Ultrasonic Cutter Mechanism (regarding oscillator)

Constant amplitude control

Constant amplitude control

 Amplitude value of blade can be set by volume of amplitude in the front panel of
oscillator.

 By performing feedback control, the set amplitude of the cutting edge is kept constant
irrespective of the change of the mechanical load (cutting resistance).

Output of oscillator (W)

 When an external load (cutting resistance) is applied to the cutter, it becomes hard to
oscillate. At that time, the oscillator keeps the amplitude of the transducer constant by
supplying more power to the transducer. When an external load exceeding the power
that the oscillator can supply is applied, it stops due to an overload error. Therefore,
when the external load is large, an oscillator with a larger output is required.

Weak against external load 100W ＜ 300W ＜ 500W Strong against external load
Automatic tracking control of resonance frequency

 The resonance frequency of the oscillator changes slightly due to a strong external load
(cutting resistance) or a change in temperature as it is weak against external loads.

 When the frequency output by the oscillator deviates from the resonance frequency of
the transducer, its amplitude sharply decreases because the transducer is no longer in
the state of resonance.

 The oscillator automatically controls the frequency of the output power so as to follow
the slight change, and constantly keeps accurate resonance.
Function of external device

<<The front panel>>

 Visualization of load level

 Variable amount of amplitude

 Setting load threshold warning

 Error status lamp (*Some models only)

1. Overload detective function

2. Overheat detective function

<<The rear panel>>

 Oscillation ON/OFF

 Emergency stop signal output

 Output switching function（*Some

models only）

 Reset function（*Some models only）

 DC analog output function（*Some

models only）

Ultrasonic Cutter Mechanism（regarding blade）

Blade material

 There are two types of blade materials, “High Speed Steel” and “Tungsten Carbide”

 Compared to high-speed blades, tungsten carbide blades have high rigidity and durability, but
since they are heavy, the burden on the oscillator increases.

 The thickness ranges of blades are from 0.4mm to 2.0mm and others.
※A thin blade cuts material well, but it is easy to bend and break. Thick blade is hard to bend and
break, but its sharpness is inferior.

Shape of blade

 The shapes of blades of “SONOFILE” are designed to oscillate well in the axial direction. The
oscillator is also adjusted so that it can be optimally controlled in that state. The blade or holder
cannot be changed freely to a different shape.

 In case of considering the change in shape of the blades or other tools, please contact us and
decide the optimal blade. *Please be noted that we do not guarantee anything when blades or
tools other than our products are used.

Standard shapes of blades Shorter blades than standard Longer blades than standard

length of blades length of blades

Custom-made blades

 We will produce custom-made blade when suitable blade cannot be found in standard blades.

 Through designing with oscillation analysis and confirmation on actual condition of oscillation,
we propose optimal blade while consulting with user.

<<Before optimization>> <<After optimization>>

<<Before optimization>>

The right and left runouts are large, there is a possibility that abnormal sounds might be generated and
the cutting edge might be broke and flew off. In addition, it may lead to breakdown of the transducer.

<<After optimization>>

The right and left runout is suppressed, and the stable oscillation is generated.
U L TRA S O NI C PO WE R TRA NS DU CE RS

 high efficiency
 large amplitude
 low heat
 stable output unaffected by variations in load
 competitive pricing
 fast delivery

Typical Applications of Piezo Ultrasonic Transducers

Piezo ultrasonic transducers are used in a wide range of applications. In both commercial and industrial
environments, these devices allow ultrasonic cleaning apparatus to work effectively — even in the most demanding
and delicate of activities, such as in ultrasonic jewelry cleaning.

In healthcare applications, piezo ultrasonic transducers provide capabilities such as the ultrasonic breaking up of
kidney stones and the removal of dental plaque. In addition, they're used to conduct precise measurements to
identify flaws and other anomalies detected between the transmitters and receivers of ultrasonic waves.

