System Development
System development in the field of piezo and ultrasonic technology
Power ultrasound, converters, sonotrodes, electronics,…
Design of individual components
We help designing ultrasonic systems, e.g. for medical and industrial applications, starting in concept phases through modeling and simulation to the construction of prototypes and functional samples. In addition, our experience and expertise also allow us assisting in series production and in optimisation of existing ultrasonic systems. We also support your development team in analysis of specific questions.
Examples of our range of services:
- Design of converters and sonotrodes
- Characterisation and optimisation of existing ultrasonic systems
- Development of electrical drives and controls
- Analysis and optimisation of existing electrical controls
- Optimisation of processes
- Development and construction of prototypes and functional modules
- Innovative actuator and sonotrode designs (e.g.
torsional, bending and shearing systems) - Characterisation by measurements
Integration into overall systems
In addition to the development of individual components of ultrasonic systems such as converters and sonotrodes, we help you integrating them into overall systems and assisting your product development. This includes, for example, the coordination between electronics and ultrasonic transducers and the design of housings and handles.
Examples of our range of services:
- Integration of ultrasonic modules into overall systems
- Comprehensive characterisation of ultrasonic systems as a basis for the development of power electronics
- Model-based design of bearings for ultrasound systems
- Simulation-based integration of special functions such as fluid supply
- Characterisation of ultrasonic systems by measurements in unloaded and in loaded states
Development of ultrasonic converters and handpieces
We are designing ultrasonic converters according to our customers‘ specifications, which are precisely tailored to their respective requirements and applications. We rely on our extensive method kit and our many years of experience in the development of ultrasound systems.
- Design, analysis, and optimisation of Ultraschall-Handstücken für die Medizintechnik
in a frequency range of 20 to 200 kHz and a power range of 10 to 500 W - Design of industrial high power converters for up to several kW
- Design of classical longitudinal converters as well as innovative torsional converters
- Design and optimisation of matched sonotrodes (longitudinal and torsional)
- Optimisation of ultrasonic systems, e.g. regarding spurious side resonances
- Evaluation and development of ultrasonic transducers with lead-free piezoceramics
- Construction of prototype systems and functional models (by precise controlled prestressing)
- Comprehensive characterization of ultrasonic converters by measurements (vibration amplitudes, heating behavior, power requirements unloaded and under load, process reactions,…)
Design of electrical supplies and ultrasound generators
An ultrasonic system can only do its job with a matched control or an ultrasound generator. As a ready-made solution, ATHENA offers a universally applicable ultrasound generator to be used for directly driving a variety of ultrasonic systems. We also support in the development of application-specific control electronics
- Advice on the selection of control concepts for ultrasonic systems
- Evaluation of the power requirements of ultrasound systems as a basis for electronics development
- Transformers and signal filtering concepts (LC, LLCC, PWM) for switching inverters
- Development of customer-specific control electronics
- Test and analysis of existing control systems and generators
- We offer the ATHENA Ultraschallgenerator as a universal stand-alone solution
Electronic monitoring system for prestressing ultrasonic converters
The precise application of the appropriate preload to the piezoceramics plays a crucial role in ensuring reproducible properties of prestressed ultrasonic converters (BLT transducers). Torque-based methods often lead to unintentionally large variations. For the defined pre-stressing of ultrasonic converters, we offer a charge-based measuring device to monitor the pre-stressing process.
- Charge-based measurement at the piezoelectric elements to minimise scatter in the prestressing process
- Display to show actually measured values and preload curves
- Analogue output, for example for automated preloading
Innovative actuator’s materials (lead-free piezoelectric ceramics)
As of today, piezoceramics based on lead-zirconate-titanate are the standard material for ultrasonic actuators (especially type PZT 8). However, for environmental reasons, the EU regulations are constantly being reviewed. Thus it is to be expected that in the future lead-free piezoceramics will become increasingly important in medical and industrial applications.
In a current cooperation project together with the University of Paderborn, we are investigating if and to what extend alternative, lead-free materials are already suitable for small and medium-power ultrasonic actuators. Is this topic also of interest to you in terms of a sustainable development strategy? Do not hesitate to contact us!
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