The ultrasonic generator is simply a high-power source that matches the frequency of the transducer.
In general, the ultrasonic generator and the ultrasonic cleaning cylinder with the transducer as the core have far been unable to keep up with the development of the times and the needs of many fields of China's economic undertakings. The current status of ultrasonic cleaning machine production is characterized by outdated technology, unsatisfactory cleaning efficiency and high failure rate. This has become a bottleneck restricting its further expansion. At present, the market is not leading the way in improving technology, improving design, simplifying process structure, reducing costs, and improving cost performance. Instead, they often compete with each other at low prices, which has negatively impacted the development of the entire industry and the ultrasonic cleaning industry. Should be of concern to us.
According to our understanding, in East China, the ultrasonic generator system is no more than the following:
1, * generation products are electronic tube type, with the advancement of technology, it has been eliminated products (but there are still manufacturers in production).
2, copying the ultrasonic generator of the US Benedict Company, the power of the single board is 300W, the frequency is fixed at 25KHz (self-excited half-bridge output circuit), equipped with a large power transformer, which is a simple machine with a large market share. type. However, the circuit is difficult to adjust at the ultrasonic resonant frequency of the ultrasonic transducer, and the output power is unlikely to achieve the desired effect, and the quality is self-evident. However, considering that the generator's circuit is relatively simple, the stability is acceptable, the whole machine is debugged well, and the failure rate is still very low. In addition, there are many enterprises for producing small and medium-sized ultrasonic cleaning machines of this type, can they How to improve and improve the line? We provide the following design scheme for reference: remove the power transformer, reduce the leakage flux of the output matching transformer, reduce the weight and volume of the whole machine, reduce the cost and improve the efficiency. To remove the power transformer, first consider solving two problems. One is the insulation problem between the power input and the high-frequency power output. The second is to reduce the power supply voltage to the withstand voltage value suitable for the normal operation of the high-power tube. The safe operation of the machine (the original machine supply voltage is between DC150V-180V). The circuit described in Figure 1 can solve the design requirements of the original machine. Note: Pay attention to safety during debugging to prevent electric shock.
The output transformer of the original machine uses a single magnetic core, and the magnetic flux leakage is large. Once it is close to the iron casing, eddy current will be formed, which will generate high heat. It is recommended to use IE core, and the coil will be changed from single group to initial and secondary. The stage double windings solve the isolation and insulation problems between the power input and the high frequency power output. The relevant technical parameters of the output transformer such as the number of turns and the turns ratio of the primary and secondary and the inductance are difficult to give a certain data due to many uncertain factors.
3, MC model and its improved model: This is also an old product, the circuit design is cumbersome, due to historical reasons, is a product that is not designed in place. The door circuit is much more used, the SCR is regulated, the process is confusing, and the failure rate is high. It has been left out by the users. The original state-owned big factory that produces this type of machine, we think that only the painful old models are developed, or With the new model, we can reinvigorate the past and stand on the market today.
The improved model simplifies the circuit and adds "frequency hopping" synchronization technology. The so-called "frequency hopping" is actually on the main vibration frequency of the PWM, and a multi-vibrator is added, and its frequency matches the main frequency. The output pulse of the oscillator then modulates the main oscillator. Although the constant power output is achieved, due to the limitation of the current capacity of the power component MOSFET, the full power output is not achieved, the output power is not satisfactory, the cleaning efficiency is not significantly improved, and the application industry is not wide, especially for each jump. In the frequency cycle, there is always a periodic sound in the cleaning cylinder. There is no slow start function, and there is a “tuning power†knob. Once the operation is wrong, it will malfunction, and it cannot be linked with other equipment.
The reason is that the design frame and ideas of the original MC model have not jumped out. Although the original dedicated control chip has been replaced, it is unfortunate that the new chip function has not been fully used.
This model is in the East China region, only a few companies are in production. If further improvements are made, the power components will be changed to IGBTs, which can expand the capacity of the whole machine, try to remove the periodic sound of the cylinder, and use all the new PWM control chips. Functions such as slow start function and pulse width modulation function make it easy to implement "one button operation" (only one power switch is provided), which is a good model.
