Characteristics of large capacity ultrasonic complex vibration sources with stepped complex transverse vibration rods

Configurations of large capacity ultrasonic complex vibration sources with multiple longitudinal transducers are proposed and studied. The ultrasonic complex vibration systems are effective and essential for new applications in various industries. The complex vibration source of 27 kHz consists of a complex transverse rod with a welding tip (aluminum alloy, stainless steel and titanium alloy), a complex vibration rod with a flange and stepped part for holding the system, a circular longitudinal vibration disk (aluminum alloy) and six bolt-clamped Langevin type PLT transducers. Three transducer pairs are driven simultaneously using three driving systems at phase difference 120 degrees, and almost circular vibration locus is obtained.     

Transverse and torsional complex vibration systems for ultrasonic seam welding of metal plates

Transverse and torsional complex vibration systems for ultrasonic seam welding of metal plate specimens, using a 27 kHz complex vibration disk welding tip vibrating in transverse and torsional vibration modes, were studied. Using a complex vibration welding system with a welding tip vibrating in elliptical or circular locus, thick plate specimens can be welded with a more uniform and larger area compared to a conventional ultrasonic welding system. The disk welding tip vibrates in an elliptical or circular locus. The complex vibration system can continuously weld multiple parts of metal plate specimens such as heat sinks with a large number of fins.     

Characteristics of coated copper wire specimens using high frequency ultrasonic complex vibration welding equipments

Welding characteristic of thin coated copper wires were studied using 40, 60, 100 kHz ultrasonic complex vibration welding equipments with elliptical to circular vibration locus. The complex vibration systems consisted of a longitudinal-torsional vibration converter and a driving longitudinal vibration system. Polyurethane coated copper wires of 0.036 mm outer diameter and copper plates of 0.3 mm thickness and the other dimension wires were used as welding specimens. The copper wire part is completely welded on the copper substrate and the insulated coating material is driven from welded area to outsides of the wire specimens by high frequency complex vibration.     

Complex vibration ultrasonic welding systems with large area welding tips

Vibration and welding characteristics of complex vibration ultrasonic welding systems of 27 and 40 kHz were studied. Complex vibration systems, which have elliptical to circular or rectangular to square locus, are effective for ultrasonic welding of various specimens including the same and different metal specimens, and for direct welding of semiconductor tips and packaging of various electronic devices without solder. The complex vibration systems consist of a one-dimensional longitudinal-torsional vibration converter with slitted part, a stepped horn and a longitudinal vibration transducer as a driving source. The complex vibration welding tips of 27 and 40 kHz have enough area of 6-8 mm square for various welding specimens. Aluminum plate specimens of 0.3-1.0 mm thickness were successfully joined with weld strengths almost equal to aluminum specimen strength, and independent to the specimen direction. Required vibration amplitude of 40 kHz is smaller than that of 27 kHz.     

Optimization design of high power ultrasonic circular ring radiator in coupled vibration

This paper presents a new high power ultrasonic (HPU) radiator, which consists of a transducer, an ultrasonic horn, and a metal circular ring. Both the transducer and horn in longitudinal vibrations are used to drive a metal circular ring in a radial-axial coupled vibration. This coupled vibration cannot only generate ultrasound in both the radial and axial directions, but also focus the ultrasound inside the circular ring. Except for the radial-axial coupled vibration mode, the third longitudinal harmonic vibration mode with relative large vibration amplitude is also detected, which can be used as another operation mode. Overall, the HPU with these two vibration modes should have good potential to be applied in liquid processing, such as sonochemistry, ultrasonic cleaning, and Chinese herbal medicine extraction.     

One-dimensional longitudinal-torsional vibration converter with multiple diagonally slitted parts

For increasing the available vibration velocity of the one-dimensional longitudinal-torsional vibration converter, a new type of complex vibration converter with multiple slitted parts installed in the positions avoiding longitudinal nodal positions along the converter for decreasing the maximum vibration stress level at the vibration nodal part was studied. The free end of the converter vibrates in an elliptical or circular locus. Complex vibration systems with elliptical to circular or rectangular to square loci can be applied effectively for various high-power applications, including ultrasonic welding of metal or plastics, ultrasonic wire bonding of IC, LSI and electronic devices, and also ultrasonic motors. The converter with multiple slitted parts was improved in the vibration stress level and the quality factor compared with the converter with single slitted part.     

