Ultrasonic generator

Abstract

The utility model discloses an ultrasonic generator, which comprises a power supply module, a linear power amplifier module, an isolation transformer, a transducer, a signal generation module and a current sampling module, according to the utility model, the current sampling module is arranged to collect the real-time current when the power supply module, the linear power amplifier module, the isolation transformer and the transducer form a resonant circuit, so that the current resonant frequency of the ultrasonic generator is calculated, and the real-time working frequency is adjusted according to the current sampling value; therefore, the generator always works at the corresponding working resonance point, and the working quality of the ultrasonic generator is improved.

Description

Technical Field

[0001] This utility model relates to the technical field of ultrasonic processing, and in particular to the technical field of ultrasonic generators. Background Technology

[0002] With the advancement of technology, the complexity of industrial products is constantly increasing, and the requirements for machining accuracy and efficiency have reached unprecedented heights. Traditional machine tools are gradually showing their limitations when dealing with some special materials and complex-shaped workpieces. For example, machining high-hardness materials is difficult, and the large cutting forces easily lead to severe tool wear; brittle materials are prone to cracking and breakage during machining.

[0003] Meanwhile, the application of ultrasonic technology in the machining field is gradually gaining attention. Ultrasonic machining utilizes the energy of ultrasonic vibrations to effectively reduce cutting forces, decrease tool wear, and improve machining quality. It is particularly suitable for machining hard and brittle materials, achieving high-precision, low-damage machining results.

[0004] In ultrasonic processing, the ultrasonic generator, which generates and drives ultrasonic signals, is a crucial component of the system. Currently, there are many types of ultrasonic generators on the market, which can be broadly categorized into analog signal generators and digital signal generators.

[0005] Ultrasonic analog signal generators are generally used in high-power applications, such as cleaning and welding, where the load does not vary significantly during operation. Since the transducer is integrated into the circuit as a signal generator component, it offers the advantage of real-time frequency tracking. However, its biggest drawback is its narrow applicable frequency range and high requirements for transducer frequency matching. Different types of transducers necessitate the use of ultrasonic generators with different frequency ranges.

[0006] Digital signal generators overcome the aforementioned drawback of a narrow frequency range, making them suitable for applications with lower power and varying resonant frequencies. Since the transducer component passively receives ultrasonic signals, frequency tracking is not directly related to the transducer. Therefore, they can be widely used in various low-power environments and possess a final-stage wireless transmission function, offering significant advantages for installation on processing tools unsuitable for wired transmission.

[0007] The problem with existing ultrasonic generators is that they cannot scan the operating frequency in real time and cannot keep the ultrasonic generator operating at the optimal frequency point. Summary of the Invention

[0008] The purpose of this invention is to solve the problems in the prior art by proposing an ultrasonic generator that can acquire real-time current values ​​through a current sampling module and adjust the real-time operating frequency point through a signal generation module so that the generator always works at the corresponding operating resonance point.

[0009] To achieve the above objectives, this utility model proposes an ultrasonic generator, comprising:

[0010] The power module is used to convert mains power into a low-voltage, stable drive power supply.

[0011] A linear power amplifier module is electrically connected to the power supply module;

[0012] An isolation transformer is connected to the linear power amplifier module;

[0013] A transducer, connected to the isolation transformer, is used to convert electrical energy into ultrasonic vibrations;

[0014] The signal generation module is controlled and connected to the linear power amplifier module;

[0015] A current sampling module is located in the circuit loop between the power supply module and the linear power amplifier module. It is used to collect the magnitude of the circuit current and transmit the collected information to the signal generation module.

[0016] Preferably, the system also includes a human-computer interaction module, which is connected to the signal generation module.

[0017] Preferably, the signal generation module includes a microcontroller and a sine wave generation module, wherein the microcontroller controls the sine wave generation module.

[0018] Preferably, the system also includes an amplitude detection module, which is communicatively connected to the signal generation module. The amplitude detection module is used to detect the actual vibration value of the ultrasonic tool or ultrasonic tool holder and feed it back to the signal generation module.

[0019] Preferably, the system also includes a wireless communication module, and the signal generating module is electrically connected to the wireless communication module.

[0020] Preferably, the system also includes a temperature detection module, which is communicatively connected to the signal generation module.

[0021] Preferably, the power module outputs a 24V DC power supply.

