January 11, 2022

Looking at 2021 – The Rear View Mirror that Wasn’t

Like many other USA based manufacturers, CPI had many reasons to be optimistic about 2021 back in December of 2020. A COVID vaccine was on the horizon, business was off, but continued at reasonable levels. There was lots of talk about pent up demand and lots of justifiable pride over our decisions to invest in our infrastructure during a time of great uncertainty. Yes, 2021 was going to be the year we put the pandemic in the rear view mirror and moved on to brave new worlds, or at least an extremely welcome status-quo.

And while 2021 was indeed a different and positive year in many ways, it was also more of the same. That rear view mirror remained foggy, and in some cases showed us exactly what we saw last year.

The global business environment remains challenging and despite some effort by governments and individuals, the pandemic remains with us, having gifted us with the omicron variant which made cautionary tales and behavior as necessary this year as last. Early year optimism has been replaced with more caution, and inflationary fears have become part of the conversation again for the first time in a long time. The effects of global warming are accelerating at a breathtaking pace, and cultural shifts in the work force have brought the changing work-life value systems of young workers to the forefront as baby boomers retire.

So where does that leave manufacturers like CPI? While there is no doubt that everyone is affected by global changes in the supply chain, inflation, and trade, we believe the key is to remain nimble and accepting in a fundamentally changing world. In 2021, we became part of discoverIE Group, a synergistic partnership that has proved prescient in the face of global economic changes. With access to a renewed presence throughout Europe and Asia as well as the USA, CPI solidifies its visibility in distribution channels and its resilience against market upheaval. Our centralized, US based manufacturing continues to be a tremendous competitive advantage in terms of responsiveness, with over 95% of our raw material sourced from the USA.

We continue to provide unique solutions to engineering problems through our waterproof switch, thermal switch, and draw wire sensor product lines, and in 2021 we drove hard into the green economy by targeting our sales and marketing efforts on green energy products in the electric vehicle, wind and solar markets — a trend we expect to continue into 2022.

When we look forward to 2022, we are cautiously optimistic about many of the same things we were cautiously optimistic about last year. We are especially thankful for the dedicated employees who come to work every day and take all necessary precautions to protect themselves and their co-workers. We’re thankful for our customers who kept the faith and continue to work with us to discover new and exciting applications for our products.

We’re cleaning off the rear view mirror, again, and we may finally see the things in there we expected to see last year. But regardless of what happens, CPI is looking forward. To learn more about us, please visit our website at: https://www.cpi-nj.com/

Original content published: https://www.cpi-nj.com/looking-at-2021-the-rear-view-mirror-that-wasnt/

October 25, 2021

Fuel Cell Thermal Management by CPI

As we all look forward to a greener, more sustainable energy future, the promise of hydrogen based fuel cells is certainly one of the most exciting energy technologies on the cusp of mainstream acceptance. Fuel cells were a 10 billion dollar industry in 2019 and that is only growing as the technology continues to become more affordable and more efficient. CPI is excited about this promising technology and even more excited that fuel cell manufacturers are choosing CPI thermal switches as key components in their evolving solutions.

What is a Fuel Cell and How does it Work?

Fuel Cell Diagram A fuel cell is an electrochemical device that combines hydrogen fuel and oxygen to produce electricity, heat and water. Fuel cells operate without combustion, so they are virtually pollution free literally producing water as a by-product. Since the fuel is converted directly to electricity and heat, a fuel cell’s total system efficiency can be much higher than internal combustion engines, extracting much more energy from the same amount of fuel. Some modern fuel cells have an overall efficiency of almost 65% compared only 20% of a gas engine. The fuel cell itself has no moving parts, making it a quiet and reliable source of power.

Of course challenges exist with fuel cells because hydrogen is not a naturally occurring element. Hydrogen must be separated from other compounds that contain hydrogen, and breaking these chemical bonds requires energy that is mostly coming from fossil fuel sources. Until renewables provide a much higher percentage of the energy grid, it is fair to say that fuel cells aren’t entirely emissions-free. And of course, in this electrochemical reaction heat is produced along with electricity and water. This heat must be managed carefully as the temperature of the fuel cell is a significant performance changing factor. That’s where CPI comes in.

