Ultrasound Regulation Loop with External Process Variable
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Solution Overview
Problem
Conventional ultrasound generator regulation systems in resonant systems for processing workpieces, such as welding or cutting, face challenges in rapidly responding to fast load changes, leading to significant amplitude fluctuations and potential mechanical component damage due to delays in reacting to system parameter changes.
Innovation Solution
Incorporating an external process variable, such as processing force or temperature, generated outside the resonant system, into the regulation loop, which is connected downstream of the regulation member, allowing for faster and more effective amplitude regulation through a PID controller and scaling element to dampen oscillations and compensate for disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional regulation means using system parameters (resonant frequency, current, voltage, phase position) are used to regulate the ultrasound generator, then the regulation system is simple and self-contained, but the regulation response is too slow to handle fast load changes, causing significant amplitude fluctuations
Solution Approach 1:
The patent introduces a feedforward control component that receives process variables (such as load changes) before they affect the resonant system. By acting in advance on the regulation variable based on anticipated disturbances, the system compensates for load changes before they cause amplitude fluctuations, thereby improving response speed without requiring complex feedback mechanisms
Solution Approach 2:
The patent introduces an intermediary process variable signal that bridges the gap between the external processing procedure and the internal resonant system regulation. This intermediary signal carries information about load changes from the processing side to the regulation side, enabling faster response without directly complicating the resonant system's internal regulation architecture
2Productivity
If the regulation parameters are set at excessively high values to accelerate the regulation repetition rate, then the response to load changes improves, but oscillation of the regulation circuit occurs
Solution Approach 1:
By implementing feedforward control that anticipates load changes through process variables, the system can use higher regulation parameters without causing oscillations. The preliminary action component compensates for disturbances before they manifest, allowing the feedback loop to run at higher speeds without becoming unstable
Solution Approach 2:
The patent combines feedforward control with optimized feedback mechanisms. The feedback component uses system parameters to detect and correct amplitude deviations, while the feedforward component prevents deviations from occurring in the first place. This dual approach allows higher regulation repetition rates while maintaining circuit stability through the stabilizing effect of predictive compensation
3Reliability
If the regulation reacts only after load changes are detected through system parameters, then the regulation system remains simple, but amplitude fluctuations exceed mechanical component limits causing damage
Solution Approach 1:
The feedforward control component uses process variables to predict and compensate for load changes before they cause damaging amplitude fluctuations. By taking preliminary protective action, the system prevents mechanical components from experiencing excessive forces, thereby improving reliability without requiring complex real-time monitoring of all system parameters
Solution Approach 2:
The patent implements a form of beforehand cushioning by introducing a damping component that anticipates and softens the impact of load changes. The feedforward control prepares the regulation variable in advance to cushion against upcoming disturbances, preventing mechanical components from experiencing shock loads that could cause damage
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 significantly reduces amplitude fluctuations during fast load changes, ensuring more stable operation and preventing mechanical component damage by incorporating real-time processing variables into the regulation process, thereby maintaining constant oscillation amplitude with improved efficiency.
Implementation Method 1
An ultrasound generator in an resonant system generates oscillations, using an electroacoustic converter, within its resonance frequency
Implementation Method 2
generates oscillations, using an electroacoustic converter
Implementation Method 3
a regulation means for the ultrasound generator, the regulation means comprising a regulation member connected upstream of the ultrasound generator, which receives a feedback signal from the resonant system
Implementation Method 4
Incorporating an external process variable, such as processing force or temperature, generated outside the resonant system, into the regulation loop, which is connected downstream of the regulation member, allowing for faster and more effective amplitude regulation through a PID controller and scaling element to dampen oscillations
Data Source
AI summary
A device for processing workpieces uses ultrasound, with an resonant system comprising an ultrasound generator, an ultrasound sonotrode, and an anvil, wherein a workpiece is processed between the anvil and the ultrasound sonotrode. The ultrasound generator comprises a regulation means which has a regulation member connected upstream of the ultrasound generator to receive a feedback signal from the resonant system and to generate a regulation variable which is supplied to the ultrasound generator. A connecting point is provided between the regulation member and the ultrasound generator, at which the regulation variable of the regulation member is linked to a process variable from the processing procedure.