Intelligent Ultrasonic Power Supply Research

Adding power ultrasound to traditional processing methods can significa nt ly improve the efficiency and quality of material processing.But during actual ultrasonic machining process,load of ultrasonic power supply horn must be influenced by high temperature and heavy force load,and resonant frequency of ultrasonic machining system will drift greatly on this count.So output frequency of ultrasonic power source need to be the same with the resonant frequency,moreover it is necessary to match piezoelectric transducer using variable capacitance and inductance.But most of the existing ultrasonic power sources have problems such as difficulty in frequency tracking,untimely circuit matching,and inability to adjust the resonant power.In addition,ultrasonic power supply is gradually developing towards intelligent and automated.More importantly,the research on the transducer under differe nt temperature or load force is still not deep enough,so it is hard to provide reference and guiding role for designing intelligent ultrasonic power supply.In order to solve those problem above,these researches have been done:a.Based on Mason equivalent circuit theory and acoustic elasticity theory,the mathematical model of the relationship between axial load force and resonant frequency of piezoelectric transducer is established,by which the conclusio n of the relationship between the axial load force and the transducer frequency in the experiment is verified.The variation of piezoelectric transducer voltage and current with the frequency of input electrical signal under different load forces is explored,and variation laws of the induction voltage phase differe nce with the increase of output frequency or axial load force are concluded.b.The effects of different temperatures on the electrical characteristics of piezoelectric transducers are investigated.And these conclusions are analyzed based on theories,providing a theoretical basis for the subsequent realizat io n of the resonant frequency tracking function of the ultrasonic power supply combined with influence of axial force.c.Based on the traditional theoretical model of rotating ultrasonic non-contact energy transmission,considering the distributed capacitance existing in the primary and secondary coils of the rotary transformer,a mathematical model is derived to form a more complete mathematical model.The mathemat ica l model can make calculation of compensation components and energy transfer efficiency more accurate.d.The intelligent ultrasonic power supply is designed and developed in a modular way,and its hardware is divided into five modules to facilitate the realizat io n of different functions in different application scenarios.e.Based on the experimental research conclusions and theoretical analysis of piezoelectric transducers in different axial load forces and temperatures,the method of full-frequency search of ultrasonic power supply and software phase-locked loop step-by-step to realize resonant frequency search and tracking is proposed,and the corresponding implementation is designed.The program was demonstrated through experiments.f.Using the MFC class library,human-computer interaction interface of the intelligent ultrasonic power supply is designed,which realizes the monitor ing of the running condition of the whole ultrasonic processing system,and it is more convenient to adjust the output voltage and the matching circuit in real time.