The TDC system

Part No.: MP-IPET-The-TDC-system
Massive time savings thanks to plugless contacting technology


The TDC System

Massive Time Savings Thanks To Plugless Contacting Technology

Our innovative and patented TDC (thermo direct connect) system allows the plugless contacting of measuring point and module. The sensor cable is directly inserted into the module, contacting and interlocking automatically. This saves precious time when setting up measuring points and sensors and further improves the workflow.


The Revolution In Thermocouple Measurement Technology!

When upgrading measuring points and sensors, the motto is: best fast, efficient, uncomplicated and error-free. But especially with thermocouples, polarity reversals can quickly occur when connecting sensor cables. In addition, upgrading is very time-consuming, since the contacts are usually made via screw contacts in the plug.

For this reason, the M-TDC 8 thermomodule is equipped with a special contacting technology that allows thermocouple measuring points to be upgraded without connectors. For this purpose, the sensor cables are simply plugged into the module; contacting and locking take place automatically.

As a result, the thermocouple connectors for contacting the measuring points no longer have to be installed in a time-consuming and labour-intensive manner - the measuring technician saves valuable time. In addition, the handling is simple and the measurement results reliable, because the asymmetrical wire cross-section prevents reverse polarity. PT100 sensors installed at each measuring input ensure high-precision temperature measurements.


TDC Starter Kit

The Perfect Start For Efficient Thermal Measurements

With the TDC Starter Kit, IPETRONIK offers the ideal package for fast, easy, and efficient thermal measurements. The case contains two thermomodules as well as the complete measuring equipment to immediately put our patented plug-in system to use.

Scope Of Supply

  • 2 x M-TDC 8 modules
  • 1 x cable 620-560.002
  • 1 x cable 620-567.015
  • 1 x plug M-CAN-ABS-100
  • 16 x TDC adapter female type K
  • 16 x TDC adapter male type K
  • 1 x TDC cutting tool
  • 1 x 150m TDC-IN cable type K
  • 1 x Quickstart Guide
  • 1 x USB stick

Advantages At a Glance

  • Enormous time savings thanks to the elimination of assembly work and direct cable contacting
  • Error-free measurement results due to polarity reversal-proof contacting
  • High flexibility thanks to compatibility with existing systems via TDC adapter female and TDC adapter male
  • Safe electrical connection thanks to high locking forces/strain relief
  • High shock and temperature resistance for safe use in harsh environments
  • Reduced storage costs for thermoelectric cables
  • Cables coated with electrically insulating Teflon®-based material


How It Works

Plugless Contacting With Automatic Interlocking

The pear-shaped sensor cable can be inserted directly into the M-TDC 8 precision contact head. Special spring contacts ensure the contacting by pushing the needle within the device into the core of the 7-strand wire of the sensor cable and establishing a secure and steady electrical connection. LEDs indicate the successful contacting.

The cable interlocks automatically – no further interaction necessary. A special locking spring fixes the cable so that pulling it out would require great effort and deform it (triple connection forces compared to miniature plugs). This guarantees uninterrupted contacting even under harsh conditions.

The M-TDC 8 provides a release leverage for each channel, expanding the locking spring and allowing the user to easily pull out the sensor cable.


Brief Instructions For Plugless Cable Contacting

Developers and OEMs often use pre-assembled sensors and compensation cables. This is why the new TDC system offers solutions for existing sensor systems using subminiature thermo plugs with contact plates as well. The following description explains how to connect the TDC-IN cable to the module and the TDC connector with thermo plugs.

First, the resistant TDC-IN cable with high mechanical strength is shortened to the required length with the specially developed TDC cutting tool.

Important: The cable must be inserted as far as it will go into the pear-shaped opening of the cutting tool before it is inserted into the module. This is the only way to make a right-angled cut.This cut must be made on both sides of the cable.


Now the first cable end is inserted into the M-TDC 8 module. The black back line is at the top. Contacting and interlocking are automatic and signalled via built-in LEDs.


The second cable end is then plugged into the TDC adapter female. This has an automatic locking mechanism which connects the TDC sensor cable via spring contact.

In the next step, the TDC adapter female is connected to the existing miniature thermoplugs (with contact plates) to which the sensor is usually attached.

To remove the cable from the module, push the lever to the left and then pull the cable out of the device. To re-contact the sensor, the cable must be cut again at right angles.


Comparison Of tThe Different Steps (Traditional Method vs. TDC)

The contacting of sensor cables and plugs still is a complex and time-consuming process. Both wires have to be connected to the screw contacts of the plugs by hand. The patented TDC method makes contacting quick, easy, and direct, facilitating the setup of thermocouple measuring points and further improving workflows.

