Numerical analysis of the design parameters on the performance of thin film temperature sensors

An embedded thin film temperature sensor onto the surface of lubricated mechanical components is promising for real-time machine condition monitoring. The present study has been concerned with the performance of thin film temperature sensors due to the design parameters such as sensor film thickness, width, length, sensing materials, insulating and protecting layer. An improved three-dimensional heat conduction model has been developed to study the influence of those design parameters on the performance of thin film sensors designed for monitoring temperature distribution in elastohydrodynamic lubrication (EHL) contacts. The finite-volume method was utilized to solve the transient, three-dimensional heat conduction equation with time-dependent heat generation due to friction over the sensor. The time response to temperature change in a lubricated contact was predicted. This research work provided more deep insights for selection of the design parameters to ensure sufficient sensitivity, fast response time and the appropriate temperature range of the EHL temperature sensor to be used.