Ultrasonic Transducers with Sound: Ultrasound Explained

Unlike other forms of energy, like radiation — which can be harmful to humans and other life forms — ultrasound is
merely a form of sound that exceeds the upper audible limits of the average adult. Beginning at 20 kHz and
upwards, ultrasonic transducers can make use of these physically shorter wavelengths. As a result, these types of
transducers are ideal for use in nondestructive test situations, as well as for the precise measurement of various
materials and physical matter, including conducting ultrasounds on human patients.

Ultrasonic Transducer Frequency Response

The high mechanical quality of APC's piezo transducers ensures that these sandwich-type ultrasonic transducers
offer high electro-acoustical efficiency and low heat generation. The mechanical connection of the piezoelectric
elements assures a large amplitude output. APC's standard ultrasonic cleaning transducers are available in four
frequencies: 28 kHz, 40 kHz, 80 kHz, or 120 kHz. APC also offers a 50 kHz power transducer that can be used in a
variety of applications, including as a fabric cleaner, nebulizer, atomizer, for ultrasonic mixing, or for cell
disruption.

Standard Ultrasonic Cleaning Transducers

APCI Drive Mechanical Coupling Capacitance Impedance Motion Allowable Power
Catalog Frequency Quality (Kp) (%) (1 kHz) (ohm) Admittance Vibration (watts)
No. (Qm) (nf) (mν) (cm/sec)
90-4040 28 kHz 800 ≥55 3.8 ≤50 60 ≤25 50 Spec Sheet
90-4050 40 kHz 800 ≥55 3.8 ≤50 65 ≤50 50 Spec Sheet
90-4060 80 kHz ≥1000 ≥55 3.7 ≤50 80 Spec Sheet
90-4070 120 kHz ≥1000 ≥55 3.7 ≤50 80 Spec Sheet
Custom Values to be Determined by Customer and APC International
Ultrasonic Transducer Generator Specifications (Cat. # 90-4200 & 90-4210)
Download the Ultrasonic Transducer Generator Spec Sheet.

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Standard Ultrasonic Power Transducer

APCI Part # Resonant Resonant Capacitance Bandwidth Insulation
Catalog No. Frequency Resistance Resistance

90-5000 APC-4SS-1550 50 ±2 kHz 60Ω (MAX) 2750±20%pF Δf ≥ 1.0 kHz R ≥ 500M Ω 2500VDC Spec Sheet

90-5010 APC-4SS-1500 with PCB Catalog #90-5000 with power supply Spec Sheet

Custom Values to be Determined by Customer and APC International

How to Make Ultrasonic Transducers for Ultrasonic Cleaning: Composite

Transducers
As is true in many other applications for piezoelectric materials, an assembly of multiple ceramic elements offers
considerable performance and production advantages in ultrasonic cleaning transducers, relative to a single
ceramic element.

In order to provide the most efficient operation, simplify manufacturing, and reduce costs, more complex
transducers intended for ultrasonic power applications usually are a composite of a piezoelectric ceramic center
(multiple thin rings or disks of ceramic, for example), encompassed by metallic end or top and bottom parts.

Under no liquid load, the mechanical quality factor, Qm, for a well-designed composite transducer will be greater
than the corresponding value for an equivalent single piece ceramic transducer, and efficient heat conduction by
the metallic portions will ensure a lower operating temperature in the ceramic portion of the transducer. The
coupling factor, k, will approach that for a single-piece ceramic transducer.

The metallic portions of a composite transducer should have the same acoustic properties and cross-sectional area
as the ceramic portion. Both metallic parts can be constructed from the same material or combination of
materials, or the two parts can be made from materials with divergent properties. Potential construction materials
include steel, aluminum, titanium, magnesium, bronze, and brass. Often, only one of the metallic parts is
intended for high intensity output.

