EP1238715A1 - Multifrequenz-Ultraschall-Betätigungsvorrichtung für Aufbaukomponente - Google Patents
Multifrequenz-Ultraschall-Betätigungsvorrichtung für Aufbaukomponente Download PDFInfo
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- EP1238715A1 EP1238715A1 EP01810227A EP01810227A EP1238715A1 EP 1238715 A1 EP1238715 A1 EP 1238715A1 EP 01810227 A EP01810227 A EP 01810227A EP 01810227 A EP01810227 A EP 01810227A EP 1238715 A1 EP1238715 A1 EP 1238715A1
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- Prior art keywords
- ultrasonic
- load
- frequency
- transducer
- acoustic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B06—GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS IN GENERAL
- B06B—METHODS OR APPARATUS FOR GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS OF INFRASONIC, SONIC, OR ULTRASONIC FREQUENCY, e.g. FOR PERFORMING MECHANICAL WORK IN GENERAL
- B06B1/00—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency
- B06B1/02—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy
- B06B1/0207—Driving circuits
- B06B1/0223—Driving circuits for generating signals continuous in time
- B06B1/0238—Driving circuits for generating signals continuous in time of a single frequency, e.g. a sine-wave
- B06B1/0246—Driving circuits for generating signals continuous in time of a single frequency, e.g. a sine-wave with a feedback signal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B06—GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS IN GENERAL
- B06B—METHODS OR APPARATUS FOR GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS OF INFRASONIC, SONIC, OR ULTRASONIC FREQUENCY, e.g. FOR PERFORMING MECHANICAL WORK IN GENERAL
- B06B1/00—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency
- B06B1/02—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy
- B06B1/0207—Driving circuits
- B06B1/0223—Driving circuits for generating signals continuous in time
- B06B1/0269—Driving circuits for generating signals continuous in time for generating multiple frequencies
- B06B1/0276—Driving circuits for generating signals continuous in time for generating multiple frequencies with simultaneous generation, e.g. with modulation, harmonics
Definitions
- the high power ultrasonic system (the subject of this invention; - see Fig. 1) generates multimode and high power mechanical oscillations in a certain mechanical system, over a wide frequency range. This is in contrast to conventional power ultrasonic systems, which operate at a single frequency. In addition the method of driving these transducers is optimized.
- the oscillations of here-described ultrasonic source are not random - rather they follow a consistent pulse-repetitive pattern, frequency and amplitude-modulated by the control system. This avoids the creation of stationary or standing waves (typically produced by traditional ultrasonic systems operating at a single frequency) that generate regions of high and low acoustic activity.
- This technique is beneficial in many other applications, e.g. Liquid processing, fluid atomization, powders production, artificial aging of solids and liquids, accelerated stress relief, advanced ultrasonic cleaning, liquid metal treatment, surface coating, accelerated electrolysis, mixing and homogenizing of any fluid, waste water treatment, water sterilization, accelerated heat exchange...
- a Multifrequency Ultrasonic Structural Actuator (see Fig. 1) consist of:
- a strong mechanical coupling of high power ultrasonic converter (B) to the test specimen or acoustical load (D) is realized using acoustic-wave guide metal rod (C).
- Ultrasonic converter (B) is electrically connected to the ultrasonic power supply (A), or ultrasonic multimode generator.
- Acoustic activity sensors (E) are realizing feedback (for the purpose of automatic process control) between Acoustical Load (D) and Ultrasonic Power Supply (A).
- Frequency sweeping is related to the vicinity of the best operating (central) resonant frequency of transducer group. Frequency sweeping can also be applied in a low frequency (PWM, ON-OFF) group modulation (producing pulse-repetitive ultrasonic train, sometimes-called digital modulation).
- multi-frequency concept can be used in Sonochemistry and Ultrasonic Cleaning when we can drive a single transducer on its ground (basic, natural) frequency and on several higher frequency harmonics (jumping from one frequency to another, without changing transducer/s).
