The composition of any ultrasonic technological installation, including the composition multifunctional devices includes an energy source (generator) and an ultrasonic oscillating system.
An ultrasonic oscillatory system for technological purposes consists of a transducer, a matching element and a working tool (emitter).
In the transducer (active element) of the oscillatory system, the energy of electrical vibrations is converted into the energy of elastic vibrations of ultrasonic frequency and an alternating mechanical force is created.
The matching element of the system (passive concentrator) carries out the transformation of speeds and ensures coordination external load and an internal active element.
The working tool creates an ultrasonic field in the object being processed or directly affects it.
The most important characteristic Ultrasound of oscillatory systems is the resonant frequency. This is due to the fact that the efficiency of technological processes is determined by the amplitude of oscillations (the values of oscillatory displacements), and the maximum amplitude values are achieved when the ultrasonic oscillatory system is excited at the resonant frequency. The values of the resonant frequency of ultrasonic oscillatory systems must be within the permitted ranges (for multifunctional ultrasonic devices this is a frequency of 22 ± 1.65 kHz).
The ratio of the energy accumulated in an ultrasonic oscillatory system to the energy used for technological impact for each oscillation period is called the quality factor of the oscillatory system. The quality factor determines the maximum amplitude of oscillations at the resonant frequency and the nature of the dependence of the amplitude of oscillations on frequency (i.e., the width of the frequency range).
Appearance A typical ultrasonic oscillatory system is shown in Figure 2. It consists of a transducer - 1, a transformer (concentrator) - 2, a working tool - 3, a support - 4 and a housing - 5.
Figure 2 - Two-half-wave oscillatory system and distribution of vibration amplitudes A and effective mechanical stresses F
The distribution of the oscillation amplitude A and forces (mechanical stresses) F in the oscillatory system has the form of standing waves (provided that losses and radiation are neglected).
As can be seen from Figure 2, there are planes in which displacements and mechanical stresses are always zero. These planes are called nodal planes. The planes in which displacements and stresses are minimal are called antinodes. Maximum values displacements (amplitudes) always correspond to the minimum values of mechanical stresses and vice versa. The distances between two adjacent nodal planes or antinodes are always equal to half the wavelength.
An oscillatory system always has connections that provide acoustic and mechanical connection of its elements. The connections can be permanent, but if it is necessary to change the working tool, the connections are made threaded.
The ultrasonic oscillatory system, together with the housing, power supply devices, and ventilation holes, is usually made in the form of a separate unit. In the future, using the term ultrasonic oscillatory system, we will talk about the entire unit as a whole.
The oscillating system used in multifunctional ultrasonic devices for technological purposes must satisfy a number of general requirements.
1) Operate in a given frequency range;
2) Work with all possible load changes during the technological process;
3) Provide the required radiation intensity or vibration amplitude;
4) Have the highest possible efficiency;
5) Parts of the ultrasonic oscillatory system in contact with the processed substances must have cavitation and chemical resistance;
6) Have a rigid mount in the body;
7) Must have minimum dimensions and weight;
8) Safety requirements must be met.
The ultrasonic vibrating system shown in Figure 2 is a two-half-wave vibrating system. In it, the transducer has a resonant size equal to half the wavelength of ultrasonic vibrations in the transducer material. To increase the amplitude of oscillations and match the transducer with the medium being processed, a concentrator is used that has a resonant size corresponding to half the wavelength of ultrasonic oscillations in the concentrator material.
If the oscillatory system shown in Figure 2 is made of steel (the speed of propagation of ultrasonic vibrations in steel is more than 5000 m/s), then its total longitudinal size corresponds to L = C2p/w ~ 23 cm.
To meet the requirements of high compactness and low weight, half-wave oscillatory systems are used, consisting of a quarter-wave converter and a concentrator. Such an oscillatory system is shown schematically in Figure 3. The designations of the elements of the oscillatory system correspond to the designations in Figure 3.
Figure 3 - Two-quarter-wave oscillatory system
In this case, it is possible to ensure the minimum possible longitudinal size and mass of the ultrasonic oscillatory system, as well as reduce the number of mechanical connections.
The disadvantage of such an oscillatory system is the connection of the converter to the concentrator in the plane of the greatest mechanical stress. However, this drawback can be partially eliminated by displacing the active element of the converter from the point of maximum effective stress.
Application of ultrasound devices
Powerful ultrasound is a unique environmentally friendly means of stimulating physical and chemical processes. Ultrasonic vibrations with a frequency of 20,000 - 60,000 Hertz and an intensity of over 0.1 W/sq.cm. may cause irreversible changes in the distribution environment. This predetermines the possibilities practical use powerful ultrasound in the following areas.
Technological processes: processing of mineral raw materials, enrichment and processes of hydrometallurgy of metal ores, etc.