Study on the high power air-coupled ultrasonic compound transducer

The high power air-coupled compound ultrasonic transducer in flexural vibration is studied. The transducer consists of a sandwich longitudinal piezoelectric transducer and a circular thin plate in flexural vibration. The resonance frequency equation and the equivalent circuit of a circular radiator with clamped boundary condition are derived. The resonance frequency equation and the equivalent circuit of the compound transducer are also obtained. The radiated acoustic field of the circular thin plate radiator is analyzed and the directional pattern is calculated. It can be seen that when the vibrational order of the circular thin plate in flexural vibration is increased, the radiated acoustic field becomes complex.     

模式转换环形耦合振动超声辐射器

提出了一种新型耦合振动环形超声辐射器,辐射器由纵振换能器及变幅杆激励特定尺寸的金属圆环,使其能有效地将纵向振动转化为圆环的径向轴向耦合振动从而向环的径向、轴向辐射超声波,并且在环的中心形成聚焦声场。推导了该辐射器的等效电路,给出了等效电路法和有限元法优化设计环形超声辐射器的详细过程。研究了耦合振动环形超声辐射器的谐振特性及其辐射声场特性,根据理论计算结果加工了相应的环形超声辐射器,实验测试结果与理论计算结果符合得较好。本文提出的模式转换环形耦合超声辐射器可望在声化学等液体处理领域获得应用。      

Equivalent circuits and directivity patterns of air-coupled ultrasonic transducers

Air-coupled transducers for producing ultrasonic radiation in gases are studied. The transducer consists of a circular thin plate in flexural vibration and a sandwich longitudinal electromechanical vibrator that is attached to the center of the plate. The lowest-order axially symmetric flexural vibrational mode of a circular thin plate is analyzed. The equivalent circuits of the circular plate in flexural vibration and the compound transducer are presented and the frequency equation is derived. The radiated ultrasonic field of the circular thin plate in flexural vibration is calculated and the directivity pattern is obtained theoretically. Some transducers of this type are designed according to the frequency equation, and their resonance frequencies are measured. The measured resonance frequencies are in good agreement with the theoretical results, and the calculated radiation ultrasonic field is also in good agreement with the measured results of a previous work.     

新型柱孔式模式转换型纵-扭复合模态超声振动系统*

为了改善基于螺旋槽结构和斜槽结构的模式转换型纵-扭复合模态超声振动系统存在的结构复杂、扭转分量较小等问题,论文提出了基于新型柱孔式复合变幅杆的模式转换型纵-扭复合模态超声振动系统,并利用有限元法和数据分析对其进行了仿真分析,结果表明,引入新型柱孔式复合变幅杆的系统的输出端面的剪切应力、旋转角度得到了大幅提升,能够有效地提高纵、扭振动的转换效率。     

Piezoelectric linear motor concepts based on coupling of longitudinal vibrations

Classically, rotary motors with gears and spindle mechanisms are used to achieve translatory motion. In means of miniaturization and weight reduction piezoelectric linear motors are of interest. Several ultrasonic linear motors found in literature base on the use of two different vibration modes. Most often flexural and longitudinal modes are combined to achieve an elliptic micro-motion of surface points. This micro-motion is converted to direct linear (or translatory) motion of a driven slider. To gain high amplitudes of the micro-motion and thus having a powerful motor, the ultrasonic vibrator should be driven near the eigenfrequency of its modes. Additionally, low mechanical and electrical losses lead to increased efficiency and large amplitude magnification in resonance. This demands a geometrical design that fits the eigenfrequencies of the two different modes. A frequency-deviation of only a few percent leads to non-acceptable disturbance of the elliptical motion. Thus, the mechanical design of the vibrators has to be done very carefully. Within this contribution we discuss different motor designs based on the coupling of two the same longitudinal vibrations within one structure to generate an elliptic motion of surface points. Different concepts based on piezoelectric plates and Langevin transducers are compared. Benefits and drawbacks against the combination of longitudinal and bending modes will be discussed. Numerical results of the stator vibration as well as motor characteristics are validated by measurements on different prototypes.     

High-frequency ultrasonic wire bonding systems

The vibration characteristics of longitudinal-complex transverse vibration systems with multiple resonance frequencies of 350-980 kHz for ultrasonic wire bonding of IC, LSI or electronic devices were studied. The complex vibration systems can be applied for direct welding of semiconductor tips (face-down bonding, flip-chip bonding) and packaging of electronic devices. A longitudinal-complex transverse vibration bonding system consists of a complex transverse vibration rod, two driving longitudinal transducers 7.0 mm in diameter and a transverse vibration welding tip. The vibration distributions along ceramic and stainless-steel welding tips were measured at up to 980 kHz. A high-frequency vibration system with a height of 20.7 mm and a weight of less than 15 g was obtained.     