- ultrasonic transducer changes drastically in relatively short time intervals, starting from a very regular and no-load situation (which is easy to control), going to a full-load situation, which changes all parameters of ultrasonic system (impedance parameters, resonant frequencies).
- ultrasonic system behaves as a typically linear system; however, in high power operation the system becomes more and more non-linear (depending on the applied mechanical load).
- the presence of dynamic and fast changing, transient situations is creating the absolute need to have one frequency auto tuning control block, which will always keep ultrasonic drive (generator) in its best operating regime (tracking the best operating frequency).
- Mechanical loading of the transducer means realizing contact/coupling of the transducer with a fluid, solid or some other media (in order to transfer ultrasonic vibrations into loading media). All mechanical parameters/properties (of the load media) regarding such contact area (during energy transfer) are important, such as: contact surface, pressure, sound velocity, temperature, density, mechanical impedance, ...
- Mechanical load can have resistive or frictional character (as an active load), can be reactivelimaginary impedance (such as masses and springs are), or it can be presented as a complex mechanical impedance (any combination of masses, springs and frictional elements).
- direct mechanical analogue to electric impedance is the value that is called Mobility in mechanics, but this will not influence further explanation.
- impedance-phase-frequency characteristics of the same transducer are not the same when transducer is driven on higher voltages (say 200 Volts/mm on piezoceramics).
- impedance-phase-frequency characteristics of one transducer are dependent on transducer's (body) operating temperature, as well as on its mechanical loading. It is necessary to mention that measuring electrical Impedance-Phase-Frequency characteristic of one ultrasonic transducer immediately gives almost full qualitative picture about its mechanical Impedance-Phase-Frequency characteristic (by applying a certain system of electromechanical analogies).
- ultrasonic, piezoelectric transducer is almost equally good as a source/emitter of ultrasonic vibrations and as a receiver of such externally present vibrations. While it is emitting vibrations, the transducer is receiving its own reflected (and other) waves/vibrations and different mechanical excitation from its loading environment. It is not easy to organize such impedance measurements (when transducer is driven full power) due to high voltages and high currents during high power driving under variable mechanical loading. Since we know that the transducer driven full power (high voltages) will not considerably change its resonant points (not more than ⁇ 5% from previous value), we rely on low signal impedance measurements (because we do not have any better and quicker option).
- the best situation is if/when transducer is driven in one of its mechanical resonant frequencies, delivering high active power (and very low reactive power) to the loading media. Since usually resonant frequency of loaded transducer is not stable (because of dynamical change of many mechanical, electrical and temperature parameters), a PLL resonant frequency (in real-time) tracking system has to be applied. When we drive transducer on its resonant frequency, we are sure that the transducer presents dominantly resistive load. That means that maximum power is delivered from ultrasonic power supply (or ultrasonic generator) to the transducer and later on to its mechanical load.
- ultrasonic power supply or ultrasonic generator
- Impedance matching is an extremely important objective for realizing a maximum efficiency of an ultrasonic transducer (for good impedance matching it is necessary to adjust ferrite transformer ratio and inductive compensation of piezoelectric transducer, operating on a properly controlled resonant frequency).
- boosters or amplitude amplifiers or attenuators
- Recently, some ultrasonic companies (Herman, for instance) used only electrical adjustments of output mechanical amplitude (for mechanical load matching), avoiding any use of static mechanical amplitude transformers such as boosters (this way, ultrasonic configuration becomes much shorter and much more load-adaptable/flexible, but its electric control becomes more complex).
- Impedance-Phase-Frequency characteristics of one transducer are giving indicative and important information for basic quality parameters of one transducer, but not sufficient information for high power loaded conditions of the same transducer. Every new loading situation should be rigorously tested, measured and optimized to produce optimal ultrasonic effects in a certain mechanical load.
- the best operating regime tuning/tracking/control should mean a 100% system control during the totality of ON and OFF regime, or during full-load and no-load conditions.
