A fully automatic multi-directional single-tank ultrasonic cleaning machine

Abstract

The present invention relates to the technical field of ultrasonic cleaning, and more specifically discloses a fully automatic multi-directional single-tank ultrasonic cleaning machine, which includes a three-dimensional transducer array module, a multi-degree-of-freedom mechanical cooperation module, a sound field perception and feedback module, an intelligent control module, and a fluid circulation system. The three-dimensional transducer array module is composed of a bottom matrix transducer, a sidewall layered transducer, and a top expandable transducer; the multi-degree-of-freedom mechanical cooperation module includes a rotating fixture, a six-axis robotic arm, and a planetary motion mechanism. By providing the three-dimensional transducer array module and the multi-degree-of-freedom mechanical cooperation module, the present invention is beneficial to the phase regulation of the three-dimensional transducer array, realizes the 360°×180° spatial scanning of the acoustic beam, supports multi-frequency compounding and pulse vortex modes, combines mechanical movement to remove large-particle pollutants and small-particle pollutants, and takes into account macroscopic impact and microscopic cleaning.

Description

Technical Field

[0001] The present invention relates to the technical field of ultrasonic cleaning, and more particularly to a fully automatic multi-directional single-tank ultrasonic cleaning machine. Background Art

[0002] The ultrasonic cavitation effect has been increasingly applied in various industries and has become an indispensable technology in fields such as biology, chemistry, and machinery. Today's ultrasonic cavitation technology is developing towards mechanical cleaning and other aspects, and the ultrasonic cleaning machine is a very good application of the ultrasonic cavitation effect. Nowadays, the cleaning industry has developed rapidly, and more and more individuals and enterprises are using ultrasonic cleaning machines. The working principle of the ultrasonic cleaning machine is that the ultrasonic waves generated by the ultrasonic generator impact the liquid, causing cavitation in the liquid to generate a large number of bubbles. These bubbles will adhere to the surface of the cleaning parts, achieving a good cleaning effect.

[0003] Chinese Patent Invention Publication No. CN110479695A discloses a single-tank multi-functional ultrasonic cleaning device, including a chassis. There is a cleaning tank in the middle of the chassis. A mechanical oscillator is provided at the bottom of the cleaning tank, and the mechanical oscillator is connected to the ultrasonic generator at the bottom of the chassis. A hanging basket is provided in the cleaning tank, and the upper part of the hanging basket is hooked on the hook of the rotating device. The rotating device is fixed on the rear wall of the upper half of the chassis. An inlet pipe is provided on the upper left side wall of the cleaning tank, and an inlet solenoid valve is provided on the inlet pipe. An outlet pipe is provided on the lower side wall of the cleaning tank, and an outlet solenoid valve is provided on the outlet pipe. A filtering device is provided at the end of the outlet pipe. A feeding device is provided on the upper right side wall of the cleaning tank. A cabinet door is provided on the front side of the chassis, an exhaust device is provided on the upper side of the chassis, and a controller is provided on one side of the chassis. The controller is electrically connected to the rotating device, the ultrasonic generator, the inlet solenoid valve, the outlet solenoid valve, the feeding device, and the exhaust device respectively. This solution has multiple functions, occupies less space, has a high degree of automation, good safety, high cleaning efficiency, and good cleaning effect.

[0004] It can be seen that the current traditional ultrasonic cleaning machines have multiple technical defects: the sound field direction is single. Since the currently used transducers are usually fixedly installed at the bottom of the tank and the sound waves propagate vertically upward, it is difficult to cover the sides, deep holes, and blind areas, resulting in cleaning dead spots; they cannot intelligently process the workpiece type and pollution degree. When there are a large number of contaminants on the workpiece, the existing ultrasonic cleaning machines cannot intelligently and dynamically adjust the cleaning strategy, cannot process various types of workpieces, and do not have the ability to handle large particle contaminants; the energy utilization rate is low. The reflection efficiency of the sound waves in the tank is less than 50%, resulting in large losses, and the flowing fluid interferes with the sound field distribution, exacerbating the energy attenuation. Summary of the Invention

[0005] In order to overcome the above-mentioned defects of the prior art, the present invention provides a fully automatic multi-directional single-tank ultrasonic cleaning machine to solve the problems existing in the above background art.

