Serpentine Pipe Insulation Thickness Measurement

New Energy04.Serpentine Water-Cooling Pipe Insulation Thickness Measurement with Chromatic Confocal Sensors

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New Energy04.Serpentine Water-Cooling Pipe Insulation Thickness Measurement with Chromatic Confocal Sensors

Aug 19, 2025

1. What It Is & Why It Matters

Serpentine water-cooling pipes are widely used in battery packs, power electronics, and thermal management systems. The insulation layer applied on these pipes ensures:

Electrical safety – preventing leakage or short circuits.
Thermal efficiency – maintaining stable cooling performance.
Durability – protecting pipes from environmental stress.

Accurate measurement of the insulation thickness is critical. Too thin may lead to insulation failure, while too thick affects assembly and heat transfer.

2. Common Measurement Methods

Measurement Method	Principle	Advantages	Limitations
Mechanical micrometer	Contact probe measures thickness	Simple, low cost	Risk of damaging insulation, low speed
Ultrasonic testing	Ultrasonic waves measure layer thickness	Non-destructive, suitable for many pipes	Limited accuracy on thin coatings
X-ray inspection	Absorption profile measures thickness	Non-contact, internal layer detection	Expensive, radiation safety required
Chromatic confocal sensor	Light dispersion measures distance	Non-contact, high precision, inline ready	Needs optical access, reflective surfaces affect result

3. Principle and Process of Chromatic Confocal Measurement

Chromatic confocal displacement sensors use wavelength dispersion to measure distances:

White light is focused through a lens system, with each wavelength converging at a different focal point.
Surface reflection is captured at the wavelength corresponding to the exact distance.
Thickness evaluation – by measuring the outer surface of the insulation and the reference pipe surface, insulation thickness can be determined.

Why it fits serpentine water-cooling pipes:

Non-contact, no risk of damaging insulation.
Works with curved or inclined surfaces (up to +60° probe angle).
Sub-micron precision for reliable layer evaluation.
Can be applied in high-temperature or vacuum environments where pipes are tested.

4. TronSight’s Solution

The TronSight TS-C Series Chromatic Confocal Displacement Sensor is optimized for insulation thickness measurement:

Up to 32kHz sampling rate, ensuring real-time data acquisition.
16-channel synchronous measurement, ideal for multi-point pipe inspection.
Probe angle up to +60°, suitable for curved pipe surfaces.
φ3.8mm minimum probe diameter, enabling measurement in compact spaces.
Compatible with high-temperature and vacuum environments, meeting demanding insulation tests.
Supports multi-layer glass/insulation measurement, suitable for coating or layered structures.

Application Example (conservative wording):
In battery cooling systems, TS-C sensors can measure the insulation thickness on serpentine pipes by detecting both the outer insulation layer and the underlying reference surface. The data supports process monitoring and quality inspection.