1.Product Overview: What is an OT head/copper ear temperature sensor?
The OT head temperature sensor, also known as the open nose temperature sensor or copper ear type temperature sensor, is a surface contact type temperature sensing device installed by bolt fixation. Its name is derived from its distinctive "O" -shaped or "T" -shaped (open) copper terminal, a design that enables it to be firmly crimped onto the terminal or busbar of the object under test through bolts, just like a cable connector.
The core function is to directly and precisely measure the temperature of conductive connection points, thereby achieving early warning and real-time monitoring of equipment overheating faults. It serves as a "temperature sentinel" to ensure the safe and stable operation of power systems, battery systems, and industrial equipment.
2. Core Advantages: Why Choose OT Head/Copper Ear Design?
✅ Stable connection and reliable contact:
The bolt fixation provides a huge contact pressure, ensuring extremely low thermal resistance and contact resistance between the sensor and the measured surface, making temperature measurement more accurate, and effectively resisting vibration and preventing loosening.
✅ Easy installation and standard universality:
The standard wiring hole position design allows direct connection to the existing electrical connection system without the need for additional equipment modification, making installation and maintenance very convenient.
✅ Strong overcurrent capacity, dual-purpose:
The high-quality tin-plated copper ear itself can serve as part of the current path, transmitting temperature signals without affecting the electrical connection of the equipment.
✅ Long service life and high reliability:
The robust mechanical structure and excellent material properties enable it to operate stably for a long time in harsh environments such as high temperature, high humidity and large current.
3. Unveiling the Manufacturing Process: How to Ensure Outstanding Performance?
The performance of OT head/copper ear sensors is highly dependent on their precise manufacturing process.
·Precision copper ear processing:
Copper ears made of T2 purple copper are precisely formed through stamping, and their surfaces are tin-plated or silver-plated to enhance electrical and thermal conductivity and prevent oxidation.
·High thermal conductivity internal packaging:
The core temperature sensing element (such as NTC thermistors or PT100 platinum resistors) is precisely assembled in the temperature-sensing area of the copper ear and encapsulated with high thermal conductivity epoxy resin or silicone gel. This step is of vital importance as it ensures that heat can be efficiently transferred from the copper ear to the sensitive element.
·Sturdy external protection:
The lead outlet is usually equipped with a PVC or silicone wire sheath to effectively prevent cable damage caused by bending or pulling. The entire component has excellent insulation and sealing performance.
4.Overview of Main Application Scenarios
OT head/copper ear type temperature sensors are widely used in all electrical connection points that require firm installation and precise temperature measurement
✅ Power distribution system:
Fixed on the incoming and outgoing line terminals of circuit breakers, contactors, and disconnectors, it monitors overheating caused by loose or aged contacts.
✅ New energy vehicles and energy storage systems (ESS) :
Connected to the Busbar (copper and aluminum bar), relay (contact actor), and fuse terminals of the battery pack, it provides critical temperature data for the battery management system (BMS).
✅ Industrial automation:
Installed at the DC bus capacitors of frequency converters and servo drives, the connection terminals of IGBT modules, as well as the winding output terminals of high-power motors, overheat protection is achieved.
✅ Renewable energy:
Monitor the connection temperatures on both the DC side and the AC side in equipment such as photovoltaic inverters and wind power converters.
Guide to Selecting OT Head Sensors
When choosing OT head/copper ear type temperature sensors, the following parameters should be noted:
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Selection dimension description |
common options |
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Temperature measurement element |
NTC: Low cost, high sensitivity, suitable for general precision requirements. PT100/PT1000: High precision and good linearity, suitable for high-precision and wide-temperature range applications. |
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Copper ear specifications |
hole diameters and hole types: They need to match the size of the on-site installation bolts (such as M4, M5, M6, etc.). Open/Closed: Open nose installation is more flexible, while closed nose connection is more stable.
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Electrical parameters |
Working voltage/insulation class: Must meet the insulation requirements of the equipment system. Lead wire specifications: Consider wire length, wire diameter (such as AWG), temperature resistance grade and color.
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Environmental requirements |
Temperature resistance range: Ensure that the sensor can withstand the highest and lowest ambient temperatures on site. Sealing grade: such as IP grade, is particularly important for outdoor or humid environments.
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OT head/copper ear temperature sensors, with their robust reliability, ease of installation and accurate temperature measurement, have become an indispensable part of modern electrical equipment temperature monitoring. The correct selection and installation are the keys to fully exerting its protective function and ensuring the safe and worry-free operation of the system. For more product information or technical support, please feel free to contact us at any time.