[0006] The present invention provides the following technical solution: a fully automatic multi-directional single-tank ultrasonic cleaning machine, including a three-dimensional transducer array module, a multi-degree-of-freedom mechanical cooperation module, a sound field perception and feedback module, an intelligent control module, and a fluid circulation system:

[0007] The three-dimensional transducer array module is composed of a bottom matrix transducer, a sidewall layered transducer, and a top expandable transducer;

[0008] The multi-degree-of-freedom mechanical cooperation module includes a rotary fixture, a six-axis robotic arm, and a planetary motion mechanism;

[0009] The sound field perception and feedback module integrates a sound pressure sensor, a turbidity sensor, and a temperature sensor;

[0010] The intelligent control module is configured to perform sound field inverse modeling, mechanical motion planning, and multi-physical field coupling optimization;

[0011] Further, in the three-dimensional transducer array module:

[0012] The bottom matrix transducer is arranged in a hexagonal honeycomb pattern, and the unit spacing is 1 / 2 of the wavelength λ;

[0013] Each layer of the sidewall layered transducer contains 8 piezoelectric ceramic units, and the layer spacing is 10 - 15 cm;

[0014] The top expandable transducer is connected through a magnetic adsorption interface and supports frequency switching in the range of 28 kHz - 1 MHz.

[0015] Further, the motion parameters of the multi-degree-of-freedom mechanical cooperation module and the sound field emission satisfy the following relationship:

[0016] ;

[0017] where ω(t) is the mechanical angular velocity, fus is the ultrasonic frequency, k is the coupling coefficient, and T is the motion period.

[0018] Further, the intelligent control module includes:

[0019] A sound field inverse modeling unit for solving the transducer excitation parameters to maximize the sound pressure in the target area;

[0020] A deep learning optimization unit that inputs the three-dimensional point cloud data of the workpiece and outputs a sound field - mechanical cooperation strategy;

[0021] A dynamic compensation unit for real-time correction of temperature drift and bubble shielding effect.

[0022] The dynamic compensation unit executes the following compensation strategy:

[0023] S101: Calculate the gradient effect caused by the flow,

[0024] ;

[0025] Wherein, Δϕ is the phase shift, f is the acoustic wave frequency, c is the sound speed, v(x) is the flow velocity distribution, and L is the propagation path;

[0026] S102: Real-time calibration of the sound speed, dynamically correcting the sound speed model according to the temperature T and the flow velocity v:

[0027] ;

[0028] C0 is the static sound speed;

[0029] S103: Phase pre-distortion correction, emitting a reverse phase wavefront through the transducer array to cancel the wavefront distortion caused by the flow (similar to adaptive optics technology).

[0030] Furthermore, the fluid circulation system includes a two-way eddy current pump installed at the bottom, a conical distributor on the side, a nozzle, and a multi-layer filter net outside;

[0031] Two-way eddy current pump, with a maximum flow rate of 200 L / min, supporting pulse mode;

[0032] Conical distributor, including spiral guide vanes, converting the liquid flow into tangential flow;

[0033] Multi-layer filter net, arranged in an aperture gradient (50 μm → 5 μm → 1 μm);

[0034] Nozzle, installed on the bottom plate at an angle of 30 degrees, providing an incident rotating laminar flow.

[0035] Furthermore, the relationship between the liquid flow velocity v and the acoustic frequency f of the fluid circulation system satisfies:

[0036] ;

[0037] To ensure the stable transport of cavitation bubbles in the liquid flow.