Steps without TDC (average: 10 minutes) 1. Stripping the cable
Steps with TDC (average: 1 minute) 1. Cutting the TDC-IN cable to the desired length
Steps without TDC (average: 10 minutes) 2. Stripping both wires
Steps with TDC (average: 1 minute) 2. Squaring the cable end
Steps without TDC (average: 10 minutes) 3. Unscrewing the plug cover and removing it
Steps with TDC (average: 1 minute) 3. Inserting the cable into the M-TDC 8
Steps without TDC (average: 10 minutes) 4. Positioning and crimping the strain relief ferrule
Steps with TDC (average: 1 minute) 4. Stripping, twisting, stranding, and welding of the wire ends
Steps without TDC (average: 10 minutes) 5. Bending the strands into U-shape
Steps with TDC (average: 1 minute) -
Steps without TDC (average: 10 minutes) 6. Unscrewing both contacts
Steps with TDC (average: 1 minute) -
Steps without TDC (average: 10 minutes) 7. Inserting the strands
Steps with TDC (average: 1 minute) -
Steps without TDC (average: 10 minutes) 8. Tightening the contact screws
Steps with TDC (average: 1 minute) -
Steps without TDC (average: 10 minutes) 9. Fitting the plug cover and tightening the screws
Steps with TDC (average: 1 minute) -
Steps without TDC (average: 10 minutes) 10. Connecting the plug to the module
Steps with TDC (average: 1 minute) -
Steps without TDC (average: 10 minutes) 11. Stripping, twisting, stranding, and welding of the wire ends
Steps with TDC (average: 1 minute) -

Asymmetrical Cross-section For Reverse Polarity Protection & Durable Cable Jacket

Together with the new needle contacting method, the cross-section of the TDC-IN cable has been reworked: It is now asymmetrical to assure reverse polarity protection – the sensor cable cannot be inserted into the module with the wrong polarity.

Moreover, the cables are coated and insulated with a very durable and electrically insulating Teflon®-based material resistant to aggressive media as well as heat and cold; it can be used from -190°C up to +260°C.

To reinsert the cable into the M-TDC 8, it has to be cut square.


Pre-assembled TDC-IN Cable

You can purchase the TDC-IN cable as „raw cable“ to assemble your own thermocouple sensors or extension cables.

The TDC-IN cable is also available as pre-assembled thermo cable with Teflon®-based coating – just cut it to the required length and insert it into the module where it will immediately contact and interlock.


Solutions With Existing Thermocouple Sensors

Thermocouple sensors are often pre-assembled. This is why the TDC system offers solutions for existing sensor systems with traditional subminiature thermo plugs.

The newly developed TDC plugs and TDC connectors can be combined with the TDC-IN cable for quick and flexible length adjustment. The connector provides an interlocking mechanism with spring contact to connect the TDC cable. However, since it does not have a release mechanism, the spring will be deformed when pulling out the cable, making it impossible to reuse the connector.


The Module


Thermomodule M-TDC 8

The M-TDC 8 is a thermomodule with 8 channels and 8 release leverages to pull out the thermocouple sensors. It is developed for engine compartment applications but due to its compact design (106 mm x 30 mm x 63 mm, 305 g), it can be installed almost everywhere. The pear-shaped sensor cable can be directly inserted into the M-TDC 8 precision contact head. The measurement data is output to CAN. The M-TDC 8 meets all quality requirements (protection class IP65, shock and temperature resistance), making it ideal for harsh environments. Measurement inputs, CAN interface, module supply, and casing are galvanically isolated. The module fits seamlessly into the IPETRONIK hard- and software infrastructure; form and casing match the M2 family so that the M-TDC can be operated in every system chain. Furthermore, it will be implemented as a new device type into the software platforms TESTdrive, X-PlugIn (X-LINK), as well as the respective IPEaddons INCA and CANape.


Highlights At a Glance

  • 8-channel thermocouple measurement inputs type K (NiCr/NiAl)
  • Plugless connection of thermocouples via TDC-IN Kabel
  • Release lever for removal of the sensor cable
  • High-precision temperature measurements thanks to PT100 reference junctions
  • Cold junction compensation per channel
  • Status LED at each measurement channel
  • Measurement data output to CAN
  • Galvanic isolation (inputs, CAN, supply, enclosure)
  • Heat and cold resistant from -40 °C to +125 °C


Connection Examples With The M-TDC 8


PC Measurement

In practice, the M-TDC 8 is often used for vehicle cooling systems. The temperature measuring points are usually located at various in- and outlets, on the cooler itself (measuring grid), on and in thermo-affected elements in the engine and passenger compartment, as well as in other important places.

The measurement values are transferred to the M-TDC 8 thermo module via the TDC-IN cable, converted into a digital signal, and transmitted to the PC (or notebook) with the IPEmotion measurement software via the CAN interface. This application requires the IPEmotion X-PlugIn to configure and operate the connected modules. During test drives, an engineer (passenger) runs the software while the driver completes test routes with different load simulations.

The collected data can be used to optimize opening and closing angles and times or to adjust the water pump flow rate. Having calibrated the control unit (with adjusted software version ), the tests are repeated to compare the data and reassess the adjustments.



Data logger Measurement

Temperature measuring points are usually located at the vehicle HVAC system, on condenser, evaporator, compressor, cooler, interior air vents, footwell area , but also within the passenger compartment as well as on the vehicle exterior.

The measurement values are transferred to the M-TDC 8 thermo module via the TDC-IN cable, converted into a digital signal, and transmitted to the data logger. Having been started via ignition signal or any other switch-on condition, the preconfigured data logger starts interpreting and storing the signals.

The driver completes test routes with different load simulations, during which the vehicle interior is heated or cooled. After the test, the measurement file can either be transferred directly to the customer’s server or to the IPEmotion measurement software via Ethernet gateway or others. This requires the IPEmotion LOG-PlugIn.

With the help of the collected data, an HVAC engineer can verify the cooling and heating performance of the cooling system and its settings.