Managing Thermal Performance of Fuel Cells.

One CPI thermal switch already seeing use in fuel cells is our AD173 bimetallic thermal switch. This switch is a small form factor switch that can detect temperatures from –18C to 148C with tolerances as tight as 2.8C. The under-clamp mounting tab makes this switch perfect for pipe or exhaust mounting and the small size and custom lead lengths mean it can fit into a tight space. Another feature of the AD series appropriate for fuel cells is the fact that it is hermetically sealed and can be deployed inside or exposed to the elements without issue. The switch is also impervious to shock and vibration for vehicle mounted cells and will not fail even under highly challenging environmental conditions.

Controlling the temperature of fuel cell reactions is critical to the overall efficiency of its operation and the AD series of thermal switches has been used for both high and low temperature detection in fuel cells for different monitoring applications.

Low Temperature Fuel Cell Detection & Prevention

Given that water is such an important part of fuel cell operation, careful precautions must be take to ensure that the water in a cell is not allowed to freeze. For this our AD series turns out to be a perfect solution as well. Deployed at a 35F set point, our AD series switches have been used to initiate anti-freeze protection extending the useful temperature range of outdoor fuel cells.

Our AD series also offers flexible off the shelf mounting options as well as customizable lead lengths. And for those who need something more, our engineering team is able to handle custom features.

Please call our team today for a consultation on your Fuel Cell Application.

Original content published: https://www.cpi-nj.com/fuel-cell-thermal-management-by-cpi/

October 12, 2021

CPI Helps Keep Windmills Warm

Earlier this year the state of Texas saw one of its most devastating statewide power outages when winter storms rolled through the state and left freezing temperatures behind for weeks. While the vast majority of power was lost due to the failure of so-called thermal sources including coal, natural gas and gas power plants, and nuclear (87% of Texas’ outages were from these sources only %13 from the failure of renewable sources*) , much was made of the failure of renewable sources like solar and wind which in normal circumstances, generate about ¼ of the state’s power.

It turns out that CPI thermal switches can be part of the solution for Texas’ infrastructure improvements, particularly in the area of wind turbines. Wind turbines can be made to work reliably even in extreme weather as they do routinely in Greenland or the Artic regions of Sweden and Finland. Here’s one of the ways we help do that.

* Electric Reliability Council of Texas (ERCOT)

Thermal Switches for cold detection in Windmills

In the great Texas freeze of 2021, it was clear that winterization techniques are now a reality to deal with a rapidly changing global climate. In the case of wind turbines, many systems can be protected from cold related failure by used of special anti-freeze fluids, more weatherproof or heated gearboxes not to mention internally heated electronics which can also fail in extreme cold.

This is a proven application for CPI thermal switches which have been used in power grid applications, windmills, and shipboard military equipment to do exactly this: accurately detect cold conditions to turn on systems that heat things up!

CPI M1 thermal Switch — CPI’s hermetically sealed M1 Thermal Switch

Commonly used in these applications is our M1001 Plugstat Thermal Switch. This switch is a hermetically sealed, bimetal thermal detector rated for accurate switching down to -17 degrees C. It is slow make and break, providing natural hysteresis against chatter. The technology is a carefully engineered and manufactured thermocouple that has decades of proven operation in the field and in applications all over the world, both hot and cold.

In windmill applications there are actually many ways to use this switch to activate heater systems or other fail prevention systems. For example, windmills depend on critical voltage converters to translate the mechanical energy of the turbine to electrical energy. But these converters have a lower limit on the temperature under which they can safely operate. Our switch is used as a cold temperature indicator that the converter controller software reads. If the temperature hits the low temperature set point (in this case -3C) it is a signal that the internal heating system for the voltage converter has failed to turn on. To prevent a failure, our switch sends a signal to raise a fault and shut down the converter.