Effects of driving frequency of longitudinal transducer on the vibration characteristics of a stepped plate

The flexural vibration characteristics of a stepped plate, driven at its center by different frequency of longitudinal transducer with a certain area are investigated. The variation in the nodal circle, fundamental frequency and displacement distribution of the stepped plate are calculated by using finite element method (FEM) under different driving frequencies. The results show that the fundamental frequency and nodal circle of the flexural-vibration stepped plate (FVSP) increase with an increase in the driving frequency of the longitudinal vibration ultrasonic transducer (LVUT), before the second-order flexural vibration occurs. When the driving frequency is f = 28 kHz, the displacement amplitude of the stepped plate can achieve the maximum, and the nodal circle radius of the stepped plate is 2.61 cm which fits evenly the edge of stepped profile. Meanwhile, the directivity and radiation efficiency of the FVSP would be greatly improved in a special driving frequency. The conclusions agree with the experimental ones and are significant for both design and applications of the stepped plate.     

类声子晶体结构对超声塑料焊接工具横向振动的抑制

利用声子晶体的带隙理论以及耦合振动理论对大尺寸矩形超声塑料焊接工具的耦合振动进行了研究.在实际工程应用中,大尺寸工具的横向振动将严重导致工具头辐射面位移不均匀,影响系统的焊接质量及工作效率.为提高其工作效率,改善工具头辐射面位移的均匀程度,利用类声子晶体结构对大尺寸超声塑料焊接工具的横向振动进行抑制,分析并得出了类声子晶体结构的横向振动带隙,同时分析了工具头横向振动未抑制与抑制后其辐射面位移的大小与均匀程度.研究表明,通过合理设计类声子晶体的结构及尺寸,可以有效抑制超声塑料焊接工具的横向振动.不但改善了焊接工具辐射面纵向振动位移的均匀程度,而且提高了焊接工具的纵向振动位移幅度.     

Two-dimensional coupled vibration and equivalent circuit of longitudinal-longitudinal orthogonal composite vibration direction converter

With the advantages of transmitting energy from multiple directions to one direction and transforming vibration from one source to multiple directions, the two-dimensional vibra?tion direction converter has important applications in power ultrasonic technology. However, for the complexity of using the wave equation to design and analysis the two-dimensional vibration direction converter, a concise equivalent circuit for the converter is investigated. By introducing the two-dimensional mechanical coupling coefficient and the longitudinal force transform coef?ficient, and using the electromechanical analogy principle, the equivalent circuit and resonance frequency equation of the two-dimensional vibration direction converter vibrating in anti-phase and in-phase two-dimensional coupled vibration are deduced. The resonance frequencies of the vibration direction converters of two different materials are calculated by using the proposed frequency equation, which are in agreement with the results from the finite element method and the experimental test. It provides a concise method for the design and applications of such ultrasonic vibration system.     

二维振动方向变换器的耦合振动及其等效电路

二维振动方向变换器集功率合成和二维超声输出的功能于一体,在功率超声技术中具有重要的应用价值。然而,对于二维振动方向变换器的设计分析只有一种较为复杂的波动方程法。为此,本文研究了二维振动方向变换器的另外一种简明的设计分析方法——等效电路法。通过引入二维机械耦合系数和纵向力转换系数,利用力电类比原理建立了二维振动方向变换器的同相及反相二维耦合振动的统一等效电路模型。利用本文提出的设计方法,计算了两种不同材料的二维振动方向变换器的谐振频率,与有限元计算结果及实验测试结果一致,为该类超声振动系统的工程应用提供了一种简洁直观的设计分析方法。      

Acoustic field modeling for physiotherapy ultrasound applicators by using approximated functions of measured non-uniform radiation distributions