4, IGBT as a power component used in ultrasonic generators has caused widespread concern and application, but from the point of view of some products, there is still no traditional design ideas and methods, for example, two push components, such as: The EXB840/841 is a thick-film integrated circuit in a rectangular flat package. Its volume and circuit and its cost have occupied a considerable proportion. It is important to know that the power requirements of a single ultrasonic generator are not very large. Of course, using IGBT as a high-frequency power component, because of its high withstand voltage, large capacity, high input impedance, and small voltage drop, is the first choice, which is also an improvement.
5, IGBT constant power ultrasonic cleaning machine:
This is based on the current internationally popular new generation of power electronic components - IGBT (Insulated Gate Bipolar High Power Transistor - Module) for high frequency power devices, military-grade dedicated integrated control chips (PWM instead of CPU) and independent intellectual property rights. The innovative circuit, combined with high-efficiency transducers, is a new generation of ultrasonic cleaners with modular design and building block installation technology.
The machine has three notable features: A: constant power output. The so-called "constant power" means that in the cleaning cylinder, the water level of different heights and the workpieces of different sizes are cleaned, and the cleaning efficiency is unchanged. (reflecting the same output power), which is stable, efficient, and longevity.
To achieve constant power output, the only way is to use frequency automatic tracking circuit to achieve, the professional magazine expert forum Zui has also discussed and analyzed this, and introduced a variety of frequency tracking circuits, unfortunately most theoretically It is easy to achieve in the process. Therefore, the frequency tracking circuit should be practical, concise, and low-cost. Otherwise it is impossible to form an industrialized product.
B: The second feature of the machine is enough to make a heating model of <99 °C, which is not a small breakthrough in the industry.
C: The simplicity of the process is the third feature of the machine. The three components form an ultrasonic power generator that can adapt to a variety of different frequencies and powers. Concise means reliable, low cost and easy to use and maintain.
A good ultrasonic power generator also needs a good transducer (cleaning cylinder) to match it, otherwise it is difficult to achieve the desired effect. Transducer (ultrasonic vibrator) in an ultrasonic cleaner
Plays a very important role and is a key actuator mechanism. In the current small and medium-sized production of ultrasonic cleaning machines, the transducers are all purchased products, paying little attention to their quality, or no equipment ability to test their main technical parameters, such as the size of the impedance, the consistency of the frequency, etc. Wait, there are countless hearts, buy it and use it on the machine, which will lay a hidden danger to the efficiency and life of the whole machine. Further, even if it is detected, it is a general process test of low power, and it is difficult to reflect the technical parameters that are actually in actual work. To this end, based on our experience and lessons learned from the production of transducers over the years, we have summarized a complete process for producing transducers, plus our own high-power transducer tester, which simulates the transducers in practice. The actual technical parameters in the work, such as the impedance are controlled below 20Ω, the frequency consistency is maintained above 90%, and the quality of the product is guaranteed from the source.
According to the previous experience and lessons, the piezoelectric ceramic transducer is prone to cracking during operation, the pole piece is easy to break, and the type of mechanism is easy to be desoldered (these are common problems in the industry). The reason, in addition to the quality of the transducer itself, is mainly because the power generator does not track well the change of the frequency of the transducer during operation due to changes in water level, temperature, and workpiece size. The result of the detuned state.
At this point, automatic tracking of frequencies is particularly important. Another reason that is not overlooked by people is that the anti-peak voltages of different frequencies generated by multiple transducers in the cylinder during operation are not effectively suppressed.
In addition, the high-frequency voltage output from the ultrasonic generator to the transducer is also an important parameter, but it cannot be considered as "an important reason for the propagation efficiency of the ultrasonic generator of different circuits whose output circuit and voltage are different" "The output voltage is low. The power consumed by the generator is large, and the vibrator is also prone to heat, and the generated induced electric field is strong. Appropriate adjustment of the circuit and increase of the voltage output to the vibrator may achieve good results."