In other applications the same switch closure is used to turn on local heating elements which prevent the gearbox and associated electronics from reaching freezing temperatures which may exceed their ratings.

The switch closure can also be used in windmills to enable the flow of antifreeze by turning on pumps and generating alarms when various temperature thresholds are reached.

For Hardening the Power Grid – Think CPI Thermal Sensors and Switches.

CPI has been evolving its thermal switches for over 50 years until now, where they are arguably the most robust, fool-proof, thermal detectors in the world. When you’re protecting something as important as the power grid, your best choice is to design-in CPI.

Call us today for a free engineering consultation on your Thermal Switch Application.

Original content published: https://www.cpi-nj.com/windmills-cpi-thermal-switches/

September 21, 2021

CPI Thermal Switches, Tried and True for Aviation Applications

Power requirements in your average helicopter represent a few uncommon challenges. Consider the startup power required to get those turbines spinning. Then the instantaneous braking force necessary to respond to the pilots commands in real-time as he dips and rises to navigate safely.

All of that requires a pretty powerful engine, and that engine is lubricated by a whole lot of oil. Over a long trip or in hot/dusty conditions, that oil gets hot, too hot to be a very effective lubricant or coolant for the engine. If it remains too hot for too long, even specialized lubricants can break down and so oil temperature control has become a key safety subsystem in many high power, high rpm engines and motors on many kinds of military and industrial vehicles, boats and planes.

CPI Thermals are Helping the Next Generation of Helicopters Fly

The road to a world filled non-polluting electric vehicles doesn’t stop with cars. Manufacturers like Kopter helicopters of Switzerland already have their eyes on the prize. Per CEO Gian Piero Cutillo, of Leonardo who recently acquired Kopter, “… (Kopter) will act as a competence center for new light helicopters, developing future advanced technologies, especially in the areas of hybrid/electrical propulsion”.

Key to the success of this future roadmap is their new AW09 light helicopter. This is the first all new single engine helicopter design in over 4 decades, reimagined to be a design that could someday represents the world’s first hybrid chopper.

The powerful Honeywell HTS 900 turbine engine with 1020 hp is of particular interest to operators who wish to avail themselves of hot and high altitude performance. But a critical single engine design requires a critical, fail-safe cooling system.

“For Kopter we actually created a custom version of our AD series SnapStat Thermal Switch with a MIL STD connector”, notes John Crozier of CPI. “The thermal switch is installed in an oil cooler heat exchanger for the helicopter”. As is common to many CPI thermal switches used in this application, the switch activates when the oil temperature is above the thermal activation temperature (pre-programmed set point). The signal is used to switch a cooling fan on or off depending on the oil temperature.

Several Characteristics Make CPI Thermals Perfect for Heat Exchangers

According to Crozier, CPI’s SnapStat line of Thermals are finding their way into more and more heat exchanger designs for a number of reasons.

Small Form Factor – AD series thermal switches like the AD197 can fit in tight spots with a surface mount footprint of less than 0.75 square inches.
Extreme Durability – The basic SnapStat design is a double snap action design making them extremely resistant to vibration, shock and other modes of field failure. In almost every case, our switches will outlive your equipment.
Standalone Operations – CPI Thermal Switch closures do not require external power or interpretation by central control circuitry. Thermocouple based closure/opening is guaranteed to happen based on set point every time, making them the ultimate fail-safe solution.
Temperature Range – CPI’s SnapStat Switches have an operating temperature range of between 0F to 300F, easily covering the breakdown temperature limits of almost any modern lubricants.
Readily Available Customizations – With CPI’s engineering ready to provide parts with your exact customizations you can fit our parts more easily into your manufacturing process and specific mounting requirements. Customer connectors, lead lengths, hermetic sealing, and double pole double throw options are all available.

For more information about any of CPI’s Thermal Switches contact John Crozier of CPI’s Application engineering team today to discuss your application.

Original content published: https://www.cpi-nj.com/cpi-thermal-switches-tried-and-true-for-aviation-applications/

August 30, 2021

CPI Custom Thermal Switches for High Dielectric Applications.

