Process Emulation System for High-Power Piezoelectric Ultrasonic Actuators

Ultrasonic actuators are used for a wide field of applications. The vibration energy can be used to realize many processes like ultrasonic welding or bonding. Furthermore there are many processes which run more efficient and faster combined with ultrasonic vibration like ultrasonic-assisted turning or drilling. Piezoelectric transducers are the main part of those applications. Most of the applications have a time-variant load behavior and need an amplitude feedback control to guarantee a stable process. To ensure correct function tests of the feedback control systems have to be done. In this case the processes have to be executed in association with a high number of cycles. To emulate the behavior of the environment the automotive and aerospace industries use hardware in the loop systems since a long time but there is no such a method for ultrasonic systems. This paper presents a method to realize high dynamic load emulation for different ultrasonic applications. Using a piezoelectric transformer it is possible to reproduce load curves by active damping on the secondary side of the transformer using a current proportional digital feedback circuit. A theoretical and experimental study of hardware in the loop system for ultrasonic applications is given by this paper. The present system allows testing a wide field of feedback control algorithms with high flexibility and a high number of cycles by utilization of low-cost components. This proceeding decreases design periods in association with feedback control.