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Ultrasonic waves at 1 MHz are used to send information across solid walls without the needs for through wall penetrations. A communication channel is established by attaching a set of three ultrasonic transducers to the wall. The first transducer transmits a continuous ultrasonic wave into the wall. The second transducer is mounted on the opposite side of the wall (inside) and operates as a receiver and signal modulator. The third transducer, the outside receiving transducer, is installed on the same side as the first transducer where it is exposed to the signal reflected from the blended interface of the inside wall and inside transducer. Inside sensor data is digitized and the bit state is used to vary in time the electrical load connected to the inside transducer, changing its acoustic impedance in accordance with each data bit. These impedance changes modulate the amplitude of the reflected ultrasonic signal. The modulated signal is detected at the outside receiving transducer, where it is then demodulated to recover the data. Additionally, some of the ultrasonic power received at the inside transducer is harvested to provide energy for the communication and sensor system on the inside. The entire system (ultrasonic, solid wall, and electronic) is modeled in the electrical domain by means of electro-mechanical analogies. This approach enables the concurrent simulation of the ultrasonic and electronic components. A model of the communication system is implemented in an electronic circuit simulation package, which assisted in the analysis and optimization of the communication channel. Good agreement was found between the modeled and experimental results.

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In many commercial, industrial, and military applications, supplying power to electronics through a thick metallic barrier without compromising its structural integrity would provide tremendous advantages over many existing barrier-penetrating techniques. The Faraday shielding presented by thick metallic barriers prevents the use of electromagnetic power-transmission techniques. This work describes the electrical optimization of continuouswave power delivery through thick steel barriers using ultrasound. Ultrasonic channels are formed by attaching pairs of coaxially-aligned piezoelectric transducers to opposite sides of thick steel blocks. The thickness of the steel considered is on the order of, or greater than, one quarter wavelength of the acoustic power signal inside of steel, requiring the use of wave propagation theory to properly analyze the system. A characterization and optimization methodology is presented which measures the linear two-port electrical scattering parameters of the transducersteel-transducer channel. Using these measurements, the simultaneous conjugate impedance-matching conditions at both transducers are calculated, and electrical matching-networks are designed to optimize the power transfer from a 50Ω power amplifier on one side of the steel block to a 50Ω load on the opposite side. In addition, the impacts of, and interactions between, transducer and steel geometries are discussed, and some general guidelines for selecting their relationships are presented. Measurements of optimized systems using transducers designed to resonate at 1 MHz with diameters from 12.7 mm to 66.7 mm, and steel block thicknesses from 9.5 mm to 63.5 mm, reveal power transfer efficiencies as high as 55%, and linear delivery of 81 watts through an optimized channel.

A finite element simulation of a through-wall ultrasonic communication system which permits data to be transferred from the inside of a sealed metal vessel to the outside without the need for physical penetrations is introduced. Two transducers are aligned axially on either side of a thick solid stainless steel wall. The outside transducer is forced with a continuous sinusoidal voltage at the crystal’s nominal 1 MHz longitudinal resonant frequency, launching a wave into the wall. The transmitted beam is partially reflected off of the inside of the wall where the inside transducer is located. The amplitude of the reflected wave is modulated by switching the electrical impedance placed across the leads of the inside transducer. The reflected wave is received at the outside transducer and the continuous wave amplitude is sensed to detect the transmitted data bits. The system is modeled and simulated using a commercial finite element modeling package. A coupled stress-strain and piezoelectric analysis is performed using an axisymmetric geometry. The model represents an existing system from which physical measurements were taken. Excellent correlation between the model and system were observed and the model has been used to further optimize the communication system.

Traditionally, power transfer through thick metallic barriers has required physical penetrations and wire feed-throughs, which reduces structural integrity and limits the environmental isolation provided by the barrier. The Faraday shielding presented by these barriers, however, prevents efficient transfer of electromagnetic power, limiting many RF coupling techniques. More recently, the use of ultrasound has been shown as an effective non-destructive technique for transmitting large amounts of power (100s of watts) through solid metallic mediums. By using two coaxially aligned piezoelectric transducers loaded onto opposite sides of the barrier through an acoustic couplant, an ultrasonic channel is formed through which efficient power delivery is possible. This work presents finite element modeling and simulations that help characterize the impacts of many mechanical design factors on the power transfer efficiency of these ultrasonic channels, including: transducer-wall coupling effects, transducer and wall resonance modes, transducer dimensions, and barrier composition and dimensions. Physical channel measurements are also presented to show the strong correlation between the finite element simulations and the systems modeled.

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