As electric vehicles begin to change the face of transportation in USA, and the world, the conversation is all about charging the batteries. Charging stations are popping up all over the country. Most of these employ traditional charging cables with compatible connectors and they work well enough for most consumer vehicles.

Wireless charging however, is the next frontier for electric vehicles, especially trucks and busses and other large vehicles for whom cable based charging represents certain challenges. Imagine a time when a self-driving rideshare vehicle automatically pulls over and picks you up and drives passenger after passenger to stops along its route without ever needing to stop to recharge its battery. Instead, power generated by nearby wind and solar sources is delivered wirelessly from the roadway to the vehicle while it is in motion.

While some problems still need to be overcome to make this work on a large scale, prototype systems are already deployed across the USA and Canada. CPI is proud to note that we are a component provider to more than one of these kinds of applications.

Wireless Charging is Driving a Demand for High Dielectric Components

You can think of wireless vehicle charging as an enhanced version of wireless smartphone charging with one important difference: The power required to generate the required electric field is significantly higher. As the power goes up, a number of additional factors needs to be considered, such as thermal losses and thermal runaway. The higher the inefficiency or distance of the energy transfer, the higher the power requirement, and the greater the heat losses and thermal management required.

Another challenge is the extremely powerful electric field generated. Electronic components need to survive in field strengths of up to 5000V, a potential well beyond the range of normal insulators.

Some manufacturers leading the development of electronic charging stations are choosing an new variation of CPI SnapStat Thermal Switches for their temperature monitoring solution.

AD190B normally-closed — AD190B (normally-closed) shown

“The high dielectric strength requirement was a customization for us”, notes John Crozier, CPI’s lead application engineer on the project. “With a requirement for survivability up to 5000v we created a custom version of our SnapStat surface mount thermal that used a special material with ultra-high dielectric resistance.” That material, commonly called Ultem, is actually an amorphous polyetherimide thermoplastic know for its tremendous insulating properties.

The AD190 High Dielectric Surface Temperature Switch will be mounted directly on the heatsink and have a preprogrammed set point of 90C. The switch is fully rated for dielectric resistance up to 5000 VAC. Because these switches were designed for high reliability, they have a double snap action making them virtually immune to shock and vibration. They are also available with epoxy sealing or glass to metal hermetic sealing for the most demanding applications.

Dielectric Switch Applications do not end with Charging Stations

Manufacturer’s of components for power distribution generally, have a need for switches that survive in high E&M field environments. Development of the “Smart Power Grid” or Smart Grid is an application that is seeing more and more requirements for dielectric hardened thermal detectors like our new AD191.

While our thermals are usually used to detect hot thermal runaway conditions at the high end, in one application the switch is being used to activate at the colder edge of its range. In Smart Grid repeaters the AD191 is turning on heaters that prevent other electronic components from getting too cold. Reliable Cold detection is a unique feature of CPI Thermal switches in that they operate down to 0 degrees Fahrenheit. With their high dielectric rating, they are virtually immune to EMI.

CPI Thermal Switches – For Standalone Performance Under any Conditions

Another feature that makes CPI Thermals perfect for applications like wireless charging systems are the fact that it is a standalone detection system: in other words, once a set point is reached switch closure is going to happen, regardless of how fried the rest of your electronics may be. Despite the availability of sophisticated remote sensors and controllers, sometimes there’s nothing better than the reliability and dependability of a well-engineered thermocouple.

For more information on CPI Thermal Switches, call our engineering team today. Original content published: https://www.cpi-nj.com/cpi-custom-thermal-switches-for-high-dielectric-applications/

August 24, 2021

It Gets Hot in the Kitchen

Food processing and Galley equipment include many components designed to reach high temperatures and stay there for extended periods of time. In this equipment, fire hazards and thermal runaway are key safety concerns. Even food packaging equipment used in production environments that pre-cook and seal food, have stringent requirements for temperature monitoring and fail-safe operation.