[0022] The beneficial effects of this ultrasonic generator are as follows: This invention collects the real-time current magnitude when the power supply module, linear power amplifier module, isolation transformer, and transducer form a resonant circuit, thereby calculating the current resonant frequency of the ultrasonic generator. Based on the magnitude of the current sampling value, the real-time operating frequency is adjusted so that the generator always operates at the corresponding resonant point, thus improving the working quality of the ultrasonic generator.

[0023] The features and advantages of this utility model will be described in detail through embodiments and accompanying drawings. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of an embodiment of an ultrasonic generator according to the present invention.

[0025] Figure 2 This is a schematic diagram of the structure of an ultrasonic generator according to Embodiment 2 of this utility model.

[0026] Figure 3 It is a waveform curve showing the relationship between the power output current and frequency of an ultrasonic generator when used in a transducer for processing hard and brittle materials.

[0027] in:

[0028] 1-Power supply module; 2-Linear power amplifier module; 3-Transducer; 4-Signal generation module; 5-Isolation transformer; 6-Current sampling module; 7-Human-machine interface module; 8-Amplitude detection module; 9-Wireless communication module; 10-Temperature detection module; 41-Microcontroller; 42-Sine wave generation module Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. However, it should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit its scope. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concept of the present utility model.

[0030] In the description of this utility model, it should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on or indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to or indirectly connected to the other element.

[0031] In the description of this utility model, it should be noted that the terms "center," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "multiple" means two or more, unless otherwise explicitly specified. "Several" means one or more, unless otherwise explicitly specified.

[0032] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances. Example 1

[0033] The waveform curve showing the relationship between the power output current and frequency in an ultrasonic generator transducer used for machining hard and brittle materials is shown in the attached diagram. Figure 3 As shown in the attached diagram of the instruction manual. Figure 3 As shown, for a low-power transducer used in the processing of hard and brittle materials, there will be three resonant points during actual operation. The first and third resonant points are the maximum values, and the second resonant point is the minimum value.

[0034] See Figure 1This utility model discloses an ultrasonic generator, comprising a power supply module 1, a linear power amplifier module 2, an isolation transformer 5, and a transducer 3 connected in sequence. The power supply module 1, the linear power amplifier module 2, the isolation transformer 5, and the transducer 3 form a resonant circuit. A current sampling module 6 is provided between the power supply module 1 and the linear power amplifier module 2 in the resonant circuit to collect the circuit current and transmit the collected information to the signal generation module 4. The signal generation module 4 is connected to the linear power amplifier module 2. The device also includes a human-machine interface module 7 connected to the signal generation module 4 to provide an interface for controlling the signal generation module 4. In this embodiment, the ultrasonic generator power supply module 1 uses a standard ±24V power supply voltage to provide the linear power amplifier module 2 to drive the ultrasonic signal applied to the transducer 3. The +24V voltage is linearly stepped down and regulated to obtain a +5V power supply for the signal generation module 4 and the human-machine interface module 7. The signal generation module 4 uses a microcontroller 41 to control the sine wave generation module 42, adjusting the frequency and amplitude of the sine wave signal digitally. This signal is amplified in amplitude and power by the linear power amplifier module 2 and then drives the transducer via the isolation transformer 5. The amplitude of the generated signal can be adjusted via the human-machine interface module 7, and the frequency can be preset. During operation, the frequency is adjusted according to the current sampling value. If the frequency cannot be adjusted to the resonant point, i.e., if the frequency cannot be adjusted to reach the minimum current value, an alarm signal is output.

[0035] When the ultrasonic generator is unloaded, perform a wide-range frequency scan, record the change in current as the frequency changes, find the frequency point where the current is at its minimum, record this frequency, and after the frequency scan is completed, preliminarily confirm that the generator is working at this frequency point, which is taken as the initial working frequency point.

[0036] After the machine starts working, the resonant frequency will change due to load variations. At this time, the actual current value of the ultrasonic generator is monitored by the current sampling module 6. After a change is detected, a narrow-range frequency scan is performed near the initial operating frequency point to find the frequency point where the current value is minimum. This is the new resonant frequency point. Thereafter, the current is continuously monitored based on this frequency. If there is a change, a narrower frequency scan is performed to find the latest resonant frequency. This method is used to continuously track the frequency so that the generator always works at the resonant point. Example 2

[0037] See Figure 2Based on Embodiment 1, an amplitude detection module 8 is also included. The amplitude detection module 8 is communicatively connected to the signal generation module 4. The amplitude detection module 8 is used to detect the actual vibration value of the ultrasonic tool or ultrasonic tool holder and feed it back to the signal generation module 4. When the ultrasonic generator is working, the microcontroller 41 of the signal generation module 4 detects the actual vibration value of the ultrasonic tool or ultrasonic tool holder through the amplitude detection module 8. If the ultrasonic generator is in working condition but the amplitude detection module 8 does not detect vibration, a fault is determined, and an alarm signal can be output through the wireless communication module 9 or the human-machine interaction module 7.