Oil and gas industry: recovery of oil wells, extraction of viscous oil, separation processes in the sand-heavy oil system, increasing the fluidity of heavy oil products, etc.
Metallurgy and mechanical engineering: refining of metal melts, grinding of ingot/casting structure, processing metal surface to strengthen it and relieve internal stresses, cleaning external surfaces and internal cavities of machine parts, etc.
Chemical and biochemical technologies: processes of extraction, sorption, filtration, drying, emulsification, obtaining suspensions, mixing, dispersion, dissolution, flotation, degassing, evaporation, coagulation, coalescence, polymerization and depolymerization processes, obtaining nanomaterials, etc.
Energy: combustion of liquid and solid fuel, preparation of fuel emulsions, biofuel production, etc.
Agriculture, food and light industry: processes of seed germination and plant growth, preparation of food additives, confectionery technology, preparation of alcoholic and non-alcoholic drinks, etc.
Utilities: water well recuperation, preparation drinking water, removing deposits from the internal walls of heat exchangers, etc.
Protection environment: cleaning Wastewater contaminated with petroleum products, heavy metals, persistent organic compounds, cleaning of contaminated soils, cleaning of industrial gas streams, etc.
Processing of secondary raw materials: devulcanization of rubber, cleaning of metallurgical scale from oil contaminants, etc.
The installation consists of a laboratory stand, an ultrasonic generator, a highly efficient, high-quality magnetostrictive transducer and three waveguide emitters (concentrators) to the transducer. has step adjustment of output power, 50%, 75%, 100% of rated output power. Power adjustment and the presence of three different waveguide emitters in the set (with a gain of 1:0.5, 1:1 and 1:2) make it possible to obtain different amplitudes of ultrasonic vibrations in the liquids and elastic media under study, approximately from 0 to 80 μm at a frequency of 22 kHz.
Many years of experience in the manufacture and sales of ultrasonic equipment confirms the perceived need to equip all types of modern high-tech production with Laboratory installations.
The production of nanomaterials and nanostructures, the introduction and development of nanotechnologies is impossible without the use of ultrasonic equipment.
Using this ultrasonic equipment it is possible to:
- obtaining metal nanopowders;
- use when working with fullerenes;
- study of the course of nuclear reactions under conditions of strong ultrasonic fields (cold thermonuclear fusion);
- excitation of sonoluminescence in liquids for research and industrial purposes;
- creation of finely dispersed normalized direct and reverse emulsions;
- scoring wood;
- excitation of ultrasonic vibrations in molten metals for degassing;
- and many many others.
Modern ultrasonic dispersants with digital generators of the I10-840 series
Ultrasonic installation (dispersant, homogenizer, emulsifier) I100-840 is designed for laboratory studies of the effects of ultrasound on liquid media with digital control, with smooth adjustment, with digital selection of operating frequency, with a timer, with the ability to connect oscillatory systems of different frequency and power and recording processing parameters into non-volatile memory.
The installation can be equipped with ultrasonic magnetostrictive or piezocermic oscillatory systems with an operating frequency of 22 and 44 kHz.
If necessary, the dispersant can be equipped with oscillating systems at 18, 30, 88 kHz.
Ultrasonic laboratory units (dispersants) are used:
- for laboratory studies of the effect of ultrasonic cavitation on various liquids and samples placed in liquids;
- for dissolving difficult or poorly soluble substances and liquids in other liquids;
- for testing various liquids for cavitation strength. For example, to determine the stability of the viscosity of industrial oils (see GOST 6794-75 for AMG-10 oil);
- to study changes in the rate of impregnation of fibrous materials under the influence of ultrasound and to improve the impregnation of fibrous materials with various fillers;
- to prevent aggregation of mineral particles during hydrosorting (abrasive powders, geomodifiers, natural and artificial diamonds, etc.);
- for ultrasonic cleaning of complex products of automotive fuel equipment, injectors and carburetors;
- for research on cavitation strength of machine parts and mechanisms;
- and in the simplest case - as high-intensity ultrasound washing bath. Sediment and deposits on laboratory glassware and glass are removed or dissolved in seconds.
Used for washing parts and assemblies of various equipment, welding various materials. Ultrasound is used to produce suspensions, liquid aerosols and emulsions. To obtain emulsions, for example, the UGS-10 mixer-emulsifier and other devices are produced. Methods based on the reflection of ultrasonic waves from the interface between two media are used in devices for hydrolocalization, flaw detection, medical diagnostics, etc.
Among other capabilities of ultrasound, noteworthy is its ability to process hard, brittle materials to a given size. In particular, ultrasonic processing is very effective in the manufacture of parts and holes of complex shape in products such as glass, ceramics, diamond, germanium, silicon, etc., the processing of which is difficult with other methods.
The use of ultrasound when restoring worn parts reduces the porosity of the deposited metal and increases its strength. In addition, warping of deposited extended parts, such as engine crankshafts, is reduced.
