Angled Ultrasonic Transducer Potting for Reflection Reduction
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Solution Overview
Problem
Existing ultrasonic sensors are complex, costly, and require intricate adjustments for angular assembly of transmitter and receiver axes, leading to measurement inaccuracies due to multiple reflections and high production and assembly costs.
Innovation Solution
An ultrasonic sensor with a sensor housing where the ultrasonic transducer is fixed using a casting compound that converts from liquid to solid, supporting the transducer at a peripheral surface area, allowing for precise angular alignment and acoustic decoupling, reducing construction and adjustment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If numerous individual parts and complex assembly structures are used for angular assembly of transmitter and receiver, then measurement precision can be improved, but device complexity and production costs increase significantly
Solution Approach 1:
The patent combines multiple functions into a single housing structure that simultaneously provides angular positioning, acoustic decoupling, and mechanical support for the piezoelectric element. The housing integrates what would traditionally require separate adjustment mechanisms, alignment fixtures, and decoupling components, thereby reducing assembly complexity while maintaining measurement precision through the fixed angular geometry of the unified structure.
Solution Approach 2:
The housing structure serves multiple purposes: it positions the piezoelectric element at the required angle, provides acoustic decoupling through integrated damping material, offers mechanical support, and enables straightforward assembly. This multi-functional design eliminates the need for numerous specialized components and adjustment mechanisms, reducing both device complexity and production costs while maintaining measurement accuracy.
2Manufacturing precision
If numerous individual parts and adjustment mechanisms are used for angular assembly, then manufacturing precision can be improved, but production costs and assembly time increase
Solution Approach 1:
The required angular orientation of the piezoelectric element is pre-established through the geometric design of the housing structure itself, rather than requiring complex adjustment mechanisms during assembly. The housing is manufactured with built-in angular features that automatically position the transducer at the correct angle, eliminating the need for costly precision adjustment equipment and reducing assembly time while maintaining manufacturing precision.
3Ease of operation
If parallel alignment of transmitter and receiver axes to detection plane is used, then ease of assembly is improved, but measurement precision deteriorates due to multiple reflections
Solution Approach 1:
The patent employs asymmetric angular positioning of the piezoelectric element relative to the detection plane, tilting it at a specific angle rather than aligning it parallel. This asymmetric configuration prevents ultrasonic waves from reflecting back along the same path, eliminating measurement errors from multiple reflections. The housing structure incorporates this asymmetric angle directly into its geometry, maintaining assembly simplicity while achieving superior measurement accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Simplifies the structure and assembly of ultrasonic sensors, reduces costs, and effectively minimizes multiple reflections by ensuring the transducer surface is angled between 1° to 20° relative to the detection plane, achieving reliable operation and improved measurement accuracy.
Implementation Method 1
The ceramic can emit ultrasonic waves by energizing it, it can also receive ultrasonic waves and convert them into electrical signals. It vibrates when it is energized or when it is hit by ultrasonic waves.
Implementation Method 2
At a temperature of around -20°C, the casting compound causes an attenuation of the ultrasonic waves of at least 40 dB.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an ultrasonic sensor with a sensor housing (2) in which at least one piezoelectric element is fixed with an angle (α) of its transducer surface (4, 4') to a detection plane (5) for objects (6). The ultrasonic transducer is fixed to the sensor housing (2) by means of a potting compound (7) that transitions from a liquid state to an elastic or solid state. The potting compound (7) is supported on a circumferential surface region (8) of the ultrasonic transducer and on the sensor housing (2).