In areas like galley kitchens on boats or planes, the stakes are even higher. Fires in these areas can quickly spread and cause catastrophic damage or injury. Better that they never get started in the first place. We can help with that.

CPI switches are a standalone solution to Thermal Control

One key consideration in selecting a thermal sensor for food processing is whether it will function on its own, or does it require a PLC to react to sensor data and provide the right fail safe operation to external relays or systems. The primary tradeoff here is related to both cost, and durability of the overall solution. Thermal sensors in a PLC environment are cheap, but as part of an overall system solution they may not be best solution for critical thermal detection. These sensors are not generally hardened, have limited temperature detection ranges, and require a central computer or logic system to provide the required control, increasing complexity and the number of failure points.

CPI has found that the vast majority of OEM’s needing robust thermal safety switching, prefer a hardened standalone thermal sensor. In this scenario, an advanced thermocouple with a fixed set point, provides local switch open/closed behavior, completely independently of any central PLC or computer control. Add to this the fact that our thermal switches cover temperature ranges up 1750F (CPI Rod & Tube Series) which is well beyond the range of any remote sensor. CPI thermal switches are also hardened for survivability in high vibration environments.

CPI Thermals come in three varieties:

CPI SnapStat (0 – 300F) Using a precisely engineered bimetal snap disc, we actuate a miniature microswitch through a double snap action. Multiple mounting options available.

CPI PlugStat (0 – 650F) Contact movement in the PlugStat is achieved by controlling the different expansion rates of 2 fused metals providing tight tolerances and a small differential.

CPI Rod & Tube (0 – 1750F) Ideal for use in galley’s or furnace controls to sense or control combustion. Very high temperature sensing with very rapid response time.

No matter what temperature range or form factor you choose, all CPI switches are hardened for longest possible lifetime, and extreme durability under adverse environmental conditions.

CPI Thermal Switches are also customizable for special mounting considerations like MIL STD bulkhead mounting or custom lead lengths or wiring insulation to achieve better thermal dissipation.

We’ve been doing this for over 70 years. Bring us your requirements, we’ll give you a solution that will be the last solution you’ll ever need.

Original content published: https://www.cpi-nj.com/it-gets-hot-in-the-kitchen/

November 23, 2018

When Part Obsolescence = Engineering Opportunity

Engineers and procurement specialists at companies large and small deal with the challenge of part and product obsolescence each and every day. Typically it goes something like this:

A subcontractor who make one or more critical parts for a larger machine or system, has gone belly up. The system is still deployed in the field and the cost and logistics of replacing it makes this option a complete non-starter. So when the sub-component breaks, spares become a problem very quickly.

In another scenario, particularly in military equipment, the list of manufacturer’s able to supply a component has dwindled to a few or even just one (single source) As a result, than manufacturer has jacked up the price for their part from $15 per part to a whopping $785.27 per part. While that still may be a fraction of the cost of the system, it doesn’t make anyone happy to know they are paying a premium just because there is no competitive or qualified alternative.

How CPI helps with Product Obsolescence Challenges.

Solving product obsolescence challenges is seldom a matter of buying a different off-the-shelf item. It usually requires re-engineering, specialized design, and even re-qualification of the new sub-component and/or new solution. At CPI this is exactly what we’ve been doing for decades: taking our line of extreme duty electro-mechanical switches and sensors and making incremental changes to adapt them to new (or old) applications. It’s the bread and butter of our engineering competency.

Here’s a couple examples of the kind of work we’ve done

CPI Linear Position Sensor Hydraulic Retrofit Application

In a heavy duty hydraulic cylinder application, Dupont had designed their system using Curtiss Wright linear position sensors (long stroke LVDTs) which have been discontinued. After discussions with our engineering team, Dupont chose our SL0390 as a replacement solution to monitor the stroke position on so called “intensifier cylinders.” These intensifiers are high pressure hydraulic devices that inject initiator into polyethylene autoclave reactors. They picked the SL0390’s for this application because it was easy to adapt their existing external mounting hardware to the SL0390 from the old LVDT sensors, which were about 24” long. According to the customer, the environmental conditions for the SL0390 installations are indoors and out of the weather, but not climate controlled so a level of robustness was a necessity.

