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Comprehensive Guide to System-Level Thermocouple Calibration

1. Principle of Thermocouple Measurement

Thermocouples operate on the Seebeck Effect: when two dissimilar metals are joined at two points and subjected to a temperature gradient, a proportional thermoelectric voltage is generated.

In a practical data acquisition (DAQ) system, the signal path is defined by the following equation:

$$V_{out} = G [V(T_{hot}) - V(T_{cold}) + V_{cjc}]$$

Variable Breakdown:

  • $T_{hot}$ (Measurement Junction): The actual temperature you are trying to measure at the tip of the probe.
  • $T_{cold}$ (Reference Junction): The point where the thermocouple wires connect to the DAQ system (which is usually copper). This connection creates a new, unwanted thermocouple.
  • $V_{cjc}$ (Cold Junction Compensation): Because the DAQ terminals are at ambient room temperature (not absolute zero or 0°C), we must compensate for this offset. The DAQ uses a localized, high-precision sensor (like an RTD or thermistor) to measure the exact temperature of the terminal block, converts that temperature to its equivalent voltage ($V_{cjc}$), and mathematically adds it back into the equation.
  • $G$ (System Gain): The amplification factor applied by the measurement hardware to scale the microvolt-level signals up to readable levels for the ADC.
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Modbus RTU (Example of load cell module)

1) Frame structure (RTU)

Field Size Notes
Address 1 byte Slave ID: 1…247 (0 = broadcast; 248–255 reserved).
Function code 1 byte e.g., 0x03 Read Holding Regs; 0x06 Write Single Reg.
Data 0…252 B Depends on function: start address, quantity, payload, byte count…
CRC-16 2 bytes Little-endian on the wire: CRC low byte first, then high byte. Polynomial 0xA001, init 0xFFFF.

Framing by silence:3.5 character times between frames; ≤ 1.5 character times between bytes within a frame.


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