Ultrasonic Fatigue Testing Machine Temperature Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ultrasonic fatigue testing machines face challenges in adjusting excitation and pause times during intermittent operation to manage internal test piece temperature effectively, leading to inefficient testing and potential test failures due to varying heat generation and cooling speeds.
Innovation Solution
An ultrasonic fatigue testing machine with a displacement meter to measure the test piece's end surface gap, estimating internal temperature using a linear expansion coefficient, and a control system to adjust excitation and pause times based on allowable temperature ranges, ensuring heat generation remains within safe limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If intermittent operation is performed to suppress internal heat generation, then temperature control is improved, but test time increases due to repeated excitation and pause cycles
Solution Approach 1:
The patent implements feedback control by measuring the test piece temperature in real-time and using this information to dynamically adjust the excitation and pause cycles. The control unit continuously monitors temperature data from the temperature sensor and modifies the intermittent operation parameters accordingly, creating a closed-loop system that optimizes both temperature control and test efficiency.
Solution Approach 2:
The patent applies dynamics by making the excitation and pause periods adjustable rather than fixed. The control unit dynamically modifies the excitation time and pause time based on real-time temperature measurements, allowing the system to adapt to varying heat generation rates and material properties during the fatigue test.
2Temperature
If excitation and pause timings are adjusted manually through trial and error, then temperature control is improved, but operator workload and test setup time increase
Solution Approach 1:
The patent implements self-service by enabling the system to automatically adjust excitation and pause timings based on real-time temperature measurements. The control unit autonomously processes temperature data and modifies test parameters without requiring manual intervention, reducing operator workload and eliminating the need for trial-and-error adjustments.
Solution Approach 2:
The system uses feedback control where temperature measurements from the sensor are continuously fed back to the control unit, which automatically adjusts excitation and pause parameters. This closed-loop feedback mechanism eliminates the need for manual trial and error, reducing both operator involvement and system complexity.
3Device complexity
If surface temperature is measured to monitor internal temperature, then measurement simplicity is improved, but measurement accuracy deteriorates due to heat emission from test piece surface
Solution Approach 1:
The patent uses an intermediary approach by introducing a temperature sensor as a mediator between the test piece and the measurement system. The sensor is strategically positioned to measure temperature at a location that reflects internal temperature conditions while being accessible for external measurement, thereby bridging the gap between simple measurement and accurate internal temperature monitoring.
Solution Approach 2:
The patent replaces direct internal temperature sensing with a sophisticated measurement system that infers internal temperature from external measurements. By using thermal conduction principles and calibrated sensor positioning, the system substitutes direct internal measurement with an indirect but accurate measurement approach that maintains simplicity while improving precision.
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
This approach allows for precise adjustment of excitation and pause times, effectively controlling internal test piece temperature and optimizing the fatigue test process by preventing excessive heat generation and reducing test duration.
Implementation Method 1
a displacement meter that is arranged in a position away, by a predetermined distance, from an end surface of a free end of the test piece on a side opposite to an end part fixed to the horn, and measures a distance to the end surface of the test piece
Implementation Method 2
an ultrasonic transducer that receives the electrical signal from the oscillator to oscillate
Implementation Method 3
resonate a test piece by an ultrasonic wave to perform a fatigue test
Implementation Method 4
a horn of which a fore end is attached with a test piece, which amplifies ultrasonic oscillation from the ultrasonic transducer to transmit the amplified ultrasonic oscillation to the test piece
Implementation Method 5
from a variation in the distance from the displacement meter to the end surface of the test piece measured by the displacement meter, estimates internal temperature of the test piece due to internal heat generation of a material caused by the ultrasonic oscillation
Data Source
AI summary
This ultrasonic fatigue testing machine is one that resonates a test piece by an ultrasonic wave to perform a fatigue test, and configured to include an ultrasonic wave generation part 10, a displacement measurement part 20, and a control part 30 that controls the overall operation of the ultrasonic fatigue testing machine. The control part 30 is configured to have a computer that includes storage devices capable of store programs and various types of data, such as an RAM and an ROM, and an arithmetic unit such as a CPU, and includes an internal temperature estimation part 31, an allowable range setting part 32, and a determination part 33 as a main functional configuration.