Per the Dupont Engineer, “The environment for these cylinders is industrial and often times hot and dirty just like any petrochemical plant along the Gulf Coast. We installed the first SL0390’s in June of last year (2017), and have been replacing others as the old LVDT’s fail on the other cylinders on the all of manufacturing units. To date, all installed SL0390’s are still in service and working properly.”

We’re not surprised. The SL0390 sensor is built to take a licking.

CPI Thermal Switch Retrofit on Chinook Helicopter

When Sensata thermal switches used to monitor the hydraulic system on the Army’s Chinhook Helicopter became obsolete, CPI was chosen to replace these thermal switches. We were able to do it with small modifications to one of our own thermals. While the original switch was most similar to our AD096 bi-metal thermal switch, the 7/8″ mounting thread and ITT connector required were not part of our standard offering. With simple modifications, CPI created the AD192-502, a form, fit function replacement.

Another consideration is that CPI can make these parts for small production runs, the kind that bigger companies won’t be bothered with. The above run was for 40 pcs, though CPI is fully able to scale production to thousands of parts per month out of our USA based manufacturing facility in East Hanover New Jersey.

Retrofit and Obsolescence are Friends of Ours.

We provide Form-Fit-Function replacement of switches and sensors in the following area’s

Waterproof, high-endurance, safety limit switches
High endurance electromechanical thermal switches
Long Stroke, Extreme Duty Hydraulic Position Sensors.

For over 70 years, our product line has succeeded in the worlds toughest application scenario’s.

Call us today for more information.

Original content posted on https://www.cpi-nj.com/blog/when-part-obsolescence-engineering-opportunity/

April 13, 2018

CPI Thermal Switches – Keeping Astronauts Safe on the ISS

ISS-CPI-Thermals2-1000x288

The International Space Station (ISS) may be one of the most underappreciated technological (and geopolitical) marvels on, or off the planet. While it has been under development since the 1990’s it is actually the joint effort of five different space agencies representing 15 countries, all of whom contributed technology and resources to the ISS, especially the United States and Russia. It is a shining example of what scientists across borders can do together when focused on a common technological challenge.

The space station is the largest structure ever assembled in space. Orbiting at about 248 miles above the earth it is so large that it is often visible at night to the naked eye. It is longer than a football field (including the end zones) and can sleep 7 astronauts. It has habitable space often compared to that on a 747 jumbo jet, or about the size of a 5 bedroom house.

Astronaut Peggy Whitson aboard ISS

The ISS has been populated by astronauts since November of 2000 and has been populated non-stop for the almost 18 years since. Its useful accomplishments range over almost the entire spectrum of scientific discovery. For instance, scientists were able to grow proteins in space with a near-perfect crystalline structure. These proteins have unique properties that prove useful in the development of new drugs. Also the detection of “dark matter” long predicted by physicists, was accomplished using the Alpha Magnetic Spectrometer, deployed on the space station. This discovery sent shock waves through the scientific community, a moment as pivotal as Einstein’s E=MC². These achievements and many more were only possible over a long period in the pure gravity free environment afforded by the ISS.

Technology and Experiments Aboard the ISS

Needless to say, the ISS houses some of the most sophisticated technology and experiments that NASA and other space agencies can think of. Safety of the astronauts and “space tourists” that visit and reside there is of paramount importance. The stringent testing and documentation required by vendors and space agencies providing parts and subsystems to NASA, is well known to every subcontractor.

One of the experiments headed for the ISS from NASA is called the Flow Boiling and Condensation Experiment (FBCE), a joint effort between the Purdue University Boiling and Two-Phase Flow Laboratory (BTPFL) and the NASA Glenn Research Center. The experiment will fly aboard the International Space Station sometime in 2020 for two years or longer. The purpose of the FBCE project is to develop an integrated two-phase flow boiling and condensation experiment for the ISS to serve as a primary platform for obtaining two-phase flow and heat transfer data in microgravity.

