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Pt100-C Platinum Thin Film Temperature Sensor: Providing Reliable Temperature Data in Critical Applications
Core Material Advantages of Pure Platinum Thin Film
Pt100-C selects high-purity platinum as the temperature-sensing material. Its resistance-temperature relationship is highly linear (approximate linear coefficient α=0.00385/℃), and its chemical stability is extremely strong, allowing it to withstand oxidation, reduction, and various corrosive media environments for long periods. It features excellent repeatability and high consistency between factory batches, ensuring data comparability during multi-point system measurements.
Thin film technology involves sputtering and depositing platinum layers onto ceramic substrates to form micron-level resistance patterns, with the 0℃ resistance precisely adjusted to 100.00Ω via laser trimming. Compared to traditional wire-wound structures, this has a smaller thermal mass, typically shortening response time (t0.5) to 3–8 seconds in air and reaching 1–3 seconds in liquids or flowing gases, significantly enhancing the ability to capture temperature transients.
The operating range is -50℃ to +500℃ (typical upper limit for thin film types), and accuracy complies with IEC 60751 Class A or B: Class A ±(0.15 + 0.002|t|)℃, Class B ±(0.3 + 0.005|t|)℃. Long-term stability has been verified by high-temperature aging tests, with 1000-hour drift <0.04% and an annual drift rate as low as 0.01–0.02%.
Adapting to Diverse and Harsh Measurement Scenarios
In industrial process control, Pt100-C directly contacts liquid, steam, or gas media. 316L stainless steel sheaths or ceramic packaging provide protection above IP67. The vibration-resistant design (withstanding 50g vibration) is suitable for vibration environments such as pumps, compressors, and mixing equipment, outputting reliable temperature signals in real-time to support closed-loop regulation.
In the new energy field, its small size (probe diameter can be as low as φ3mm) and fast response characteristics make it ideal for lithium battery BMS, solid-state battery thermal management, and temperature monitoring of photovoltaic inverter power devices. In thermal runaway risk scenarios, it can provide accurate feedback within the first few seconds of temperature rise, assisting in the execution of protection strategies.
In wind power and outdoor equipment, the sensor's encapsulation process ensures resistance to weathering, salt spray, and UV, reducing maintenance frequency in extreme weather. The compact structure facilitates embedding into blade bearings, gearboxes, or generator windings for continuous online monitoring.
Unity of Technical Features and Engineering Practice Value
Pt100-C achieves a balance across multiple indicators in its design: equal emphasis on initial accuracy and long-term stability, with self-heating effects controlled within 0.1℃ (0.3–0.5mA excitation); the thin film structure brings fast response while mechanical strength is not inferior to wire-wound types; the compact volume facilitates integration into tight spaces without sacrificing durability.
Three-wire or four-wire connections eliminate the influence of lead resistance, making it compatible with most PLCs, transmitters, and data acquisition modules. Low self-heating and high insulation (>100MΩ/500VDC) are suitable for precision measurement. Welding is compatible with reflow/wave soldering, supporting automated production lines.
In critical applications, choosing Pt100-C means trustworthy data: battery systems reduce misjudgments of thermal runaway, wind power equipment extends failure-free operation time, and process control reduces energy consumption and scrap rates caused by deviations.
Selection, Installation, and Long-term Usage Guide
When selecting, focus on accuracy (Class A high precision, Class B economy), probe form (thread/ferrule/surface mount), and lead material (glass fiber/PTFE/silicone, depending on temperature and environment). Connections of three-wire or higher are recommended, with excitation current ≤1mA.
Ensure good thermal contact during installation and avoid stress concentration or over-temperature; add protective covers for outdoor applications to prevent condensation. Periodically calibrate (1–2 years) by checking 0℃/100℃ points with a standard constant temperature source; replace the core rather than the entire system if drift is abnormal.
Frequently Asked Questions (FAQ)
| Question | Detailed Answer |
|---|---|
| Q1: Compared to traditional wire-wound Pt100, what specific improvements does the Pt100-C thin film sensor offer in response speed and mechanical performance? | A1: The thin film structure has a small thermal mass, shortening t0.5 response time to 3–8 seconds (air) and 1–3 seconds in liquids, which is about 1/3–1/5 of the wire-wound type; vibration resistance is strong (50g), suitable for mobile or vibrating equipment, whereas wire-wound types are prone to wire breakage from mechanical stress. |
| Q2: How do Class A and Class B tolerances in the IEC 60751 standard actually perform on Pt100-C thin film types? | A2: Class A ±(0.15 + 0.002|t|)℃ means ±0.15℃ at 0℃ and ±0.35℃ at 100℃, suitable for high-precision BMS or laboratories; Class B ±(0.3 + 0.005|t|)℃ means ±0.3℃ at 0℃ and ±0.8℃ at 100℃. Thin film types are suitable for -50 to +500℃ with high cost-performance, meeting most industrial monitoring needs. |
| Q3: Is the response speed of Pt100-C sufficient to support thermal runaway early warning in new energy battery thermal management? | A3: Yes, the low thermal inertia design allows the sensor to output reliable signals within seconds of a sharp rise in surface temperature, far superior to NTC. It has been adopted by many BMS as a key sampling point, and with algorithms, it can achieve early protection triggering. |
| Q4: What is the drift situation of the sensor after long-term use? How to judge if it needs replacement? | A4: High-quality thin film Pt100 drift is <0.04% after 1000 hours at 200℃, with an annual drift rate of 0.01–0.02%. Periodically calibrate 0℃ and 100℃ resistance values using an ice point/boiling point or constant temperature bath; replacement of the core is recommended if deviation exceeds 2 times the tolerance. |
| Q5: How to wire correctly to minimize lead resistance error, especially in long-distance installations? | A5: Prioritize the three-wire system (two same-colored wires connected to one end) to basically cancel error; for highest precision, use the four-wire system (Kelvin connection) to eliminate it completely. Avoid two-wire systems for long-distance leads; the three-wire system can control error within 0.05℃. |
| Q6: Is Pt100-C suitable for extreme outdoor environments like wind power? How is weather resistance guaranteed? | A6: 316L sheath + sealing process supports resistance to salt spray, UV, and temperature changes from -50 to +500℃. IP67 protection reduces condensation impact. Actual wind farm deployments show that with reasonable installation, several years of low-maintenance operation can be achieved. |
| Q7: How to avoid damaging thin film elements during welding or installation? | A7: Reflow/wave soldering is supported, but lead base temperature should be controlled <260℃ for 10 seconds; use heat sink clips to protect the sensing area, giving priority to spot welding or low-temperature tin. Ceramic encapsulated types have better heat resistance; avoid direct heating of the film. |
| Q8: Can Pt100-C's reliability withstand strong vibrations on compressors or pumps? | A8: The thin film is tightly bonded to the substrate, and its resistance to mechanical shock and vibration is superior to wire-wound types (withstanding over 50g). In actual engineering, the false alarm rate in vibrating environments is low. Combined with three/four-wire systems and good fixing, it provides long-term stable and reliable data. |
Summary
Nexisense Pt100-C platinum thin film temperature sensor, with the linear stability of pure platinum materials and the fast response and durability of thin film technology, provides a reliable temperature data foundation for critical applications in new energy, wind power, and industrial processes. In scenarios with increasingly strict requirements for measurement accuracy, response timeliness, and environmental adaptability, it helps systems improve safety margins, reduce operation and maintenance costs, and provide credible support for engineering decisions through balanced technical performance. For detailed specifications, selection guidance, or sample verification, please refer to Nexisense product documents or contact the technical team for professional support.
