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How does an ultrasonic converter work?

The ultrasonic converter is a device that can convert the electricity we use in our daily lives into mechanical energy. It is an energy conversion device. Ultrasonic converters have a wide range of applications and many types of models. The materials used for making the converters are piezoelectric ceramics, single crystals, composite materials, and magnetostrictive materials, among which piezoelectric ceramics are used more. The working principle of the ultrasonic converter is to convert the input electrical energy into mechanical energy and then pass it to the ultrasonic sonotrode. Ultrasonic converters play an essential role in the ultrasonic welding process.

Working Method

Due to different processing methods and requirements, the working methods of converters can be divided into continuous work and pulsed work. Different working methods have different requirements for converters. Generally speaking, continuous work has almost no pause time, but the working current is not very large; pulsed work is intermittent, with pauses, but the instantaneous current is very large. On average, both states have a lot of power.

working style of converter
use of converter

Use of Converter

The matching of the converter with the ultrasonic electric box and the sonotrode is the basis for the reliability of the ultrasonic system. The converter and booster make up the transducer. And the transducer is completed, there will be no adjustable parts. Adjust the ultrasonic electrical box and sonotrode to match the working state of the transducer.

Ultrasonic Generator Working Principle

The ultrasonic generator is a device used to generate and provide ultrasonic energy to an ultrasonic transducer. It can convert the mains power (220V/380V, 50Hz/60Hz) into a high-frequency alternating current signal that can match the ultrasonic transducer.

Recommendations for Adjusting The Ultrasonic Generator And Sonotrode To Fit The Transducer

To adjust the ultrasonic generator and sonotrode to match the transducer, here are the tips for adjusting the matching:
Step 1:  Adjust the oscillation frequency of the ultrasonic generator to suit the dynamic range of the transducer;
Step 2: Adjust the matching circuit so that the no-load current of the transducer is less than 0.5A. The tuning current deviation should always be less than 0.2A, and check whether the vibration and heating of the transducer are normal;
Step 3: Connect the sonotrode, with the load, and adjust the ultrasonic generator to make the output power of the system meet the requirements of use;
Step 4: Full power test for a certain period of time to check whether the state changes of the transducer and the ultrasonic generator are within the normal range.

Common Problems About the Ultrasonic Transducer
  1. The ultrasonic transducer is wet. You can use a megohmmeter to check the plug connected to the transducer and check the insulation resistance value to determine the basic situation. Generally, the insulation resistance is required to be greater than 5 megohms. If the insulation resistance value cannot be reached, generally the transducer is damp. You can put the whole transducer (excluding the plastic-sprayed casing) into the oven and set it at about 100°C for 3 hours or use a hair dryer to remove moisture until the resistance value turns normal.
  2. The transducer vibrator ignites and the ceramic material is broken, which can be checked with the naked eye and a megohmmeter. Generally, as an emergency measure, individual damaged vibrators can be disconnected without affecting the normal use of other vibrators.
  3. The vibrator is degummed. Our transducers adopt the double guarantee process of gluing and screw tightening, which does not occur in general.
  4. The stainless steel vibration surface is perforated. Generally, the perforation of the vibration surface may not occur until the transducer is fully loaded for 10 years.
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