[0038] Furthermore, the circulating cooling system includes a cooling heat exchange ring, and multiple cooling heat exchange rings are connected through a circulation pipeline. The cooling heat exchange ring is connected to the external fluid circulation system through a guide pipe.

[0039] Furthermore, the bottoms of the nozzles are all connected to the two-way eddy current pump, and the liquid filtered by the multi-layer filter net enters the nozzles through the two-way eddy current pump.

[0040] A cleaning method for a multi-directional single-tank ultrasonic cleaning machine, including the following steps:

[0041] S1: Loading the three-dimensional model of the workpiece; identifying the contaminated area and geometric features;

[0042] S2: Generate initial transducer phase / amplitude parameters based on inverse modeling of the acoustic field;

[0043] S3: Plan the mechanical motion trajectory and calculate the time sequence of spatiotemporal synchronization with the sound field;

[0044] S4: Start ultrasonic emission and mechanical movement, and monitor the sound pressure distribution in real time;

[0045] S5: Dynamically optimize cleaning parameters through deep learning models until the preset cleanliness threshold is reached.

[0046] Technical effects and advantages of the present invention:

[0047] The present invention is provided with a three-dimensional transducer array module and a multi-degree-of-freedom mechanical coordination module, which is beneficial to the phase control of the three-dimensional transducer array, realizes 360°×180° spatial scanning of the acoustic beam, supports multi-frequency compound (28kHz / 120kHz) and pulse vortex mode, combines mechanical movement to remove large and small particle pollutants, and takes into account both macro-impact and micro-cleaning.

[0048] The present invention is equipped with an intelligent control module, which is conducive to identifying and analyzing various workpiece types and pollution levels, distinguishing the pollution levels of workpieces, and targetedly treating the workpiece surface to remove large and small particles of pollutants. It controls the precise positioning of sound waves in combination with workpiece parameters, accurately determines the cleaning position, improves the utilization rate of sound energy to 85%, and shortens the cleaning time. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 It is a schematic diagram of the overall structure of the present invention.

[0050] Figure 2 It is a cross-sectional view of the overall structure of the present invention.

[0051] Figure 3 It is a schematic diagram of the nozzle structure of the present invention.

[0052] Figure 4 It is a schematic diagram of the structure of the circulating cooling system of the present invention.

[0053] Figure 5 It is a schematic diagram of the intelligent control logic relationship of the present invention.

[0054] Figure 6 It is a schematic diagram of the cleaning method of the present invention.

[0055] Figure 7 This is a schematic diagram of the spatiotemporal synchronization control logic of the present invention.

[0056] Figure 8 Schematic diagram of the deep learning optimization method of the present invention.

[0057] The attached drawing reference numerals are: 1. Three-dimensional transducer array module; 101. Bottom matrix transducer; 102. Sidewall layered transducer; 103. Top expandable transducer; 2. Multi-degree-of-freedom mechanical cooperation module; 201. Rotating fixture; 202. Six-axis robotic arm; 203. Planetary motion mechanism; 3. Sound field perception and feedback module; 301. Integrated sound pressure sensor; 302. Turbidity sensor; 303. Temperature sensor; 4. Intelligent control module; 401. Sound field inverse modeling unit; 402. Deep learning optimization unit; 403. Dynamic compensation unit; 5. Fluid circulation system; 501. Bidirectional eddy current pump; 502. Conical distributor; 503. Multi-layer filter screen; 504. Nozzle; 6. Circulating cooling system; 601. Cooling heat exchange ring; 602. Circulating pipeline; 603. Diversion pipe. Detailed implementation manners

[0058] The technical solutions in the present invention will be clearly and completely described below with reference to the drawings in the present invention. In addition, the forms of the structures described in the following embodiments are only examples, and a full-automatic multi-directional single-tank ultrasonic cleaning machine related to the present invention is not limited to the structures described in the following embodiments. All other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the protection scope of the present invention.

