost advantage in the production of large quantities of sensors, starting from 50 units. The miniature design not only fit perfectly into their heating systems, but also enabled easy handling, which greatly accelerated the installation process. What's more, the possibility of automated or semi-automated processing of semi-manufactured parts allowed further increases in production efficiency, while reducing costs. In addition, the circuit boards we designed underwent rigorous testing in accordance with DIN EN IEC 60751, providing the customer with confidence that their products are robust, resistant to thermal cycling and ready for long-term use.

About the author

My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.

Comments

We encourage you to leave comments using the form below. They will be published online after they have been approved by our verification process.