Technicians at work preparing the FBCE for launch in 2020.

One of the key safety concerns of the FBCE experiment involves preventing the formation of a highly dangerous gas during the boiling phase of the experiment. The system uses a special fluid called perfluorohexane as the primary boiling/condensation substance, however when this substance exceeds 200C it can degrade into a highly toxic gas called Perfluoroisobutene (PFIB). PFIB when inhaled can cause pulmonary edema and other heart disorders. The goal is to have thermal switching in place at setpoints well below the 200C to prevent such an occurrence.

CPI’s Thermal Safety Solution for the FBCE.

CPI was approached by NASA to consider the use of a thermal switch solution based on our M1102 “PlugStat” series of thermal switches. The PlugStat Series of close tolerance, bimetal thermal switches act as a robust and accurate temperature control switch in a wide variety of thermal control systems at temperature ratings from 17C (0F) to 343C (650F). This is a slow make and break, open-on-rise device that is hermetically sealed, with 1/2-20UNF-3A thread mounting.

Despite NASA’s stringent material and electrical requirements, CPI’s off-the-shelf M1102 met their need for a reliable, space deployable, thermal safety switch solution.

Our switch uses:

Stainless Steel type 304
Stainless Steel type 321
Inconel Alloy 600
Stycast type 2651
Platinum Contacts

Our standard electrical rating of 2A at 28V was able to meet the electrical needs of NASA in the application. Additionally CPI provided all applicable CoC’s, Material Test Reports, and Chemical Analysis’ required to meet NASA’s stringent quality control.

CPI Thermal Switches – Good for the International Space Station…Good For You Too.

Sometimes a robust thermal switch is what you need, remote sensors and controls systems have their place, but in tough applications, they have their limits too.

The chances are that the team at CPI can fit our thermals into whatever application you have, without expensive customization.

Call the thermal switch engineering team today to discuss your application!

Original content posted on https://www.cpi-nj.com/blog/cpi-thermal-switches-keeping-astronauts-safe-on-the-iss/

February 9, 2018

New MSHA Specification Requires Compressor Thermal Monitoring.

If you’re a manufacturer of high pressure, high horsepower industrial air compressors, like the kind that might be used in large drilling or mining operations, you need to know that the Mine Safety and Health Administration has new safety requirements affecting high horsepower, recirculating type air compressors.

The issue is related to the fact that an overstressed compressor can get extremely hot. So hot in fact that it can approach the flashpoint of the compressor’s lubricating oil. Indeed this is a common concern in machinery generally, where normal operating temperatures are driven to extremes by deployment in hot ambient environments, or extended non-stop usage, or even equipment failure.

Thermal runaway monitoring is a common problem in industrial compressors, generators, pumps, essentially anything that uses a motor and oil.

It is a problem that CPI thermal switches were designed to solve.

CPI Snap Stat Thermal Safety Switches – A brief Primer.

The key engineering concerns of designers looking for thermal safety in industrial applications are typically the robustness of the thermal switch, and the accuracy of the set point. In most thermal safety applications temperature set points are well known, being driven by the flash point of lubricants, with a wide safety margin, typically 50F or more. Upon reaching the flash point safety point, the thermal switch will trip, shutting down the compressor, generator, or motor. It can also be used to put the machine in a lower rpm state for critical systems.

Below is an image of the internal construction of our Snap-Stat switches

The CPI SnapStat Switch is designed for durability and reliability above all things. With a temperature range from 0 to 300F they cover most of the flash point settings common to high power machinery lubricants. Set points are built in at the factory and remain fixed and reliable for the life of the switch.

CPI’s SnapStat thermal switches have a bimetal snap disc that actuates a miniature microswitch . This double snap action makes these switches virtually immune to shock and vibration. Epoxy sealing or glass to metal hermetic sealing makes them ideal for demanding industrial or military applications.

