Ultrasonic Converter Adapter Coupling for Thin-Wall Components
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Solution Overview
Problem
Existing methods for coupling ultrasonic converters to components, such as silos, heat exchangers, and pipelines, face challenges in achieving both mechanical stability and effective ultrasound transmission, especially with thin component walls, and are difficult to replace when defective.
Innovation Solution
A method involving an adapter with a contact surface and an anchor, welded to the component with a circumferential weld seam and filled with potting compound, which is then hardened, providing mechanical strength and effective ultrasonic coupling, with the ultrasonic converter anchored via an internal thread or other means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a blind hole with internal thread is used to screw the ultrasonic converter into the component, then mechanical coupling strength is improved, but the method becomes ineffective for thin component walls where sufficiently deep blind holes cannot be provided
Solution Approach 1:
An adapter is introduced as an intermediary component between the ultrasonic converter and the component. The adapter includes a contact surface for the component, an opening extending from the contact surface, and an anchor for the ultrasonic converter. This adapter enables effective coupling on thin walls by providing its own structural support rather than relying on the component wall depth.
Solution Approach 2:
The coupling system is divided into separate functional components: the adapter (with contact surface and opening), the anchor (for securing the converter), and the ultrasonic converter itself. This segmentation allows each component to be optimized independently and facilitates replacement of the converter without damaging the component.
2Strength
If welding is used to attach the ultrasonic converter to the component, then mechanical stability is improved, but replacement of a defective ultrasonic converter becomes difficult
Solution Approach 1:
The system is segmented into a permanent part (adapter welded to component) and a replaceable part (ultrasonic converter anchored to adapter). This allows the converter to be replaced independently without affecting the welded connection to the component.
Solution Approach 2:
The anchoring connection between the adapter and ultrasonic converter is designed to be detachable (e.g., via internal thread and coupling thread), enabling dynamic replacement of the converter while maintaining the permanent welded connection of the adapter to the component.
3Ease of manufacture
If clamping, welding, or gluing methods are used to couple the ultrasonic converter, then installation is simplified, but effective ultrasound transmission or mechanical stability is inadequate
Solution Approach 1:
The adapter serves as an intermediary that provides a dedicated contact surface for optimal ultrasound transmission to the component. This separate coupling element ensures effective acoustic contact while maintaining mechanical stability, overcoming the limitations of direct clamping, welding, or gluing methods.
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
Ensures secure mechanical and ultrasonic coupling, allowing for easy replacement of the ultrasonic converter, while maintaining effective ultrasound transmission and mechanical stability, even in applications with varying component shapes and temperatures.
Implementation Method 1
welding the positioned adapter to the component using a circumferential weld seam
Implementation Method 2
The ultrasonic converter typically has a piezoelectric ultrasonic actuator
Implementation Method 3
subject the component, especially its wall, to high-frequency vibrations using an attached ultrasonic converter. Repeated ultrasonic excitation in the frequency range between approximately 18 kHz and 50 kHz
Data Source
Figure 1
Figure 2~3b
Figure 4~5
AI summary
A method (1) for coupling an ultrasonic converter to a component (2), comprising the steps of: providing (3) an adapter (4) with a contact surface (5) for the component (2), an opening (6) extending from its contact surface (5), and an anchoring (7) for the ultrasonic converter; applying (10) the contact surface (5) of the provided adapter (4) to the surface (11) of the component (2); welding (12) the applied adapter (4) to the component (2) using a circumferential weld seam (13) while leaving at least one gap (14) in the weld seam (13); introducing (15) potting compound between the contact surface (5) of the adapter (4) and the surface (11) of the component (2) through the opening (6) until potting compound emerges from the at least one gap (14); allowing (16) the introduced potting compound to harden; and anchoring (17) the ultrasonic converter to the anchor (7) of the adapter (4).