- Response time of permanently controlled/driven ultrasonic transducers can be significantly faster than in the case when we start tracking and control from the beginning of new Power-ON period.
- transducers When transducers are driven full power, it happens in the process of harmonic oscillation, so input electrical energy is permanently transformed to mechanical oscillations. What happens when we stop or break the electrical input to the transducer? - The generator no longer drives the transducer, and/or they effectively separate. The transducer still continues to oscillate certain time, because of its elastomechanical properties, relatively high electro-mechanical Q-factor, and residual potential (mechanical) energy.
- the simplest analogy for an ultrasonic transducer is a certain combination of Spring-Mass oscillating system. Any piezoelectric or magnetostrictive transducer is a very good energy transformer.
- the transducer will react by giving mechanical output; but, if the active, electrical input is absent (generator is not giving any driving signal to the transducer) and the transducer is still mechanically oscillating (for a certain time), residual electrical back-output will be (simultaneously) generated. It will go back to the ultrasonic generator through the transducer's electrical terminals (which are permanently connected to the US generator output). Usually, this residual transducer response is a kind of reactive electrical power, sometimes dangerous to ultrasonic generator and to the power and frequency control. It will not be synchronized with the next generator driving train, or it could damage generator's output switching components.
- Frequency control of high power ultrasonic converters (piezoelectric transducers) under mechanical loading conditions is a very complex situation.
- the problem is in the following: when the transducer is operating in air, its resonant frequency control is easily realizable because the transducer has equivalent circuit (in the vicinity of this frequency) which is similar to some (resonant) configuration of oscillating R-L-C circuits.
- the transducer is under heavy mechanical load (in contact with some other mass, liquid, plastic under welding...), its equivalent electrical circuit loses (the previous) typical oscillating configuration of R-L-C circuit and becomes much more closer to some (parallel or series) combination of R and C.
- ultrasonic transducers that are used for ultrasonic equipment (piezoelectric or sometimes magnetostrictive) have complex electrical impedance and strong coupling between their electrical inputs and relevant mechanical structure (to understand this we have to discuss all relevant electromechanical, equivalent models of transducers, but not at this time). This is the reason why parallel or serial (inductive for piezoelectric, or capacitive for magnetostrictive transducers) compensation has to be applied on the transducer, to make the transducer closer to resistive (active-real) electrical impedance in the operating frequency range. The reactive compensation is often combined with electrical filtering of the output, transducers driving signals.
- the best we can achieve is to maximize active/real power transfer, and to minimize reactive/imaginary power circulation (between ultrasonic generator and piezoelectric ultrasonic transducer). If/when our (manually controlled) sinus generator produces/supplies low electrical power, the efficiency of loaded ultrasonic conversion is also very low, because there is a lot of reactive power circulating inside of loaded transducer (and back to the generator).
- loaded ultrasonic transducer (optimally) driven by high power will have some other resonant frequency, different than the frequency when it was driven by low power, and also different than its resonant frequency (or frequencies) in non-loaded conditions (in air), because resonant frequency is moving/changing according to time-dependant loading situation (in the range of ⁇ 5% around previously found resonant frequency).
- active electrical power ⁇ active mechanical power, for an electromechanical system where we transfer electrical energy to the mechanical load.
- the appearance of cavitation is the principal sign of producing active ultrasonic power. To control this we need sensors of ultrasonic cavitation.
- ultrasonic generator frequency control circuit
- parallel added capacitance could't be changed by transducer parameters variation.
- Ultrasonic Converter (B), driven by Power Supply (A), is producing a sufficiently strong pulse-repetitive multifrequency train of mechanical oscillations or pulses (see Fig. 1).
- Acoustical load (D), driven by incoming frequency and amplitude modulated pulse-train starts producing its own vibration and transient response, oscillating in one or more of its vibration modes or harmonics. As the excitation changes, following the programmed pattern of the pulse train, the amplitude in these modes will undergo exponential decay while other modes are excited.
