Abstract: A method of positioning a tape preform as a layer onto a resistive device substrate during the manufacture of a layered resistive device is provided. The method includes locating the tape preform in a predetermined position and translating one or more of the following relative to each other until a portion of the positioning device engages the tape preform: a positioning device, the resistive device substrate, and the tape preform. The method also includes continuing the translation until the tape preform engages the resistive device substrate and continuing the translation such that components of the positioning device progressively translate around the resistive device substrate and subsequently position the tape preform onto the resistive device substrate. In some forms, the method includes using a controller and/or applying a predetermined cycle of temperature, pressure, and time to the substrate and tape preform.

Abstract: A temperature sensor includes an autonomous sensing element and a plurality of conductive wires connected to the sensing element. An electrical insulator surrounds the sensing element and the conductive wires for firmly holding the sensing element and conductive wires. The insulator includes substantially crushed and compacted powder insulation. A tube encases the insulator in a compressed manner and has a first end, a second end, a first portion having a first inside diameter located in the proximity of the first end and a second portion having a second inside diameter. The second inside diameter being greater than the first inside diameter. The sensing element is positioned within the second portion of the tube. Methods of manufacturing a temperature sensor are also included.

Abstract: Methods of securing a thermocouple to a ceramic substrate are provided. The thermocouple includes a pair of wires that define a junction, and the method comprises directly bonding the junction of the thermocouple to the ceramic substrate. In one form, the junction is directly bonded using an active brazing material.

Abstract: An assembly includes a circuit board, a terminal and a pin. The circuit board is for a controller and includes terminal mounting holes. The terminal mounting holes include a first mounting hole and a second mounting hole. The terminal includes a first mounting post that has an interference fit with said first mounting hole. The terminal also includes a second mounting post that has a transitional fit with the second mounting hole. A pin is electrically coupled to one or more of the first mounting post and the second mounting post and couples to a block connector.

Abstract: A method of securing a terminal to a ceramic heater is provided by the present disclosure. The ceramic heater includes a ceramic substrate and a resistive heating element, and the method includes exposing a portion of the resistive heating element, forming an intermediate layer on at least one of the portion of the resistive heating element and the ceramic substrate proximate the portion of the resistive heating element, the intermediate layer being selected from a group consisting of Mo/AlN and W/AlN, and bonding the terminal to the intermediate layer.

Abstract: A sensor adaptor circuit housing assembly and method of manufacturing includes a circuit board, a housing, an input wire, and a connector. The circuit board includes an electrical circuit configured for receiving a sensor signal and generating a sensor characteristic in response to the received sensor signal. The housing includes a body and a cavity defined by inner surfaces of the body and adapted for receiving the circuit board, the circuit board being positioned within the cavity. The input wire is configured for receiving the signal from a sensor and can be formed with an insulated solid or stranded conductor. The connector includes a unitary body, a first end of the unitary body attached directly to an end of the input wire, a second end of the unitary body positioned within the cavity and attached directly to the circuit board and making a first electrical connection with the electrical circuit.

Abstract: A ceramic heater is provided that includes a power terminal for connecting a resistive heating element to a power source. An intermediate layer is disposed on an AlN ceramic substrate proximate the resistive heating element. The power terminal is bonded to the intermediate layer by an active brazing material. The intermediate layer is formed of Mo/AlN or W/AlN and has a coefficient of thermal expansion between that of the active brazing material and that of the AlN ceramic substrate so that thermal stress generated in the ceramic substrate can be reduced.

Abstract: A temperature sensor assembly and method of manufacturing thereof having a temperature probe, a mounting connector, a wire set, a transition component, a housing, and a circuit is provided. The temperature probe includes a probe body, a temperature sensor and at least one conductor configured for providing a temperature signal indicative of a temperature over the at least one conductor. The circuit is enclosed within the housing and configured for receiving the temperature signal from the temperature probe and generating the temperature characteristic in response to the received temperature signal.

Abstract: A power control system includes a base having a housing configured for releasably receiving a control unit and a cavity within the housing for receiving a solid state relay having a hockey puck configuration. The base includes an input power terminal for coupling to an input power source, an output power terminal for coupling to a power receiving load, and coupling fixtures for fixedly and electrically coupling to input and output power terminals and control terminals of the received solid state relay. A control unit is configured to control the solid state relay for selectively providing, at least a portion of, the power received at the input power terminal to the output power terminal. The control unit has a housing adapted to be releasably coupled to the base housing. The control unit and base each configured to electrically couple the control unit to the control terminals of the received solid state relay as a function of the control unit being coupled to the base.

Abstract: A method and a housing assembly including a case defining an opening, and a coupler positioned within the opening and configured for coupling to a connector, wherein the case defines a securing portion positioned proximate to the opening and is configured for securing a portion of the connector when coupled with the coupler.

Abstract: A power control assembly for use in an integrated power control system has a base with a housing that defines a cavity adapted for receiving a power switch. The control assembly includes a control module configured for generating control signals for controlling the power switch for selectively providing power to a load. A control housing houses the control module and is adapted to be releasably coupled to the base housing and is configured for electrically coupling to control couplers on the base housing for providing the generated control signals to the power switch within the housing cavity upon coupling the control housing to the base housing.

Abstract: A method of diagnosing a temperature sensing system having a temperature sensor, a field processing module coupled to the temperature sensor, a bitbus, a fieldbus, and an auxiliary processing module communicating with the bitbus and the fieldbus. The method includes generating a temperature characteristic at the temperature sensor, processing the temperature characteristic at the field processing module, and generating field operating data including a temperature diagnostic parameter as a function of the temperature characteristic. The method also includes communicating the field operating data including the temperature diagnostic parameter over the bitbus from the field processing module to the auxiliary processing module, generating at the auxiliary processing module auxiliary field data as a function of the received field operating data, and communicating the auxiliary field data over the fieldbus.

Abstract: A heat trace assembly for heating a conduit is provided that comprises at least one preformed heat trace section adapted to be placed around at least a portion of the conduit and a connector secured to the heat trace section. The connector is adapted for coupling the heat trace section to an adjacent heat trace section, and the heat trace section and the connector have mating mechanical features to allow the heat trace section to be quickly connected to and disconnected from the conduit. Additionally, a heat trace junction is provided that preferably defines a cross configuration and comprises a plurality of arms extending from a central portion of the heat trace junction. The plurality of arms are deformable to conform to a junction within a conduit system. Thermal insulation jacket configurations are also provided in accordance with several embodiments of the present invention.

Abstract: A distributed operations system having integrated diagnostics, a bitbus and a fieldbus and includes a field device for generating a field operating characteristic and a field processing module for receiving the field operating characteristic from the field device. The field processing module includes a field diagnostic component and a field communication component configured for communication over the bitbus. The field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic. An auxiliary processing module is configured for communicating with the bitbus and receiving the field operating data. The auxiliary processing module includes an auxiliary diagnostic component and an auxiliary communication component having a fieldbus interface and a gateway component.

Abstract: A heater system is provided that comprises a plurality of layered heater modules, each module comprising a plurality of resistive zones. The layered heater modules are disposed adjacent one another to form the heater system, which can be adapted for a multitude of different sizes of heating targets. Preferably, the resistive zones comprise a plurality of resistive traces arranged in a parallel circuit and oriented approximately perpendicular to a primary heating direction, wherein the resistive traces comprise a positive temperature coefficient material having a relatively high TCR. The resistive traces are responsive to the heating target power gradient such that the resistive traces output additional power proximate a higher heat sink and less power proximate a lower heat sink along the primary heating direction.