Ultrasonic Sonotrode Sensor for Non-Contact Workpiece Inspection
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Solution Overview
Problem
Existing devices for inspecting workpiece surfaces struggle to maintain a constant distance between sensors and moving workpieces, especially when dealing with oscillating strip materials and out-of-round rollers, which leads to measurement errors and potential damage or temperature alteration of the workpiece surface during inspection.
Innovation Solution
A device utilizing an ultrasonic sonotrode mechanically coupled with a sensor, which produces a levitation force field to maintain a consistent distance from the workpiece surface, preventing direct contact and allowing for rapid adjustment of the sensor's position using varying sound wave energy, thereby minimizing temperature impact and ensuring precise measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is mechanically coupled with a support wheel rolling on the strip material surface, then the sensor maintains a constant distance to the strip surface, but the support wheel contact may damage the sensitive surface or alter the surface temperature
Solution Approach 1:
The patent replaces the mechanical support wheel system with an ultrasonic vibration-based distance control system. The sensor unit is vibrated ultrasonically in the direction of the strip surface, and by controlling the vibration amplitude, the sensor maintains a precise measuring distance without mechanical contact. This substitutes mechanical contact with acoustic field interaction, eliminating surface damage and temperature alteration while maintaining measurement precision.
Solution Approach 2:
The patent changes the operating parameters by using ultrasonic vibration amplitude control instead of mechanical wheel rotation. By dynamically adjusting the vibration amplitude of the sensor unit, the system maintains constant measuring distance without physical contact. This parameter-based control replaces the mechanical support wheel's geometric constraint with an active control mechanism based on vibration parameters.
2Stability of the object's composition
If rigid traverse bars are used to move the sensor across the strip material, then the sensor position is stable, but measurement errors occur due to strip material oscillation and roller out-of-roundness
Solution Approach 1:
The patent replaces the rigid traverse bar mechanical positioning system with an ultrasonic vibration-based active distance control system. Instead of relying on mechanical rigidity to maintain position, the system uses ultrasonic vibration and real-time distance measurement to actively control the sensor's distance from the strip surface, compensating for strip oscillations and roller imperfections.
Solution Approach 2:
The patent implements a feedback control mechanism where the sensor's distance to the strip surface is continuously measured and the ultrasonic vibration amplitude is adjusted accordingly. This closed-loop feedback system compensates for disturbances such as strip oscillation and roller out-of-roundness, maintaining measurement accuracy while the sensor moves across the material.
3Measurement precision
If the sensor is moved in close proximity to the strip material surface, then measurement accuracy improves, but the risk of surface damage and temperature alteration increases
Solution Approach 1:
The patent replaces mechanical contact-based positioning with ultrasonic vibration-based non-contact positioning. The sensor unit vibrates ultrasonically close to the strip surface, and the vibration amplitude is controlled to maintain a precise measuring distance without physical contact. This allows high measurement accuracy while eliminating the harmful effects of mechanical contact such as surface damage and temperature alteration.
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
Enables precise and rapid adjustment of the sensor's position above moving workpieces without direct contact, reducing measurement errors and maintaining the workpiece's temperature distribution, allowing for accurate inspection of surface structures and material properties without damaging the surface.
Implementation Method 1
the sound-emitting surface of the sonotrode executes ultrasonic oscillations so that an ultrasonic levitation force field acts in the presence of a gaseous medium between the workpiece or strip surface and the sound-emitting surface to generate a counterforce in opposition to the urging force so that the sensor unit is held hovering at a distance to the workpiece or strip surface
Data Source
AI summary
A device for inspecting a workpiece surface includes a sensor, a sonotrode having a sound-emitting surface and rigidly connected to the sensor to form a sensor unit, and a movable positioning device coupled with the sensor unit to position the sensor unit in a position opposite to the workpiece surface. The positioning device includes a force-applying member to urge the sensor unit in a direction of the workpiece or strip material surface by applying a predefined urging force or using gravity as the urging force. The sound-emitting surface of the sonotrode generates ultrasonic oscillations to produce an ultrasonic levitation force field in the presence of a gaseous medium between the workpiece surface and the sound-emitting surface to thereby generate a counterforce in opposition to the urging force so that the sensor unit is held hovering at a distance to the workpiece or strip surface.