[0038] See Figure 2 It also includes a wireless communication module 9, which is electrically connected to the signal generating module 4. This module is used for wireless communication with other devices to transmit signals.

[0039] See Figure 2 It also includes a temperature detection module 10, which is communicatively connected to the signal generation module 4. It is used to monitor temperature; if the temperature is too high, it can output an alarm signal or stop operation via the wireless communication module 9 or the human-machine interaction module 7.

[0040] The working process of this utility model:

[0041] In the operation of this ultrasonic generator, the power supply module 1 provides a standard ±24V power supply to the linear power amplifier module 2 to drive the ultrasonic signal applied to the transducer 3. The +24V voltage is linearly stepped down and regulated to obtain a +5V power supply for the signal generation module 4 and the human-machine interface module 7. The signal generation module 4 uses a microcontroller 41 to control the sine wave generation module 42, digitally adjusting the frequency and amplitude of the sine wave signal. This signal is amplified in amplitude and power by the linear power amplifier module 2 and then drives the transducer through the isolation transformer 5. The amplitude of the generated signal can be adjusted through the human-machine interface module 7, and the frequency can be preset. During operation, the frequency is adjusted according to the current sampling value. If the frequency cannot be adjusted to the resonant point, i.e., if the frequency cannot be adjusted to reach the minimum current value, an alarm signal is output.

[0042] All standard parts used in this application can be purchased from the market. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the existing technology. The internal components of the electric slide rail, cylinder, welding machine, electric telescopic rod and controller all adopt conventional models in the existing technology, and their internal structure belongs to the existing technology structure. Workers can complete the normal operation of them according to the existing technical manual. In addition, the circuit connection adopts the conventional connection method in the existing technology, and will not be described in detail here.

[0043] It should be noted that although the above embodiments have been described herein, this does not limit the scope of patent protection for this utility model. Therefore, any changes and modifications made to the embodiments described herein based on the innovative concept of this utility model, or equivalent structural or procedural transformations made using the content of this utility model's specification and drawings, directly or indirectly applying the above technical solutions to other related technical fields, are all included within the scope of protection of this utility model patent.

Claims

1. An ultrasonic generator, characterized in that, include: Power module (1) is used to convert mains power into low-voltage stable drive power; The linear power amplifier module (2) is electrically connected to the power supply module (1); An isolation transformer (5) is connected to the linear power amplifier module (2); The transducer (3) is connected to the isolation transformer (5) and is used to convert electrical energy into ultrasonic vibration; The signal generation module (4) is controlled to be connected to the linear power amplifier module (2); The current sampling module (6) is located on the circuit loop between the power supply module (1) and the linear power amplifier module (2) to collect the magnitude of the circuit current and transmit the collected information to the signal generation module (4).

2. An ultrasonic generator as described in claim 1, characterized in that: It also includes a human-computer interaction module (7), which is connected to the signal generation module (4).

3. An ultrasonic generator as described in claim 1, characterized in that: The signal generation module (4) includes a microcontroller (41) and a sine wave generation module (42), and the microcontroller (41) controls the sine wave generation module (42).

4. An ultrasonic generator as described in claim 1, characterized in that: It also includes an amplitude detection module (8), which is communicatively connected to the signal generation module (4). The amplitude detection module (8) is used to detect the actual vibration value of the ultrasonic tool or ultrasonic tool holder and feed it back to the signal generation module (4).

5. An ultrasonic generator as described in claim 1, characterized in that: It also includes a wireless communication module (9), and the signal generating module (4) is electrically connected to the wireless communication module (9).

6. An ultrasonic generator as described in claim 1, characterized in that: It also includes a temperature detection module (10), which is communicatively connected to the signal generation module (4).

7. An ultrasonic generator as described in claim 1, characterized in that: The power module (1) outputs a 24V DC power supply.

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