Ultrasonic Probe Array Optimization for Deposit-Free Surfaces
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Solution Overview
Problem
Existing ultrasound-based methods for removing or preventing deposits on surfaces, such as biofilm, face challenges in achieving 100% area coverage due to structural or material properties of the surface, reinforcements, and varying flow conditions, leading to patchy coverage and susceptibility to deposits.
Innovation Solution
The method involves attaching multiple ultrasonic probes to a body surface and optimizing their placement by checking for ultrasound detection between probes, adjusting their positions, and potentially increasing or decreasing their number to ensure comprehensive coverage, using the inverse and piezoelectric effects to emit and detect sound waves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple ultrasonic transducers are used for larger areas, then the coverage area increases, but the area coverage cannot reach 100% due to structural properties and positioning limitations
Solution Approach 1:
The system uses active ultrasonic probes to emit sound events and passive ultrasonic probes to detect them, creating a feedback mechanism that verifies whether the emitted ultrasound is actually detected. This feedback loop allows the system to identify gaps in coverage and adjust probe positions accordingly, ensuring 100% area coverage is achieved.
Solution Approach 2:
The probe positions are made dynamically adjustable rather than fixed. The system iteratively optimizes the positions of ultrasonic probes by evaluating detection results and repositioning probes to eliminate coverage gaps caused by structural properties, reinforcements, or suboptimal initial placement.
2Productivity
If the ultrasonic probe power is increased to improve coverage, then the cleaning effectiveness improves, but cavitation damage may occur
Solution Approach 1:
The system uses periodic ultrasonic excitation at specific frequencies that are tuned to resonate with the coating layers, creating controlled mechanical vibrations that remove deposits without exceeding the cavitation threshold. This periodic action at optimized frequencies achieves effective cleaning while avoiding harmful cavitation effects.
Solution Approach 2:
The system carefully controls and optimizes the frequency and power parameters of the ultrasonic transducers, operating below the cavitation limit while maintaining effective cleaning performance. By adjusting these parameters within safe ranges, the system achieves productivity improvement without introducing harmful cavitation damage.
3Manufacturing precision
If more ultrasonic probes are added to ensure complete coverage, then the area coverage improves, but the device complexity and cost increase
Solution Approach 1:
The system uses a predetermined plurality of ultrasonic probes that may initially seem excessive, but through iterative optimization and position adjustment, the system determines the minimum necessary number of probes required to achieve 100% coverage. This approach ensures complete coverage while minimizing the actual number of probes needed.
Solution Approach 2:
The system divides the large surface area into multiple zones, each monitored and treated by specific ultrasonic probes. By segmenting the coverage area and assigning probes to specific zones, the system can achieve complete overall coverage with a optimized number of probes rather than requiring uniform distribution across the entire surface.
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 enables 100% area coverage, effectively preventing or removing deposits like biofilm by ensuring that each probe emits ultrasound effectively, thereby improving the prevention and removal of inorganic and organic deposits across the surface.
Implementation Method 1
use the ultrasonic transducers attached to a body as ultrasonic probes, which are thus set up to emit ultrasound due to the inverse piezoelectric effect
Implementation Method 2
detect (ultra)sound due to the piezoelectric effect
Implementation Method 3
the combination of which is usually below the cavitation limit in order to prevent damage caused by cavitation effects
Data Source
AI summary
Ultrasonic generators fastened to a body are used as ultrasonic probes which, on account of the inverse piezoelectric effect, are thus used for emitting ultrasound and, on account of the piezoelectric effect, are also used for detecting (ultra)sound. In the process, a plurality of ultrasonic probes are initially fastened at predetermined positions on a surface, which positions likely ensure the largest possible surface area coverage, wherein this is thereby checked regarding whether a sound event emitted by a single ultrasonic probe can be detected by at least one other ultrasonic probe. Since in each case only one ultrasonic probe is connected for emitting a sound event and the remaining ultrasonic probes are connected for receiving, in each case the position of each ultrasonic probe can be adjusted, which leads to optimised surface area coverage. Optionally, the number of provided ultrasonic probes can also be increased or reduced.