Ultrasonic frequency power supply

• US 5,777,860 A
• Filed: 10/16/1996
• Issued: 07/07/1998
• Est. Priority Date: 10/16/1996
• Status: Expired due to Term

• Current Assignee: Branson Ultrasonics Corporation (Emerson Electric Company)
• Original Assignee: Branson Ultrasonics Corporation (Emerson Electric Company)
• Inventors: Halbert, Robert C.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): Patel, Rajnikant B.
• Application Number:
  US08/733,117
• Time in Patent Office: 629 Days
• Field of Search: 363/34, 363/37, 363/98, 307/64, 307/85, 307/66, 310/316, 310/317, 219/10.49
• US Class Current: 363/34
• CPC Class Codes: B06B 1/0253 taken directly from the generator circuit
• CPC Class Codes: B06B 2201/71 Cleaning in a tank
• CPC Class Codes: H02M 7/53871 with automatic control of output voltage or current
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

An ultrasonic power supply for driving piezoelectric transducers in an ultrasonic cleaning apparatus comprises a full-wave rectifier for providing unfiltered direct current to an inverter circuit of the clamped mode resonant converter type, which provides alternating current output at the series resonant frequency condition of the transducers. The inverter circuit switching cycle is controlled responsive to means for causing a set average power level to be maintained, means for causing the resonant frequency to be maintained and including means for causing the resonant frequency to be swept symmetrically by an adjustable sweep frequency. Also, power modulation means are provided for optionally providing to the transducers power bursts of a set amplitude, but at the set average power level. As a result of the unfiltered direct current from the full-wave rectifier, the power supply will operate substantially at unity power factor.

Claims

1. An ultrasonic frequency power supply for driving transducer means providing ultrasonic energy to a cleaning liquid, comprising:

means for receiving alternating current input and providing substantially unfiltered full wave rectified direct current output, the undulations of the direct current voltage output having substantially the same phase and amplitude as the voltage of said alternating current input;

inverter means coupled for receiving said direct current output and producing responsive to power control means acting upon said inverter means and series connected impedance matching means an alternating current voltage for driving said transducer means;

said power control means operating said inverter means responsive to;

(a) power measuring means and power adjustable means connected to said control means for causing said transducer means to operate at a set average power level;

(b) phase detection means and frequency control means connected to said control means for causing said transducer means to operate substantially at its resonant frequency; and

(c) power modulation means connected to said control means for optionally providing to said transducer means peak power pulses of a set amplitude but at constant said set average power level.

2. An ultrasonic frequency power supply as set forth in claim 1, said phase detection means and frequency control means causing said transducer means to operate at its series resonant frequency condition.

3. An ultrasonic frequency power supply as set forth in claim 1, said frequency control means including sweep frequency generating means for causing said resonant frequency to be swept symmetrically over a set frequency range and at a set rate.

4. An ultrasonic frequency power supply as set forth in claim 1, said inverter means comprising switching means operable at a variable duty cycle responsive to input signals from said power control means for providing said alternating current voltage, whereby the amplitude of said alternating current voltage is responsive to the duty cycle of said switching means.

5. An ultrasonic frequency power supply as set forth in claim 1, said inverter means comprising a clamped mode resonant converter.

6. An ultrasonic frequency power supply as set forth in claim 1, said impedance matching means including an isolation transformer and an inductance dimensioned for providing operation of said transducer means at said resonant frequency and substantially filtering out harmonics having a frequency higher than said resonant frequency.

7. An ultrasonic frequency power supply as set forth in claim 1, said power control means including means for ramping the power driving said transducer means from an OFF condition to a set average power level.

8. An ultrasonic frequency power supply as set forth in claim 1, said power modulation means including a generator for producing triangular wave signals, control means for setting the peak of said wave signals, and a multiplier circuit for multiplying said triangular wave signals with a signal corresponding to the set average power level, thereby causing the transducer means to receive periodic power burst pulses at a set peak to average power ratio.

9. An ultrasonic frequency power supply for driving transducer means at its series resonant frequency and said transducer means adapted to provide ultrasonic energy to a cleaning liquid comprising:

rectifier means for receiving alternating current input and providing a substantially unfiltered direct current voltage having undulations whose amplitude and phrase are substantially coincident with the alternating current input voltage;

inverter means having switching means coupled for receiving said direct current voltage and producing, responsive to power control means acting upon said switching means, a direct current voltage, the value of which is commensurate with pulse width modulation effective upon said switching means by said power control means;

impedance matching means coupled in series with said inverter means for receiving said direct current voltage from said inverter means and causing filtered alternating current voltage for energizing said transducer means;

frequency control means and phase detection means coupled to said power control means for receiving a signal responsive to the phase difference between the alternating voltage and current energizing said transducer means and controlling said inverter means responsive to said phase difference signal for minimizing said phase signal indicating said resonance frequency condition;

means coupled for causing said resonant frequency to be swept symmetrically over a set frequency range and at a set rate;

further means coupled for measuring the electrical power energizing said transducer means and causing said power control means to control the pulse width modulation of said switching means to provide a substantially constant set average power;

power modulator means coupled to said power control means for optionally causing power bursts of a set peak to set average power ratio to be provided to said transducer means; and

electrical circuit means coupled in circuit with said power control means for causing the power delivered to said transducer means to be ramped up from a power OFF condition to the set average power.