For maximum energy transfer from the transducer to the solvent in the ultrasonic cleaning tank, a composite
ultrasonic transducer usually is a half-wavelength transducer with a resonance frequency of 20 kHz or 40 kHz. The
electroacoustic efficiency of a composite ultrasonic transducer has an inverse relationship with the
electromechanical coupling factor and the various quality factors of the components.

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Pre-Stressed Composite Ultrasonic Transducers
Seldom will the ceramic component of a composite transducer have adequate tensile strength to
withstand the high mechanical stress associated with the power demands for ultrasonic cleaning
applications. The tensile strength of the ceramic elements can be supplemented by mechanically
pre-stressing the elements along the direction of polarization. Pre-stress is introduced by
incorporating a single, large, central bolt or several smaller, peripherally arranged bolts into the
design of the transducer. The single central bolt design offers slightly higher efficiency than the
multiple peripheral bolt design, but manufacturing costs can be higher, assembly can be more
difficult and, physically, the transducer will be significantly longer.

How Does An Ultrasonic Transducer Work?

For the conditions under which ultrasonic cleaning devices are operated, pre-stress of less than
approximately 30 MPa usually is sufficient to protect the ceramic components of the transducer.
On the other hand, if the prestress is too low, excessive mechanical losses at the ceramic /
metallic interfaces can reduce efficiency. Pre-stress can be estimated by using a torque wrench,
calibrated against charge, to tighten the bolts. This measuring method is simple, but it is not the
most accurate, and consequently it is recommended primarily for production-run transducers for
which the variations among corresponding components are, hopefully, minimal. The more
accurate way of measuring pre-stress is to measure the charge generated in the ceramic elements
under short circuit conditions. A capacitor connected to the transducer’s electrical terminals and
to a direct current voltmeter facilitates measurement of the charge as each bolt is tightened.

How Does an Ultrasonic Transducer Work with Water?

In ultrasonic cleaning applications, effects of the dimensions and configuration of the water tank, the water load,
and the thickness of the bonding layer affixing the transducer to the water tank combine to slightly reduce the
frequency of the transducer and give rise to several additional resonances. Despite these negative factors,
however, a well-designed transducer, incorporated in a well-designed circuit, will operate near its resonance
frequency.

Cavitation
Cavitation occurs when the vibration of a transducer surface interfacing with a liquid (usually water, but possibly a
water / organic solvent mixture in an ultrasonic cleaning application) is sufficient to create a partial vacuum that
exceeds the vapor pressure of the liquid, and bubbles form at the vibrating surface. Cavitation is a desirable
feature in ultrasonic cleaning or liquid vaporizing applications, but obviously must be avoided in signal
transmission applications.
At atmospheric pressure, and with water alone as the interfacing liquid, the threshold for cavitation, pC0 (bar), is:

pC0=(0.00025ƒ)2 + (0.045ƒ-1) Equation 5.9

For frequencies from kilohertz to several hundred kilohertz (2). If the transducer is submerged, and the vibrating
surface is several meters or more below the atmosphere / liquid interface, the threshold for cavitation increases
to:

pCh=pC0 + 0.10h Equation 5.10

where
pCh= threshold for cavitation in atmospheres at depth h in meters (bar)
pC0= threshold for cavitation at zero depth (bar)

Cavitation (J) can be initiated when the acoustic intensity at the vibrating surface, in W/cm2, is:

J=0.15(pC0 + 0.10h)2 Equation 5.11

The acoustic intensity at the vibrating surface can be determined from:

(acoustic output power of transducer) (surface area of transducer).

In application, however, because the threshold for cavitation is affected by the characteristics of the transducer
(signal frequency, acoustic pulse length, acoustic uniformity / non-uniformity of the vibrating face) and by various
conditions (depth of submersion, temperature, dissolved air content of the liquid), cavitation may not be initiated
until the acoustic intensity is significantly higher, e.g., between 0.3 (P C0 +0.10h)2 and 0.4 (PC0 + 0.10h)2.