Ultrasonic Sonotrode Coupling at Bending Vibration Minima

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Solution Overview

Problem

Ultrasonic sonotrodes and oscillators often experience bending vibrations during operation, which are transmitted to the ultrasonic converter, leading to potential impairment or destruction.

Innovation Solution

The ultrasonic oscillator is designed with a coupling surface positioned at a bending vibration minimum, reducing the transmission of bending vibrations to the ultrasonic converter, and featuring a recess that enhances rigidity and stability, allowing for increased oscillation amplitude and potentially dispensing with the need for an ultrasound booster.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the coupling surface is positioned at the rear of the ultrasonic transducer (conventional arrangement), then the structure is simple, but bending vibrations are transmitted to the ultrasonic converter causing damage

Engineering Contradiction:

Improveprotection of ultrasonic converter from bending vibrationsVSAvoidstructure of ultrasonic transducer

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The coupling surface is moved from the rear end surface to the side surface of the ultrasonic transducer, changing the spatial dimension of coupling. This positional change in another dimension allows the coupling surface to be located at a bending vibration minimum, reducing vibration transmission while maintaining structural simplicity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The coupling surface is specifically positioned at a location on the side surface where bending vibration amplitude is minimal (at least one bending vibration minimum). This local quality optimization ensures that coupling occurs at a point with favorable vibration characteristics, protecting the ultrasonic converter

Inventive Principle:

Principle #3Local quality

2Use of energy by moving object

If the coupling surface area is increased, then coupling efficiency improves, but the transducer cross-section must be larger

Engineering Contradiction:

Improvecoupling efficiency of ultrasonic vibrationsVSAvoidcross-section of ultrasonic transducer

Core Design Contradiction:

Use of energy by moving objectVSArea of stationary object

Solution Approach 1:

The coupling surface area is optimized to be at least 10% of the total cross-sectional area, with preference for 20-50%. This parameter optimization achieves sufficient coupling efficiency without requiring a large transducer cross-section, maintaining compact device dimensions

Inventive Principle:

Principle #35Parameter changes

3Power

If the ultrasonic transducer operates with high power input, then output performance increases, but bending vibrations increase causing converter damage

Engineering Contradiction:

Improvepower input to ultrasonic transducerVSAvoidbending vibrations transmitted to converter

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The side surface coupling arrangement, initially seeming to reduce coupling efficiency, actually converts the harmful bending vibrations into a beneficial configuration where coupling occurs at vibration minima. This allows high power operation while protecting the converter, as the coupling geometry itself mitigates the harmful effect

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

Significantly reduces the impact of bending vibrations on the ultrasonic converter, minimizing the risk of damage and allowing for higher power input with lower vibration transmission.

Implementation Method 1

an input region (11) having a coupling surface (12) for coupling ultrasonic vibrations into the ultrasonic transducer

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

the coupling surface (12) is located in the region of a bending vibration minimum of the ultrasonic transducer

Methodology Applied

Scientific EffectBending vibration minimum: Vibration

Data Source

PatentEP3663008B1Ultrasonic oscillator, ultrasonic oscillation system and method for operating the same

Publication Date: 2023.10.25 TELSONIC HLDG AG

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AI summary

Disclosed is, among other things, an ultrasonic transducer (10; 30), in particular a sonotrode (10) or an ultrasonic booster (30), with an input area (11; 31) comprising at least one input surface (12; 32) for coupling ultrasonic vibrations into the ultrasonic transducer (10; 30), in particular from an ultrasonic converter (40) or an ultrasonic booster (30), and at least one output surface (33; 43), in particular at least one working surface (13) of a sonotrode (10), for emitting the ultrasonic vibrations. The input area (11; 31) has a recess (14; 34) with a bottom surface forming the input surface (12; 32), which is arranged in the region of a bending vibration minimum (M) of the ultrasonic transducer (10; 30). The depression (14; 34) can be fully enclosed by a side surface (15; 35).Furthermore, an ultrasonic vibration system (50) is shown, which comprises such an ultrasonic transducer (10; 30) and an ultrasonic transmitter (30; 40) with a coupling surface (33; 43) via which ultrasonic vibrations from the ultrasonic transmitter (30; 40) can be coupled into the coupling surface (12; 32) of the ultrasonic transducer (10; 30). A method for operating such an ultrasonic transducer is also described.