We believe that this formulation is to be discussed and discussed. The voltage output from the generator to the transducer is an important factor affecting the efficiency, but it is not a fixed parameter. It depends on the frequency of the transducer and the transduction. The number of power (power) is adjusted accordingly. When the transducer frequency is high, the voltage is correspondingly low, and the transducer frequency is low. The same voltage should be increased accordingly. In addition, the main factor of the vibration of the vibrator is that the frequency of the generator and the actual resonant frequency of the vibrator are in a detuned state. Second, the output impedance of the generator does not match the overall impedance of the load vibrator. If the above two conditions are met, that is, the frequency is neither detuned and the impedance is matched, that is, the efficiency is good, and the temperature rises low. If the output voltage is simply increased, it may increase the power consumption and cause the vibrator to generate heat.
Fortunately, the constant power ultrasonic cleaning machine has successfully solved these problems through the unremitting efforts of the past five years, the innovative "full-frequency, real-time" automatic tracking circuit and non-general processing. There are several heating models that have been operating safely and trouble-free for nearly three years. It can be said that the constant power ultrasonic cleaning machine brings a spring to the whole industry.
Second, the recommendations for the production of ultrasonic cleaners
1. Introduce industry standards as soon as possible to purify the market---ultrasonic cleaning machine
It is undeniable that due to the influence of the planned economic system in the past, there have been many sequelae in various industries, and the industry is no exception. For example, a well-known large state-owned factory was restructured into a limited company a few years ago, but the mechanism and operation methods have not changed much. It is still the old one. Even a 50W ultrasonic cleaning machine has not been developed in more than ten years. come out. The old system and the outdated products are its fatal wounds, which are regrettable and regrettable. The reasons are also thought-provoking.
Today, under the great environment of rapid development of the socialist market economy, a large number of private enterprises have emerged. As far as Wuxi and its surrounding areas are concerned, there are nearly 100 ultrasound production companies, among which there are many manufacturers of scale. This is a very good phenomenon.
However, we must also be soberly aware that many companies do not have the ability to develop new products on their own, especially those that produce ultrasonic cleaning machines. More than 90% of them use “takenism†to imitate ready-made products, so the market The products on the market are all 25KHz old faces. Instead of product innovation and pragmatism, it is a price war with a vicious circle. Even some products that can be said to have inferior quality from the inner quality to the appearance are sold at extremely low prices. This phenomenon is obvious to all. Very dangerous, you can imagine that even if you have innovative and good products, in such an external environment, sometimes it seems powerless.
To this end, we call on the industry standards for ultrasonic cleaning machines to be widely available on the basis of extensive solicitation of opinions, so that enterprises can follow the rules and regulations, so that the industry can go on a healthy and orderly path. At the same time, I hope that the product technical quality supervision department can
Further standardize the market, seriously investigate and eliminate unqualified and inferior products, purify the market environment, and give enterprises a good space for development.
2, existing products always have room for improvement and innovative space - ultrasonic cleaning machine
In the absence of funds and talents, some small and medium-sized enterprises have to update their products and make innovations easier.
We believe that even if it is a small enterprise, as long as it has a correct understanding of the quality concept, review and summarize the existing products, find out the hidden dangers or deficiencies, study them, analyze them objectively and scientifically, and repeatedly test them. And improve, so that the product will continue to improve. If you are producing imitation products, don't be superstitious, think that this is perfect, any product is not perfect, there is always room for improvement and innovation.
3, the peer should be the family - ultrasonic cleaning machine
We are faced with a common cause, an extremely large market and users. In front of them, we are consistent.
We sincerely hope that the "China Cleaning Engineering Technology Cooperation Association" will play a greater role in "organizing industry technology research, guiding cooperation and development, and promoting the overall technological progress of the industry...". We are also willing to cooperate with our peers or people of insight in a wide range of cooperation and exchanges on the premise of waiting and reciprocity to revitalize our common cause for a common purpose.
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