- a simplified analogy is a single pulsed excitation of a metal bell that will continue oscillating (ringing) on several resonant frequencies for a long time after the pulse is over. How long each resonant mode will continue to oscillate after a pulse depends on mechanical quality factor in that mode.
- Every mechanical system (in this case the components B, C and D) has many resonant modes (axial, radial, bending, torsional, ...) and all of them have higher frequency harmonics.
- Some of resonant modes are well separated and mutually isolated, some of them are separated on a frequency scale but acoustically coupled, and some will overlap each other over a frequency range - these will tend to couple particularly well.
- acoustical load (D) is connected to an ultrasonic converter (B) by an acoustical wave-guide (C)
- acoustical relaxing and ringing oscillations are traveling back and forth between the load (D) and ultrasonic converter (B), interfering mutually along a path of propagation.
- the best operating frequency of ultrasonic converter (B) is found by adjustment when maximum traveling-wave amplitude is reached, and when a relatively stable oscillating regime is found.
- the acoustical load (D) and ultrasonic converter (B) are creating a "Ping-Pong Acoustical-Echo System", like two acoustical mirrors generating and reflecting waves between them.
- an amplitude sensor (E) of any convenient type e.g. accelerometer, ultrasonic flux sensor
- the sensor is connected by a feedback line to the control system of Ultrasonic Power Supply (A).
- This self-generated and multifrequency Doppler effect is able to initiate different acoustic effects in the load (D), for instance to excite several vibrating modes in the same time or successively, producing uniform amplitude distribution of acoustic waves in acoustic load (D), etc.
- D acoustic load
- the oscillating system described here is very different from the typical and traditional half-wave, ultrasonic resonating system, where the total axial length of the ultrasonic system consists of integer number of half-wavelengths.
- the ultrasonic power supply (A) is also able to produce variable frequency-sweeping oscillations around its central operating frequency (with a high sweep rate), and has an amplitude-modulated output signal (where the frequency of amplitude modulation follows sub harmonic low frequency vibrating modes).
- the ultrasonic power supply (A) is also contributing to the multi-mode ringing response (and self-generated multifrequency Doppler effect) of an acoustical load (D).
- the ultrasonic system described here can drive an acoustic load (D) of almost any irregular shape and size. In operation, when the system oscillates we cannot find stable nodal zones, because they are permanently moving as a result of the specific signal modulations coming from Ultrasonic Power Supply (A)).
- Differently formulated, low thermal dissipation on mechanical system means that the ultrasonic power supply (A) is driving the ultrasonic converter (B) with limited current and sufficiently high voltage, delivering only the active or real power to a load.
- the multifrequency ultrasonic concept described here is a kind of "Maximum Active Power Tracking System", which combines several PLL and PWM loops.
- the actual size and geometry of acoustical load are not directly and linearly proportional to delivered ultrasonic driving-power. It can happen that with very low input-ultrasonic-power, a bulky mechanical system (B, C, D) can be very strongly driven (in air, so there is no additional load), if the proper oscillating regime is found.
- PLL Phase Locked Loop
- load voltage and current have the same frequency
- PLL Phase Locked Loop
- Active Load Power we make zero phase difference between current and voltage signals (controlling the driving voltage frequency).
- Switch-Mode operating regimes for driving Half or Full Bridge, or some other output transistors configuration/s.
- the voltage shape on the output of the Power Bridge is square shaped (50% Duty Cycle), and current (in case of R/L/C resonant circuits as electrical loads) always has a sinusoidal shape.
- current in case of R/L/C resonant circuits as electrical loads
- the special ultrasonic power supply, (A), Fig. 1, (applicable for Multifrequency Structural Actuators) is delivering square shaped, PWM and modulated-frequency output (driving voltage signal), causing that the load (output) current presents multifrequency and multicomponent (basically periodical, sinusoidal) signal (of course, the load current can also have the same frequency as the driving voltage signal, but this would be the case of traditional PLL).