The strongest therapeutic effects in ultrasonic physiotherapy are mainly produced at the first centimeters, i.e. close to the applicator surface and, in general, only in the near-field zone. The acoustic field produced in practice by this type of transducers differs from the classical models because the vibration distribution on the real transducer surfaces is non-uniform. However, neither models using uniform distribution, nor those using typical non-uniform distribution patterns for the source accurately represent the radiation of this kind of transducers. Although this therapy is widely used and many efforts have been made in experimentally studying the patterns of ultrasound radiation produced during physiotherapy applications (IEC-61689, 1998), additional modeling researches still would be needed in order to achieve improved models giving field patterns closer to the measured ultrasonic results. In this paper, acoustic patterns produced from two source radiation functions are proposed and evaluated for field modeling of physiotherapy applicators. Both the functions are approximations to the pressure distribution measured close to the emitting surface and they are based on the modulation of the classical simply-supported function using either sinusoidal or Bessel-type distributions. The simply-supported function is accounted for the radiator-fixing condition and the modulation function simulates the complex vibration distribution of this kind of transducer. The modulator Bessel function is based on reports about Bessel-type vibration distributions found in piezoelectric disk resonators. The use of a selected sinusoidal segment represents another analytical option for obtaining an approximated behavior of the measured data in a real applicator. Both the field models are implemented using the finite element method (FEM) to obtain the numerical solution of wave equation at each point in the radiated space. The solution is reached by considering axisymmetric radiation in attenuation-free media. The results indicate the viability of applying an adequate model for acoustic field calculation by simulating the radiating distribution on the emitting surface as either sinusoidal or Bessel-modulated functions. Models using both the functions describe reasonably real behaviors, but those based on Bessel functions are better correlated with the measurements. The results for three commercial applicators indicate the possibility of representing, with adequate verisimilitude, the acoustic field radiated by physiotherapy ultrasound transducers using linear combinations of Bessel profiles describing the radiation source.     

Vibrational response of a moving suspension-slider loading system exciting a rotating flexible disk

To investigate the vibrational response of the magnetic read/write head in hard disk drives this paper models a rotating flexible disk excited by a moving suspension-slider system which is considered to be a mass-dashpot-spring loading system, with the initial unstressed transverse runout integrated into the rotating disk dynamic model. The slider motion on the disk surface is driven by the suspension rotating at a constant speed. By subtracting the steady-state deflection component from the instantaneous deflection response of the rotating disk system, the relative vibration transverse deflection of the slider caused by the motion of the suspension-slider loading system is obtained. The effects of the slider initial and final positions, speed of movement, the disk rotational speed, and the disk mode of the initial transverse runout on the maximum amplitude of the relative vibration deflection are analyzed.     

Analysis of the sandwich piezoelectric ultrasonic transducer in coupled vibration

The coupled vibration of the sandwich piezoelectric transducer with a large cross-section is analyzed using an approximate analytic method. The resonance frequency equations of the transducer are derived and the effect of the geometrical dimensions on the resonance frequency is studied. It is illustrated that when the radial vibration in the transducer is considered, the vibration of the sandwich transducer becomes more complex. Apart from the longitudinal resonance frequency, the radial resonance frequency can also be obtained. For comparison, numerical methods are also used to simulate the coupled vibration; the resonance frequency and the vibrational displacement distribution are computed. Compared with one-dimensional longitudinal theory, the radial dimensions of the transducer are no longer limited because the coupled vibration is considered. Compared with numerical methods, the physical meaning of the analytic method is concise. It is illustrated that the resonance frequencies obtained from the coupled resonance frequency equations are in good agreement with those from numerical methods, and they are in better agreement with the measured results than those from one-dimensional theory. Since the radial and the coupled vibration are considered in the analysis, more resonance frequencies can be obtained. Therefore, using the coupled resonance frequency equations, the sandwich transducer with multifrequency or wide frequency bandwidth can be designed and used in ultrasonic cleaning, ultrasonic sonochemistry and other applications.     

The transducer vibratory profile effects on the detection of the transient ultrasonic field scattered by a rigid point reflector

In this study a generalized approach, based on the impulse response technique, is developed to evaluate the transient ultrasonic field scattered by a rigid point reflector and detected by a planar circular transducer characterized by a non-uniform vibratory profile. For this purpose, several analytical functions are used to represent the non-uniform vibration amplitude of the transducer. All these functions have maximum amplitude at the transducer’s center and decrease monotonically away from axis. The amplitude variation of these functions has a direct effect on the shape of the average pressure detected by the transducer. Some numerical results are presented to illustrate the effects of a non-uniformly vibrating source on the detected transient pressure. The results show the relative importance of the edge wave modifications in the case of source having non-uniform vibration amplitude distribution.