Ultrasonic Drive Frequency Tracking for Stable Tool Impedance
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Solution Overview
Problem
Ultrasonic tools face variations in frequency-domain impedance characteristics due to temperature, pressure, and deformation, affecting processing quality and efficiency.
Innovation Solution
An ultrasonic drive system with a switch module, sensing element, and control element that adjusts the operating frequency of the ultrasonic tool in real-time to maintain consistent impedance and amplitude, using a frequency sweep function to determine the operating interval and resonance reference point, and a frequency following function to adjust the frequency accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the ultrasonic tool operates continuously for processing, then the processing speed and efficiency are improved, but the frequency-domain impedance characteristic varies due to temperature, pressure and deformation
Solution Approach 1:
The patent implements a feedback control system where the control element continuously monitors the impedance characteristic of the ultrasonic tool through sensing elements and automatically adjusts the operating frequency to maintain consistent impedance. This closed-loop feedback mechanism resolves the contradiction by enabling continuous operation while dynamically compensating for impedance variations caused by temperature, pressure, and deformation changes.
Solution Approach 2:
The patent employs dynamic frequency adjustment capability, allowing the ultrasonic drive to change its operating frequency in real-time based on detected impedance variations. This dynamic adaptation enables the system to maintain optimal performance and consistent impedance characteristics throughout continuous processing operations, rather than operating at a fixed frequency.
2Manufacturing precision
If the operating frequency is adjusted to maintain consistent impedance, then the processing quality is improved, but the system complexity increases due to frequency sweep and frequency following functions
Solution Approach 1:
The patent combines the frequency sweep function and frequency following function into a single integrated control element that performs both impedance characterization and automatic frequency adjustment. By merging these functions into one unified control system rather than separate systems, the patent reduces overall system complexity while maintaining the ability to achieve consistent impedance and high processing quality.
3Stability of the object's composition
If the impedance of the ultrasonic tool is kept consistent through frequency adjustment, then the amplitude stability is improved, but the response time increases due to continuous frequency monitoring and adjustment
Solution Approach 1:
The patent implements continuous impedance monitoring and continuous frequency adjustment rather than periodic or discrete adjustments. This continuous operation ensures that amplitude stability is maintained at all times during processing, with no interruptions or delays in the control action. The frequency following function operates continuously to track and compensate for impedance changes as they occur.
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 consistent processing quality by maintaining impedance and amplitude, thereby improving the efficiency and lifespan of the ultrasonic tool.
Implementation Method 1
the control element acquires a frequency-domain impedance characteristic according to a voltage and a current of the ultrasonic tool
Implementation Method 2
the cutter not only rotates but also vibrates in a direction perpendicular to the processing surface with high frequency
Implementation Method 3
the control element determines an operating interval and an operating frequency of the ultrasonic signal in the frequency-domain impedance characteristic according to the resonance reference point
Implementation Method 4
The switch module outputs an ultrasonic signal to the ultrasonic tool according to the control signal, and the ultrasonic tool vibrates under the control of the ultrasonic signal
Data Source
AI summary
The present disclosure provides an ultrasonic drive and driving method configured for driving an ultrasonic tool. The ultrasonic drive includes a switch module, a sensing element and a control element. The sensing element senses the voltage and current of the ultrasonic tool and generates a sensing signal accordingly. The control element receives the sensing signal and outputs a control signal. The switch module outputs an ultrasonic signal according to the control signal for controlling the vibration of the ultrasonic tool. When the ultrasonic drive operates a frequency sweep function, the control element determines an operating interval and an operating frequency of the ultrasonic signal. When the ultrasonic drive operates a frequency following function, the control element adjusts the operating frequency according to the sensing signal for keeping the impedance of the ultrasonic tool consistent.