- This method looks like creating the multiple PLL-s between the envelope of the output active power signal and certain frequency-modulating signal (PLL with sub-harmonic/s in a low frequency domain), combined with the second PLL ("in-average-PLL") between the high (resonant) frequency output load current and voltage (this way practically realizing a double PLL frequency control).
- PLL frequency-modulating signal
- in-average-PLL the second PLL
- the new Power-BFF, Multifrequency Actuator concept can be summarized as: Input values, Source CAUSE ⁇ (driving voltage) Produced Response CONSEQUENCE/s (output current) Regulation method in order to get maximal Active Output Power: The average phase differences between the output HF current and voltage and their subharmonies (on the output ferrite transformer) should be minimal (in average) Square shaped voltage on the output Power Bridge: PWM + Band Limited, Frequency Modulation (+ limited phase modulation in some applications) Multi-mode or single sinusoidal output current (or ringing decay current) with Variable operating frequency + Harmonics First PLL at resonant frequency: To control the central operating frequency (of a driving-voltage signal) in order to produce the Active Load Power to be much higher than its Reactive Power.
- the New BFF (multiple "In Average-PLL”) concept is the most general case of Maximum Active Power Tracking and it covers the Traditional PLL concept.
- a number of variations of Power-BFF are imaginable depending on resonant-load applications (like suppressing or stimulating certain operating frequencies or harmonics, implementing frequency sweeping, or randomized frequency and phase modulation / s etc.).
- the PLL concept is applied to immediate load current and voltage signals, and in Power-BFF we apply the similar concept to the immediate active load-power signal.
- the principal objectives are to realize optimal and maximal active power transfer to the load, and that complete power system (in-average, time-vise) looks like resistive load to the main supply input, and this is exactly how Multifrequency Structural Actuators operate.
- the present invention achieves the above objects by realizing wide-band, "Maximum Active Power (multifrequency) tracking” delivering complex vibrations to an ultrasonic transducer and to its mechanical load, all of that already described in this invention, or realizing the specific Ultrasonic Power Supply able to perform multifrequency and multimode transducer-driving.
- Fig. 1 depicts the Block Diagram of a Multifrequency Structural Actuator System, containing 5 different functional blocks, marked with A, B, C, D and E;
- the present invention achieves multifrequency and multimode response in an acoustic load by driving an ultrasonic transducer, connected to its load, with mixed PWM, pulse-repetitive, amplitude, frequency and phase modulated signal, while tracking the selected group of characteristic resonant and modal frequencies belonging to the same acoustic load (taking the feedback signal that is the spectral signature of the load pulse response), and applying the power regulation principle that only Maximal Active Power should be delivered to the load.
- the load is driven only on its most sensitive and natural resonant areas, receiving mixed, low frequency and ultrasonic frequency driving signals, where for every particular oscillating mode a separate PLL tracking (and PWM regulation) is implemented, and all of them are mutually synchronized, having common ultrasonic frequency carrier.
- the ultrasonic carrier-frequency is also frequency and phase modulated by the same feedback signal.
- An additional alternative embodiment of the present invention can achieve further performance enhancement in some applications by providing somewhat different loading and fixation arrangements between ultrasonic transducer and its load. Modifications of this type could allow the single-sided, unidirectional and/or omni-directional load-radiation to be optimized for somewhat different operating frequency bands, and thus increase the total operating bandwidth and uniformity of acoustical activity of the transmitting system and Acoustic Load. Especially convenient ways for realizing effective and omni-directional multifrequency excitation on different acoustical loads is to install (to fix rigidly or to weld) appropriate mounting interfaces, metal shells, rings, tight and pre-stressed metal envelopes... around the acoustical load, and to fix the wave guide rod and ultrasonic transducer to such mounting interfaces.
- Another additional alternative embodiment of the present invention can achieve further performance enhancement in some applications by connecting several ultrasonic transducers (in parallel) to drive the same load, and/or by connecting several ultrasonic power supplies to different ultrasonic transducers (each of them driving the same load), and to use, or not to use, acoustic wave-guide rods between ultrasonic transducer/s and acoustic load/s.