[0059] Referring to Figures 1-5 , the present invention provides a full-automatic multi-directional single-tank ultrasonic cleaning machine, including a three-dimensional transducer array module 1, a multi-degree-of-freedom mechanical cooperation module 2, a sound field perception and feedback module 3, an intelligent control module 4, and a fluid circulation system 5, characterized in that:

[0060] The three-dimensional transducer array module is composed of a bottom matrix transducer 101, a sidewall layered transducer 102 and a top expandable transducer 103;

[0061] The multi-degree-of-freedom mechanical cooperation module 2 includes a rotating fixture 201, a six-axis robotic arm 202 and a planetary motion mechanism 203;

[0062] The sound field perception and feedback module 3 integrates a sound pressure sensor 301, a turbidity sensor 302 and a temperature sensor 303;

[0063] The intelligent control module 4 is configured to perform sound field inverse modeling, mechanical motion planning and multi-physical field coupling optimization;

[0064] The main difference between this embodiment and the prior art is that in this embodiment, the geometric model and the pollution distribution map are superimposed to achieve the applicability and precise cleaning of various workpieces, specifically in the three-dimensional transducer array module 1 and the intelligent control module 4;

[0065] The above structure is the main structure of this embodiment, which solves the problem that traditional ultrasonic cleaning machines cannot accurately judge cleaning in real time according to workpieces and execute cleaning strategies.

[0066] Referring to Figures 1-2 , in the three-dimensional transducer array module 1:

[0067] The bottom matrix transducer 101 is arranged in a hexagonal honeycomb pattern, and the element spacing is 1 / 2 of the wavelength λ;

[0068] Each layer of the sidewall stratified transducer 102 contains 8 piezoelectric ceramic elements, and the layer spacing is 10 - 15 cm;

[0069] The top expandable transducer 103 is connected through a magnetic attraction interface and supports frequency band switching from 28 kHz to 1 MHz.

[0070] In this embodiment, it should be specifically noted that:

[0071] Referring to Figure 2 , the fluid circulation system 5 includes a two-way eddy current pump 501 installed at the bottom, a conical distributor 502 on the side, and a multi-layer filter screen 503 outside;

[0072] The two-way eddy current pump 501 has a maximum flow rate of 200 L / min and supports pulse mode;

[0073] The conical distributor 502 includes spiral guide vanes to convert the liquid flow into tangential flow;

[0074] The multi-layer filter screen 503 is arranged according to the pore size gradient (50 μm → 5 μm → 1 μm).

[0075] In this embodiment, it should be specifically noted that the bottoms of the nozzles 504 are all connected to the two-way eddy current pump 501, and the liquid filtered by the multi-layer filter screen 503 enters the nozzles 504 through the two-way eddy current pump 501. The relationship between the liquid flow velocity v of the fluid circulation system 5 and the sound frequency f satisfies:

[0076] ;

[0077] To ensure the stable transport of cavitation bubbles in the liquid flow.

[0078] Referring to Figure 2 , the motion parameters of the multi-degree-of-freedom mechanical cooperation module 2 and the sound field emission satisfy the following relationship:

[0079] ;

[0080] Among them, ω(t) is the mechanical angular velocity, fus is the ultrasonic frequency, k is the coupling coefficient, and T is the motion period.

[0081] Referring to Figure 5, the intelligent control module 4 includes:

[0082] An acoustic field inverse modeling unit 401, configured to solve transducer excitation parameters to maximize the sound pressure in the target area;

[0083] A deep learning optimization unit 402, which inputs the three-dimensional point cloud data of the workpiece and outputs an acoustic field-mechanical collaborative strategy;

[0084] A dynamic compensation unit 403, which corrects the temperature drift and bubble shielding effect in real time.

