Sonochemical processes applied to wastewater treatment have an influence on the behavior of ultrasonic systems. This is especially due to the load characteristic of the sonochemical process itself and the temperature increase caused by internal damping within the converter. Hence, a controlling device is needed to guarantee the operation in resonance and to keep the vibration amplitude constant. This paper presents a digital control system for the operation of weak to strong damped ultrasonic devices and its application for inactivating Escherichia coli in wastewater. In an experimental investigation, the electric data during a sonochemical process to inactivate E. coli in wastewater is taken into account to analyze the efficacy of the treatment process and the reaction of the vibration system to the process. Frequency response measurements depict that the resonance frequency changes with the sonicated medium and the vibration amplitude decreases with driving current. In addition to a common continuous operation of the system, different pulsed modes are investigated. The experiments prove the common dependencies between inactivation and power level or treatment time. Additionally, it is pointed out that the control of the sonochemical device is of utmost importance to guarantee an efficient treatment of water, because fast process changes, especially in pulsed operation modes, need to be controlled to a steady state as fast as possible. Although a water treatment efficiency increase using pulsed modes was not proved, it is shown, that the performance of the control unit is capable of using different driving modes in water treatment.
There are many reasons for influencing the laser beam induced weld pool. The manipulation of the dynamics, the solidification, the resulting grain size, and in the end, as a result of the aforementioned influencing, the mechanical characteristics of the weld is the aim of different attempts to gain an impact on the melt. Aluminum alloys tend to porosity formation because of different solubility of hydrogen in solid and liquid states. For reliable welds, the porosity has to be limited. An ultrasound excitation is one possibility to allow a fast degassing, especially for the considered round bars, for which no welding through is possible for geometric reasons. The presented research shows the influence of the ultrasonic amplitude on the microstructure of laser beam welded round bars of the aluminum alloy AA6082-T6. Furthermore, the position of the weld pool in the vibration distribution is varied and the influence evaluated. Metallographic cross sections show in analyses the resulting weld characteristic and the microstructure of the weld metal. The grain size and the grain orientation are evaluated for the different ultrasound parameters. Additionally, the summed porosity area is compared to acquire knowledge about the correlation between ultrasound excitation (with regard to vibration amplitude and position in the vibration distribution) and pore formation.
Laser beam welding is a commonly used technology for joining similar and dissimilar materials. In order to improve the mechanical properties of the weld, the introduction of ultrasonic vibration into the weld zone has been proposed [5]. The ultrasonic system consists of an electronic control, a power supply, a piezoelectric converter and a sonotrode, which introduces the vibration into the weld zone. Its proper design is of great importance for the process performance. Furthermore, the effects of ultrasound in a melt pool need to be understood to evaluate and optimize the process parameters. In addition, it is important to find out the limits of ultrasonic excitation with respect to a maximum vibration amplitude. Therefore, firstly different methods of ultrasonic excitation are investigated and compared with respect to their performance. A system which is based on using longitudinal vibrations turns out to be the best alternative. Secondly, the system design is described in detail to understand the boundary conditions of the excitation and finally, simulations about the influence of ultrasonic vibrations are done by using a simplified model. The system is used to perform experiments, which aim at detecting the maximum vibration amplitude doing bead on plate welds of EN AW-6082 aluminum alloy. The experiments reveal a significant change of the weld shape with increasing ultrasonic amplitude, which matches the simulative findings. If the amplitudes are small, there is a marginal effect on the weld shape. If the amplitudes are high, melt is ejected and the weld shape is disturbed. In the present case, amplitudes over 4 µm were found to disturb the weld shape.
In the field of sonochemistry, many processes are made possible by the generation of cavitation. This article is about closed loop control of ultrasound assisted processes with the aim of controlling the intensity of cavitation-based sonochemical processes. This is the basis for a new research field which the authors call "sonomechatronics". In order to apply closed loop control, a so called self-sensing technique is applied, which uses the ultrasound transducer's electrical signals to gain information about cavitation activity. Experiments are conducted to find out if this self-sensing technique is capable of determining the state and intensity of acoustic cavitation. A distinct frequency component in the transducer's current signal is found to be a good indicator for the onset and termination of transient cavitation. Measurements show that, depending on the boundary conditions, the onset and termination of transient cavitation occur at different thresholds, with the onset occurring at a higher value in most cases. This known hysteresis effect offers the additional possibility of achieving an energetic optimization by controlling cavitation generation. Using the cavitation indicator for the implementation of a double set point closed loop control, the mean driving current was reduced by approximately 15% compared to the value needed to exceed the transient cavitation threshold. The results presented show a great potential for the field of sonomechatronics. Nevertheless, further investigations are necessary in order to design application-specific sonomechatronic processes.
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