Liquid Condition Sensor for Ultrasonic Cleaning
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Solution Overview
Problem
Ultrasonic cleaning systems are inefficient due to dissolved gases in the cleaning liquid and suboptimal liquid levels, which reduce cavitation and increase cleaning times and costs.
Innovation Solution
A liquid condition sensor system that detects signals from ultrasonic transducers to determine suboptimal liquid levels and high concentrations of dissolved gases, providing warnings and automatically adjusting the degassing process or liquid levels to optimize energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic transducers are operated continuously, then cleaning efficiency is improved, but energy is wasted when liquid level is suboptimal or dissolved gas concentration is high
Solution Approach 1:
The system monitors the ultrasonic signal characteristics in real-time and uses this feedback to detect suboptimal liquid levels or high dissolved gas concentrations. When such conditions are detected, the system automatically adjusts operation to prevent energy waste, thus resolving the contradiction between maintaining high productivity and avoiding energy loss.
Solution Approach 2:
The ultrasonic cleaning system performs self-diagnosis by analyzing its own operating parameters and automatically adjusts its operation. The system monitors its own energy transfer efficiency and takes corrective action without external intervention, enabling it to maintain high productivity while minimizing energy waste through autonomous optimization.
2Device complexity
If liquid level is not monitored, then device complexity is reduced, but cleaning time increases due to suboptimal liquid levels
Solution Approach 1:
The ultrasonic transducer serves dual functions: it not only performs the primary cleaning function but also acts as a sensor to monitor liquid level and dissolved gas concentration by analyzing changes in the ultrasonic signal characteristics. This multi-functionality allows the system to gain monitoring capabilities without adding separate monitoring devices, thus maintaining low complexity while reducing cleaning time.
Solution Approach 2:
The system uses its own ultrasonic transducers to monitor liquid conditions, eliminating the need for separate monitoring sensors. By repurposing existing components for dual functions, the system achieves automatic liquid level and gas concentration monitoring without increasing device complexity, thereby reducing cleaning cycle time through timely detection and adjustment.
3Loss of time
If dissolved gases are not removed, then degassing process time is reduced, but cavitation is interfered with reducing cleaning effectiveness
Solution Approach 1:
The system continuously monitors the ultrasonic signal to detect the presence of dissolved gases that interfere with cavitation. When gas interference is detected, the system automatically initiates or extends the degassing process until optimal conditions are restored, ensuring reliable cavitation effectiveness while minimizing unnecessary degassing time through real-time feedback control.
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
The system enhances the efficiency of ultrasonic cleaning by reducing wasted energy, shortening cleaning cycles, and minimizing the need for manual adjustments, thereby improving the overall cleaning process.
Implementation Method 1
the ultrasonic transducers transmit ultrasonic energy into the liquid-filled tank at frequencies of 18 kilohertz or greater
Implementation Method 2
the ultrasonic energy also creates cavitation bubbles within the liquid where the sound pressure exceeds the liquid vapor pressure. When the cavitation bubbles collapse, the interaction between the ultrasonically agitated liquid and the contaminants on the parts
Implementation Method 3
a first circuit configured to detect a signal transmitted from an ultrasonic generator to one or more ultrasonic transducers located in the tank. The liquid condition sensor further includes a second circuit coupled to the first circuit, the second circuit configured to determine if the signal is indicative of one of a suboptimal liquid level, and an unacceptably high concentration of dissolved gases
Data Source
AI summary
A liquid condition sensor configured to monitor the condition of a liquid in an ultrasonic cleaning system tank, the liquid condition sensor including a first circuit configured to detect a signal transmitted from an ultrasonic generator to one or more ultrasonic transducers located in the tank. The liquid condition sensor further includes a second circuit coupled to the first circuit, the second circuit configured to determine if the signal is indicative of one of a suboptimal liquid level, and an unacceptably high concentration of dissolved gases in the cleaning liquid, and a third circuit coupled to the second circuit, the third circuit configured to provide a warning if one of a suboptimal liquid level, and an unacceptably high concentration of dissolved gases in the cleaning liquid is indicated by the second circuit.