[0085] In this embodiment, it should be specifically noted that: the dynamic compensation unit 403 executes the following compensation strategy:

[0086] S101: Calculate the gradient effect caused by the flow,

[0087] ;

[0088] where Δϕ is the phase shift, f is the acoustic wave frequency, c is the sound speed, v(x) is the flow velocity distribution, and L is the propagation path;

[0089] S102: Real-time calibration of the sound speed, dynamically correct the sound speed model according to the temperature T and the flow velocity v:

[0090] ;

[0091] C0 is the static sound speed;

[0092] S103: Phase pre-distortion correction, emitting a reverse phase wavefront through the transducer array to cancel the wavefront distortion caused by the flow (similar to adaptive optics technology);

[0093] Refer to Figure 4 , the circulating cooling system 6 includes a cooling heat exchange loop 601, multiple cooling heat exchange loops 601 are connected through a circulating pipeline 602, and the cooling heat exchange loop 601 is connected to the external fluid circulation system 5 through a diversion pipe 603.

[0094] In this embodiment, it should be specifically noted that: the robotic arm joints need to have an IP68 protection level to prevent liquid infiltration.

[0095] A cleaning method for a multi-directional single-tank ultrasonic cleaning machine includes the following steps:

[0096] S1: Load the three-dimensional model of the workpiece, and the high-precision three-dimensional scanner and the multi-spectral imaging system scan the workpiece to generate a three-dimensional mesh model in STL format with an accuracy of less than 10 μm; identify the contaminated areas and geometric features, use an industrial camera in cooperation with an LED light source to capture surface particles and scratches, and at the same time use laser-induced breakdown spectroscopy to on-line detect the components of the contaminants, and use the geometric model to overlay with the pollution distribution map to mark the coordinates of high pollution;

[0097] S2: Generate initial transducer phase / amplitude parameters based on inverse sound field modeling; Sound field modeling process: Through the governing equation (Helmholtz equation):

[0098] ;

[0099] Construct the transfer function Hmn from each transducer unit to the target point (m: transducer number, n: target point number) using the transfer matrix:

[0100] ;

[0101] Inverse solution process: Optimization objective (maximize the sound intensity in the target area, minimize the energy in the non-target area)

[0102] ;

[0103] Solution algorithm: Use convex optimization (CVX toolbox) or genetic algorithm (population size 100, iterate 50 times), and output the transducer phase , amplitude .

[0104] S3: Plan the mechanical motion trajectory: Use the RRT algorithm and B-spline curve to generate a smooth spline curve suitable for complex geometric obstacle avoidance, solve the problem that the inner wall of the cavity is difficult to clean, and calculate the spatio-temporal synchronization timing with the sound field: The position and pose P(t) of the robotic arm and the sound field parameters (phase , amplitude ) are synchronized according to the time stamp, and the actual position of the robotic arm is monitored in real time , and the sound field direction is adjusted through the PID controller:

[0105] ;

[0106] Achieve spatio-temporal synchronization control;

[0107] S4: Start the synchronous movement of ultrasonic emission and mechanical movement. After the robotic arm reaches the starting point, send a synchronization signal to the ultrasonic generator. The synchronous control structure drives the transducer array according to the preset phase / amplitude parameters. The sound pressure, turbidity, and temperature data are collected through the fiber optic hydrophone, sound pressure sensor, and turbidity sensor and output to the industrial control computer to generate a three-dimensional sound field cloud map, and the sound pressure distribution is monitored in real time. When the robotic arm enters the high-risk area of the sound field, the power is automatically reduced or the emission is paused. When the transducer temperature > 45°C, trigger frequency reduction + forced cooling;

[0108] S5: Dynamically optimize the cleaning parameters through the deep learning model, and dynamically adjust the parameters according to the real-time data until the preset cleanliness threshold is reached.