Ultrasonic cleaning of parts
Ultrasonic cleaning of parts or objects is used before repair, assembly, painting, chrome plating and other operations. Its use is especially effective for cleaning parts that have complex shape And hard to reach places in the form of narrow slits, slits, small holes, etc.
The industry produces a large number of ultrasonic cleaning units, varying design features, bath capacity and power, for example transistor: UZU-0.25 with an output power of 0.25 kW, UZG-10-1.6 with a power of 1.6 kW, etc., thyristor UZG-2-4 with an output power of 4 kW and UZG-1-10/22 with a power of 10 kW. The operating frequency of the units is 18 and 22 kHz.
The ultrasonic unit UZU-0.25 is designed for cleaning small parts. It consists of an ultrasonic generator and an ultrasonic bath.
Technical data of the ultrasonic installation UZU-0.25
Network frequency - 50 Hz
Power consumed from the network - no more than 0.45 kVA
Operating frequency - 18 kHz
Output power - 0.25 kW
Internal dimensions of the working bath - 200 x 168 mm with a depth of 158 mm
On the front panel of the ultrasonic generator there is a toggle switch for turning on the generator and a lamp indicating the presence of supply voltage.
On back wall The generator chassis contains: a fuse holder and two plug connectors, through which the generator is connected to the ultrasonic bath and the power supply, and a terminal for grounding the generator.
Three stacked piezoelectric transducers are mounted in the bottom of the ultrasonic bath. The package of one transducer consists of two piezoelectric plates made of TsTS-19 material (lead zirconate titanate), two frequency-reducing pads and a central rod made of of stainless steel, the head of which is the radiating element of the converter.
On the bath casing there are: a fitting, a faucet handle with the inscription “Drain”, a terminal for grounding the bath and a plug connector for connecting to the generator.
Figure 1 shows the principle electrical diagram ultrasonic installation UZU-0.25.
Rice. 1. Schematic diagram of the ultrasonic installation UZU-0.25
The first stage is one that operates on transistor VT1 according to an inductive circuit feedback and an oscillating circuit.
Electrical oscillations of ultrasonic frequency 18 kHz, arising in the master oscillator, are fed to the input of the pre-power amplifier.
The pre-power amplifier consists of two stages, one of which is assembled on transistors VT2, VT3, the second - on transistors VT4, VT5. Both power pre-amplification stages are assembled in a series-push-pull circuit operating in switching mode. The key mode of operation of transistors makes it possible to obtain high efficiency at sufficiently high power.
Base circuits of transistors VT2, VT3. VT4, VT5 are connected to separate, counter-connected windings of transformers TV1 and TV2. This ensures push-pull operation of the transistors, that is, alternate switching on.
Automatic bias of these transistors is provided by resistors R3 - R6 and capacitors C6, C7 and C10, C11, connected to the base circuit of each transistor.
The alternating excitation voltage is supplied to the base through capacitors C6, C7 and C10, C11, and the direct component of the base current, passing through resistors R3 - R6, creates a voltage drop across them, ensuring reliable closing and opening of the transistors.
The fourth stage is a power amplifier. It consists of three push-pull cells on transistors VT6 - VT11, operating in switching mode. The voltage from the pre-power amplifier is supplied to each transistor from a separate winding of the TV Z transformer, and in each cell these voltages are out of phase. From the transistor cells, alternating voltage is supplied to the three windings of the TV4 transformer, where power is added.
From the output transformer, voltage is supplied to piezoelectric transducers AA1, AA2 and AAZ.
Since the transistors operate in switching mode, the output voltage containing harmonics has a rectangular shape. To isolate the first voltage harmonic on the converters, a coil L is connected to the output winding of transformer TV4 in series with the converters, the inductance of which is designed in such a way that, with the converters’ own capacitance, it forms an oscillating circuit tuned to the 1st voltage harmonic. This allows you to obtain a sinusoidal voltage at the load without changing the energetically favorable mode of the transistors.
The installation is powered from the network alternating current voltage 220 V with a frequency of 50 Hz using a power transformer TV5, which has a primary winding and three secondary windings, one of which serves to power the master oscillator, and the other two serve to power the remaining stages.
The master oscillator is powered from a rectifier assembled using (diodes VD1 and VD2).
The preliminary amplification stages are powered from a rectifier assembled using a bridge circuit (diodes VD3 - VD6). The second bridge circuit using diodes VD7 - VD10 powers the power amplifier.
Depending on the nature of the contamination and materials, the cleaning medium should be selected. If trisodium phosphate is not available, soda ash can be used to clean steel parts.
Cleaning time in an ultrasonic bath ranges from 0.5 to 3 minutes. Maximum permissible temperature washing medium - 90 o C.