Example of SnapStat use on a Commercial Compressor

One of the most common mounting options chosen by equipment manufacturers is exemplified by our AD-173, a pipe clamp mount version that integrates easily to existing designs.

Our client, a large compressor manufacturer for reciprocating type air compressors, uses our sensor on the compressor discharge line to monitor temperature. Locations and setpoints for the sensor may vary depending on whether you are designing in, or retrofitting into your compressor.

Other options include surface mount, thread mount, flange mount, and custom configurations.

CPI Thermal Switches are Problem Solvers For Machine Safety.

We’ve been creatively solving thermal safety problems for equipment manufacturers for over 60 years. Whatever your application, chances are we’ve got a robust, off the shelf solution for you.

Give CPI a call today to discuss your Thermal Switch Applicatiion.

Original content posted on https://www.cpi-nj.com/blog/new-msha-specification-requires-compressor-thermal-monitoring/

December 26, 2017

When to use a Real Thermal Switch not a Sensor

When CPI started making thermal switches for the Military in the 40’s, there really wasn’t any other choice. Thermocouple based switches with variable set-points and various temperature ranges of operation were made using the thermocouple materials of the day, mostly copper, aluminum, and chrome. The concept of a thermocouple had been around for over 100 years but CPI switches of that time stood out because they provided reliable operation over an extended temperature range, in an environmentally hardened package suitable for battlefield conditions.

Temperature switch technology has evolved over the last 75 years however, and depending on what you’re trying to do, alternate thermal switching technologies abound. For instance, in applications where smaller temperature differences need to be measured with high accuracy (like from 0-100C at 0.01%), technologies like thermistors, temperature sensors tied to external control systems, or simple resistance thermometers may be more suitable and cost effective.

CPI Rod & Tube Thermal Switches

Still, traditional thermal switches have evolved too. The variety of types, and use of metal alloy’s has been informed by discovery, experimentation, and improvements in manufacturing processes. Today’s CPI thermal switches come in three basic types, covering a thermal range from 0 to 1750 degrees Celsius. And as always, CPI switches maintain their hardened design making them unique in the world for their electromechanical endurance, and their survivability.

Thermal Switch Applications

Perhaps one of the best ways to understand the applications that are better suited for thermal switches vs. sensors is to look at common applications for these switches.

Galley Temperature Sensors – Prevention of galley fires is critical on both Navy Ships and around any high temperature professional cooking stations. With flash points over 1000 degrees, these systems usually do not have a controller and so local switching to turn of gas supply or raise an alarm is appropriate.

Steel Manufacturing – Thermal Switches are used extensively in the steel and iron industries to monitor temperatures and chemistry throughout the steel making process. Disposable, immersible, type S thermocouples are regularly used in the electric arc furnace process to accurately measure the temperature of steel before tapping. The cooling curve of a small steel sample can be analyzed and used to estimate the carbon content of molten steel.

Engine Cooling Fan Control – Thermal Switches are commonly used to locally control cooling fans which prevent engine overheat on everything from generators to jet engines.

Gas Shut-Off – In systems using pilot lights, a thermal switch will often sense the presence of the pilot and shut off gas flow if the pilot should go out for any reason.

Oil Refining – Control of temperature in the oil refinery requires accurate and hardened thermal sensing for many fail-safe systems in the refining process.

Avionics Bay Over-Temp – In both commercial and military aircraft, ambient temperature in the avionics bay can reach well over 100 degrees C as components heat up, contributing to early system failure. Thermal switches are used here to economically activate cooling systems.

CPI Thermal Switches

Our three lines of thermal switches include the following.

Snapstat (0 – 300C)
Plugstat (0-600C)
Rod & Tube (0-1750C)

All switches are characterized by flexible mounting options, highly accurate and programmable set points, and hardened construction for extreme environments.

For more information on CPI thermal switches, please contact our engineering team today.

Original content posted on https://www.cpi-nj.com/blog/when-to-use-a-real-thermal-switch-not-a-sensor/

Control Products, INC

Providing creative & reliable control solutions

Thermal Switches