How to repair the failure of ultrasonic transducer?
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The core configuration of ultrasonic cleaning machine is ultrasonic transducer. High quality ultrasonic cleaning machine transducer can greatly improve the stability of ultrasonic cleaning machine and reduce power consumption. The ultrasonic transducer is composed of shell, matching layer, piezoelectric ceramic disk transducer, backing, outgoing cable and cymbal array receiver. The piezoelectric ceramic disk transducer is made of PZT-5 piezoelectric material polarized in the thickness direction. The cymbal array receiver is composed of 8 ~ 16 cymbal transducers, two metal rings and rubber gaskets.
If the ultrasonic transducer breaks down, such as the transducer vibrator of the ultrasonic cleaning machine is ignited, and the ceramic material is broken, it can be checked with the naked eye and a megger. Generally, as an emergency treatment measure, it can disconnect individual damaged vibrators, which will not affect the normal use of other vibrators.
Repair method of transducer degumming:
Guanboshi’s transducer adopts the double guarantee process of bonding and screw fastening, which will not happen in general. Due to the role of screws, the vibrator will not fall from the vibrating surface after degumming. The general method of judgment is to gently shake the tail of the vibrator by hand and carefully observe the glue on the vibrating surface to make a judgment.
Generally, the output power of the ultrasonic power supply is normal after the degumming of the vibrator. However, due to the poor connection between the vibrator and the vibrating surface, the vibration effect of the vibrating surface is not good. The power supply is often burned out, and the vibrator may be burned out after a long time. The treatment method of the degumming of the vibrator is relatively troublesome, and generally, it can only be sent back to the manufacturer for solution. The effective way to avoid the degumming of the vibrator is to pay attention not to hit the vibrating surface or place cleaning materials directly on the vibrating surface during normal use.
Maintenance method of vibration surface perforation:
This is generally a common mechanical failure after 3 years of full load operation, with perforation of the vibration surface. This phenomenon is the cavitation corrosion phenomenon of ultrasonic.
Maintenance method for damp vibrator:
1. Use a megger to check the plug connected to the transducer, and check the insulation resistance between the positive and negative poles of the transducer to determine.
2. Observations. Generally, the insulation resistance of the transducer of ordinary ultrasonic cleaning machine is required to be greater than 30 megohm. If this insulation resistance value is not reached, the sensor is likely to be damp.
3. After checking the fault, we can sequence it. The repair method is to put the whole transducer (excluding the plastic sprayed shell) into the oven and set it at about 100 ° C.
4. The time setting of this oven is also very particular. It can’t be too long or too short. Generally, three hours is enough. If you don’t want to use this method, you can also choose to use a hair dryer.
Solution to vibrator heating:
The transducer of ultrasonic cleaning machine is a key part of cleaning machine, and its quality directly affects the cleaning effect. The front cover of the transducer of the ultrasonic cleaning machine adopts a horn shape. According to the design requirements, the transducer should have a wide frequency band. Generally, the cleaning needs continuous work, and the heating problem of the used transducer is relatively serious. Forced air cooling must be adopted for high-power operation.
High power ultrasonic cleaning machines generally require multiple transducers to work at the same time, so special attention should be paid to when installing and fixing, because their distribution directly affects the sound field distribution in the tank and the load characteristics of the generator. If the position is improper, the cleaning effect will be extremely poor, and sometimes it will cause unnecessary vibration and empty power consumption. How to install depends on the structure of the tank, the number of transducers and other factors.
Due to the long working time of ultrasonic cleaning machine, the heating problem is very prominent. The following aspects should be considered:
1. Heat dissipation
The radiator should be properly selected, and air cooling should be added if necessary.
2. FET absorption
The R and C absorption at both ends of the FET must be appropriate, otherwise the heating problem of the FET is still serious.
3. Drive circuit
The driving waveform of ultrasonic cleaning FET should be steep, such as increasing the driving output power and reducing the grid resistance.
4. Center frequency adjustment
The output frequency of the ultrasonic cleaner generator directly affects the load characteristics, and then affects the on-off state of the power tube. If the frequency is not appropriate, the FET will generate extremely serious heat.