[0109] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A fully automatic multi-directional single-tank ultrasonic cleaning machine, comprising a three-dimensional transducer array module (1), a multi-degree-of-freedom mechanical cooperation module (2), a sound field perception and feedback module (3), an intelligent control module (4), a fluid circulation system (5), and a circulating cooling system (6), characterized in that: The three-dimensional transducer array module is composed of a bottom matrix transducer (101), a sidewall layered transducer (102), and a top expandable transducer (103); The multi-degree-of-freedom mechanical cooperation module (2) includes a rotary fixture (201), a six-axis robotic arm (202), and a planetary motion mechanism (203); The sound field perception and feedback module (3) integrates a sound pressure sensor (301), a turbidity sensor (302), and a temperature sensor (303); The intelligent control module (4) is configured to perform sound field inverse modeling, mechanical motion planning, and multi-physical field coupling optimization; The intelligent control module (4) includes: A sound field inverse modeling unit (401) for solving transducer excitation parameters to maximize the sound pressure in the target area; A deep learning optimization unit (402) that inputs the three-dimensional point cloud data of the workpiece and outputs a sound field-mechanical cooperation strategy; A dynamic compensation unit (403) for real-time correction of temperature drift and bubble shielding effect; The fluid circulation system (5) includes a two-way eddy current pump (501) installed at the bottom, a conical distributor (502) on the side, a nozzle (504), and an external multi-layer filter screen (503); The two-way eddy current pump (501) has a maximum flow rate of 200 L / min and supports a pulse mode; The conical distributor (502) includes spiral guide vanes to convert the liquid flow into a tangential flow; The multi-layer filter screen (503) is arranged in an aperture gradient, and the aperture sizes are 50 μm, 5 μm, and 1 μm in sequence; The nozzle (504) is installed on the bottom plate at an angle of 30 degrees to provide an incident rotating laminar flow; The circulating cooling system (6) includes a cooling heat exchange ring (601), and multiple cooling heat exchange rings (601) are connected through a circulation pipeline (602). The cooling heat exchange ring (601) is connected to the external fluid circulation system (5) through a diversion pipe (603); The bottom of the nozzle (504) is connected to the two-way eddy current pump (501), and the liquid filtered by the multi-layer filter screen (503) enters the nozzle (504) through the two-way eddy current pump (501).

2. The fully automatic multi-directional single-tank ultrasonic cleaning machine according to claim 1, wherein: In the three-dimensional transducer array module (1): The bottom matrix transducer (101) is arranged in a hexagonal honeycomb pattern, and the unit spacing is 1 / 2 of the wavelength λ; Each layer of the sidewall layered transducer (102) contains 8 piezoelectric ceramic units, and the layer spacing is 10 - 15 cm; The top expandable transducer (103) is connected through a magnetic adsorption interface and supports frequency band switching from 28 kHz to 1 MHz.

3. The fully automatic multi-directional single-tank ultrasonic cleaning machine according to claim 2, wherein: The motion parameters of the multi-degree-of-freedom mechanical cooperation module (2) and the sound field emission satisfy the following relationship: ； Where ω(t) is the mechanical angular velocity, fus is the ultrasonic frequency, k is the coupling coefficient, and T is the motion period.

4. The fully automatic multi-directional single-tank ultrasonic cleaning machine according to claim 3, wherein: The relationship between the liquid flow velocity v of the fluid circulation system (5) and the sound frequency f satisfies: ； To ensure the stable transport of cavitation bubbles in the liquid flow.

5. A cleaning method for the multi-directional single-tank ultrasonic cleaning machine according to claim 4, characterized in that, Including the following steps: S1: Load the three-dimensional model of the workpiece; identify the contaminated area and geometric features; S2: Generate the initial transducer phase / amplitude parameters based on the inverse acoustic field modeling; S3: Plan the mechanical motion trajectory and calculate the spatio-temporal synchronization timing with the acoustic field; S4: Start the ultrasonic emission and mechanical motion, and monitor the sound pressure distribution in real time; S5: Dynamically optimize the cleaning parameters through the deep learning model until the preset cleanliness threshold is reached.

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