Before changing the washing liquid, the generator should be turned off, preventing the converters from operating without liquid in the bath.
Cleaning of parts in an ultrasonic bath is carried out in the following sequence: the power switch is set to the “Off” position, the drain valve of the bath is in the “Closed” position, the cleaning medium is poured into the ultrasonic bath to a level of 120 - 130 mm, the power cable plug is plugged into an electrical outlet 220 V mains.
Test the installation: turn the toggle switch to the “On” position, the signal lamp should light up and the operating sound of cavitating liquid should appear. The appearance of cavitation can also be judged by the formation of tiny moving bubbles on the bath converters.
After testing the installation, it should be disconnected from the network, load contaminated parts into the bath and begin processing.
Ultrasonic installations designed for processing various parts with a powerful ultrasonic acoustic field in liquid medium. The UZU4-1.6/0 and UZU4M-1.6/0 units allow solving the problems of fine cleaning of filters of fuel and hydraulic oil systems from carbon deposits, tarry substances, oil coking products, etc. Cleaned filters actually get a second life. Moreover, they can be subjected to ultrasonic treatment repeatedly. Installations are also available low power UZSU series for cleaning and ultrasonic surface treatment of various parts. Ultrasonic cleaning processes are needed in the electronics, instrumentation industries, aviation, rocket and space technology and wherever high-tech clean technologies are required.
Installations UZU 4-1.6-0 and UZU 4M-1.6-0
Ultrasonic cleaning of various filters aircraft from resinous substances and coking products.
Ultrasonic installation for fine grinding of materials in an aqueous environment under the influence of an ultrasonic wave during the process of cavitation.
The ultrasonic installation is designed for dispersing materials of varying degrees of hardness in a liquid medium to nanosize, homogenization, pasteurization, emulsification, intensification of electrochemical processes, activation, etc.
Description:
The “Hammer” ultrasonic installation is designed for dispersing materials of varying degrees of hardness in a liquid medium to nanosize, homogenization, pasteurization, emulsification, intensification of electrochemical processes, activation, etc. The ultrasonic unit is used as a dispersant (grinder), homogenizer, emulsifier, pasteurizer, etc.
Is ultrasonic cavitation installation flow type. Main details and interior lining reactors are made of cavitation-resistant material.
Thanks to design features and uniqueness generator ultrasonic vibrations, ensuring simultaneous ultrasonic impact on the internal work area cavitation chamber of all piezoelements. Under these conditions, the impact force becomes sufficient to break even the hardest mineral substances, such as quartz sand, barite, etc. For softer substances and organic materials (such as diatomaceous earth, sawdust etc.) the power of the installation changes.
Individual calculation and production of an ultrasonic installation is possible, depending on the requirements for the final result. For each individual production, an additional calculation is possible according to technological features integrating the installation into an existing production line.
Installation diagram:
Advantages:
– absence of mechanical grinding process, rubbing units and parts,
– The ultrasonic unit is easy to install and operate,
– an ultrasonic installation allows you to grind materials in a liquid medium to sizes comparable to the size of molecules (~10 nm),
– allows you to grind materials with a productivity of up to 3 m 3 of finely dispersed mixture per hour,
– reduced cost of lines for the production of building materials(gas supply costs are eliminated, energy consumption costs are reduced, repair and maintenance costs are reduced),
– length reduced production line and occupied area,
– accelerated technological process,
– Burnout of part of the product is excluded,
– the level of fire and explosion safety of the facility has been increased,
– safety (complete absence of dust, harmful substances),
– the number of service personnel has been reduced,
– The reliability of the grinding element has been increased due to the absence of moving and rubbing parts and mechanisms.
Application:
– grinding of materials for the production of water-dispersed paint and varnish materials,
– preparation of grain, sawdust in the alcohol industry,
– pasteurization of milk,
– extraction of medicinal herbs,
– highly productive waste-free production of juices, purees, jams,
– disinfection and Cleaning of drains,
– processing of bird droppings and manure,
– production of barite drilling fluids,
– receiving grouting solutions,
– disposal of radiation waste,
– extraction of vanadium from southern Russian oil,
– preparing clay in ceramic production,
– production of concrete with the addition of barite,
– obtaining fire-retardant coatings with the addition of barite,
– production of car shampoos based on titanium dioxide,
– production of ceramic bonds for abrasive tools,
– production of paraffin-based engine coolants.
Specifications:
| Characteristics: | Meaning: |
| Fully assembled weight, kg | no more than 28 |
| Energy consumption of the installation complete with generator with a productivity of 1-2 m3/h of finished suspension, kW/h. | no more than 5.5 |
| Percentage ratio of dry matter to liquid before ultrasonic treatment | can reach 70:30 |
The main characteristics of the installation for processing materials (using the example of micromarble calcite):
Note: description of the technology using the example of an ultrasonic material grinding installation “Molot”.
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