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- Apparatuses For Generation Of Mechanical Vibrations (AREA)
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EP01810227A EP1238715A1 (de) | 2001-03-05 | 2001-03-05 | Multifrequenz-Ultraschall-Betätigungsvorrichtung für Aufbaukomponente |
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EP01810227A EP1238715A1 (de) | 2001-03-05 | 2001-03-05 | Multifrequenz-Ultraschall-Betätigungsvorrichtung für Aufbaukomponente |
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Cited By (22)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6791242B2 (en) | 2001-11-02 | 2004-09-14 | Product Systems Incorporated | Radial power megasonic transducer |
DE102004016196A1 (de) * | 2004-04-01 | 2005-11-03 | Forschungszentrum Karlsruhe Gmbh | Verfahren zur Verringerung/Unterdrückung unerwünschter Schwingungsmodi eines elektromechanischen Systems und Vorrichtung zur Durchführung des Verfahrens |
DE102009004201A1 (de) | 2008-01-16 | 2009-07-23 | Daimler Ag | Lichtbogendrahtspritzverfahren |
DE102008004601A1 (de) | 2008-01-16 | 2009-07-30 | Daimler Ag | Lichtbogendrahtbrenner und zugehöriges Lichtbogendrahtspritzverfahren |
DE102008004602A1 (de) | 2008-01-16 | 2009-07-30 | Daimler Ag | Lichtbogendrahtbrenner |
WO2015157488A1 (en) * | 2014-04-09 | 2015-10-15 | Etegent Technologies Ltd. | Active waveguide excitation and compensation |
US9182306B2 (en) | 2011-06-22 | 2015-11-10 | Etegent Technologies, Ltd. | Environmental sensor with tensioned wire exhibiting varying transmission characteristics in response to environmental conditions |
DE102015213436A1 (de) * | 2015-07-17 | 2017-01-19 | Robert Bosch Gmbh | Verfahren zum Verbinden wenigstens zweier Bauteile mittels einer Stanznietvorrichtung und Fertigungseinrichtung |
DE102015213433A1 (de) * | 2015-07-17 | 2017-01-19 | Robert Bosch Gmbh | Verfahren zum Verbinden wenigstens zweier Bauteile mittels einer Stanznietvorrichtung und Fertigungseinrichtung |
DE102015213761A1 (de) * | 2015-07-22 | 2017-01-26 | Robert Bosch Gmbh | Übertragungselement für eine Stanznietvorrichtung, Stanznietvorrichtung, Fertigungseinrichtung und Verfahren zum Ermitteln eines Schwingungsverhaltens |
GB2504636B (en) * | 2011-05-19 | 2018-08-01 | Agresearch Ltd | Ultrasonic Device |
US10151731B2 (en) | 2015-11-13 | 2018-12-11 | The Boeing Comapny | Ultrasonic system for nondestructive testing |
WO2019023523A1 (en) | 2017-07-26 | 2019-01-31 | Flodesign Sonics, Inc. | AUTOMATIC STARTING AND RUNNING OF ACOUSTIC TRANSDUCER |
US10352778B2 (en) | 2013-11-01 | 2019-07-16 | Etegent Technologies, Ltd. | Composite active waveguide temperature sensor for harsh environments |
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US10854941B2 (en) | 2013-11-01 | 2020-12-01 | Etegent Technologies, Ltd. | Broadband waveguide |
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WO2022174661A1 (zh) * | 2021-02-20 | 2022-08-25 | 山东骏腾医疗科技有限公司 | 一种基于超声波的快速病理组织处理方法及装置 |
US11473167B2 (en) | 2017-05-12 | 2022-10-18 | Chirag Satish Shah | Automated device for degassing and/or foaming of metals and their alloys and process thereof |
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US11772330B2 (en) | 2020-05-12 | 2023-10-03 | Honeywell International Inc. | Tunable system and method for stress resolution in additive manufacturing |
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