1D Ultrasonic Transducer Array with Wavelength-Spaced Sound Channels
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Solution Overview
Problem
Existing ultrasonic transducers for industrial applications face challenges in maintaining temperature stability, electromagnetic compatibility, and robustness against harsh environments, while also being limited by the size and spacing requirements that restrict frequency range and detection capabilities.
Innovation Solution
A 1D ultrasonic transducer unit with individually controllable transducers and sound channels that allow for precise, directional detection and adjustable wavefronts, enabling larger measurement areas and object scanning, using piezoelectric ceramics like PZT with a housing design that ensures robustness and efficient frequency utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If piezoelectric ceramics such as PZT are used to achieve long detection ranges, then detection range is improved, but device size and spacing requirements increase
Solution Approach 1:
The patent divides the ultrasonic detection system into multiple discrete transducer elements arranged in an array. Each transducer element can be independently controlled, allowing the system to achieve long detection ranges through coherent summation of signals from multiple elements while keeping individual element sizes small.
Solution Approach 2:
The patent transitions from single-element to multi-element array configuration, adding spatial dimensionality to the system. This allows achieving extended detection range through phased array techniques without increasing the physical size of individual transducer elements.
2Measurement precision
If the distance between adjacent ultrasonic transducers is reduced to meet wavelength requirements, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple discrete transducer elements into a unified phased array system with integrated control. The control unit coordinates all transducer elements together, managing the complex interactions and signal processing required for high-resolution near-field detection.
Solution Approach 2:
The patent implements dynamic control of each transducer element's excitation timing and amplitude through the control unit. This dynamic adjustment allows optimization of beam forming and focusing, achieving improved near-field resolution while managing system complexity through adaptive control strategies.
3Measurement precision
If higher frequencies are used to improve detection precision, then measurement precision is improved, but attenuation in gaseous media increases
Solution Approach 1:
The patent employs periodic pulsed excitation of the transducer elements rather than continuous wave operation. This allows using higher frequencies for improved precision during the pulse duration while minimizing overall energy loss through the periodic nature of the excitation, reducing average attenuation in the gaseous medium.
Solution Approach 2:
The patent maintains continuous monitoring capability through overlapping pulses and coherent integration of signals from multiple transducer elements. This continuous useful action allows maintaining high detection precision while managing energy loss through efficient signal processing and integration across the transducer array.
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 reliable and cost-effective monitoring of fill levels and surface structures with adjustable viewing angles, reducing the need for multiple transducer units and ensuring precise detection of objects and materials, even in harsh conditions.
Implementation Method 1
each ultrasonic transducer has a transducer housing, a piezoelectric body arranged in the transducer housing and a sound decoupling layer arranged at an open end of the transducer housing for coupling out into a gaseous medium
Implementation Method 2
sound decoupling layer arranged at an open end of the transducer housing for coupling out into a gaseous medium
Data Source
Figure 1A~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an ultrasonic transducer unit (10) for material detection comprising a housing (14) having securing means for securing to a surface and having at least three discrete ultrasonic transducers (12) designed to decouple sound waves with a consistent working frequency between 20 kHz and 400 kHz in a gaseous medium, and a control unit designed to individually control each ultrasonic transducer (12), wherein two respective directly neighbouring ultrasonic transducers (12) are spaced apart by a distance (A1), the 1D ultrasonic transducer unit (10) has one sound channel (22) per ultrasonic transducer (12) with an respective inlet opening (24) associated with exactly one respective ultrasonic transducer and with an respective outlet opening (26), wherein the outlet openings (26) are arranged along a straight line, a distance (A2) between directly neighbouring outlet openings (26) corresponds to the whole or half the wavelength in the gaseous medium and is smaller than the corresponding distance (A1), a ratio of a surface area of the outlet opening (26) to a surface area of the inlet opening (24) is between 0.30 and 1.2, and every sound channel (22) has at least one length corresponding with the diameter of the inlet opening (24).