Ultrasonic Stack Resonance Tracking for Startup Under Load
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Solution Overview
Problem
Ultrasonic power supplies face overloads when starting under load due to frequency shifts, as they are designed for operation in air and lack an automatic method to adjust startup frequency accurately.
Innovation Solution
Conduct a scan of impedance and phase under various operating loads to determine resonance and phase, and operate the ultrasonic stack at the determined resonance and phase while contacting a workpiece under load, using a controller to adjust the phase and amplitude based on load changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ultrasonic power supply starts with the stack under load using a default startup frequency designed for air operation, then the frequency shift causes overload of the power supply, but manually adjusting the startup frequency is imprecise and not automatic
Solution Approach 1:
The system performs an automated impedance scan at startup to measure the actual resonance frequency of the ultrasonic stack under load conditions. The controller uses this feedback information to automatically adjust and lock onto the correct operating frequency, eliminating both the overload problem and the need for manual adjustment. This closed-loop feedback mechanism ensures reliable startup under load while maintaining full automation.
Solution Approach 2:
The system dynamically changes the operating frequency parameter based on the measured impedance characteristics of the ultrasonic stack under load. By scanning through a frequency range and identifying the resonance peak, the system automatically adapts the frequency parameter to match the actual loaded conditions, preventing overload while maintaining automated operation.
2Measurement precision
If the ultrasonic stack operates at a fixed resonance frequency designed for air, then the frequency shift under load reduces operating precision, but manual frequency adjustment is not automatic
Solution Approach 1:
The system continuously monitors the impedance of the ultrasonic stack and uses feedback control to maintain operation at the resonant frequency. The controller adjusts the driving frequency based on real-time impedance measurements, ensuring precise operation under varying load conditions without requiring manual intervention.
Solution Approach 2:
The operating frequency is made dynamic rather than fixed. The system automatically tracks and adjusts the resonance frequency as load conditions change, allowing the ultrasonic stack to operate at optimal frequency precision throughout the welding process. This dynamic adaptation eliminates the need for manual frequency adjustment while maintaining high measurement 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
Prevents overloads by accurately adjusting the ultrasonic system to the load conditions, ensuring stable operation and preventing component damage.
Implementation Method 1
an ultrasonic stack (14) connected to the ultrasonic power supply (12)
Implementation Method 2
taking a scan of impedance and phase of an ultrasonic stack under operating load. Determining from the scan what the resonance is under load
Data Source
AI summary
A method of operating an ultrasonic system under load at startup, includes taking a scan of impedance and phase of an ultrasonic stack under operating load. Determining from the scan what the resonance is under load and what the phase is at that resonance and while contacting a workpiece under load at startup, operating the ultrasonic stack at the determined resonance and phase.