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Ultrasonic Transducer

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Shanghai Huashuo: Your Professional Ultrasonic Transducer Manufacturer!

 

Shanghai Huashuo Intelligent Equipment Co., Ltd. s a company specializing in the production and processing of automation machinery, mechanical accessories and other products. Our company has had technical exchanges and cooperation with many German-funded enterprises at the beginning of its establishment. By combining German advanced technology and scientific management mode, it has formed a complete R&D, assembly, testing, and marketing system.

 

Our Advantages
 

Various Products
Our company provides High Shear Disperser, Emulsifier, Homogenizer, Colloid mill, Powder-liquid mixer, Grinding machine, Vacuum Emulsifier, Ultrasonic Disperser, Ultrasonic Welding, Ultrasonic Cutting, Ultrasonic Homogenizer, Ultrasonic Emulsifier, Ultrasonic Transducer, Ultrasonic Generator, Ultrasonic Milling Machine.

 

Advanced Equipment
Our company has advanced production equipment including CNC lathe, CNC milling machine, Polytec laser doppler vibrometer and Resistance furnace temperature controller, which has a high level of automation and intelligence.

 

Product Application
Dye dispersion, food homogenization, ink dispersion, oil-water emulsification, graphene dispersion, graphene preparation, alumina dispersion, metal melt refinement, ultrasonic dispersion, ultrasonic homogenization, ultrasonic emulsification, non-woven fabric welding, PP/PE Welding and cutting, food cutting and processing, ultrasonic auxiliary equipment.

 

Integrated Process Technology
Our company provides customers with complete process technology solutions, ultrasonic welding, ultrasonic dispersion and other ultrasonic equipment and supporting processes, including grinding, emulsification, dispersion, homogenization, stirring, mixing, Drying, cooling, ultrasonic dispersion, extraction, emulsification, welding, cutting, testing and other processes.

 

Between 15khz to 70khz, 100w to 4200w, used for weld, cut and sonochemistry, the core parts of the ultrasonic work.

 

Introduction to Ultrasonic Transducer

 

 

An ultrasonic transducer is a device used to convert some other type of energy into an ultrasonic vibration. There are several basic types, classified by the energy source and by the medium into which the waves are being generated. Mechanical devices include gas-driven, or pneumatic, transducers such as whistles as well as liquid-driven transducers such as hydrodynamic oscillators and vibrating blades.

 

Components of Ultrasonic Transducer

The Piezoelectric Crystal
The center of the ultrasonic transducer is introduced as the ‘active ingredient’ of the system. It tolerates rarefactions and compressions in order to transform the electrical energy into ultrasonic energy or contrariwise. A fault detector is another instrument utilized to produce the electrical pulse, which then conveys to the transducer.

 

The Backing
It is a very dense substance, which is also too fundamental. The exclusive target of this is to absorb the energy that emits from the back of the crystal to monitor the vibrations. An excellent accuracy transducer can be constructed by controlling the acoustic impedance of the backing substance of the crystal. If the backing material is transformed, the difference in this acoustic impedance can be modified. This will certainly influence the transducers as the resolution may change much higher.

 

Wear-plate
A wear plate is set in the ultrasonic transducer to support the piezoelectric crystal in different applications. The environmental problems are that it protects the ultrasonic transducer from usually wear and tear and corrosion. The wear plate generally operates as an acoustic converter between the crystal and water, wedge, or delay line.

 

Types of Ultrasonic Transducer

 

Dual Element Transducers
A dual element transducer consists of two crystal elements housed in the same case, separated by an acoustic barrier. One element generates sound waves, and the other element acts as a receiver.
Here’s how it works: the two elements are angled toward each other to create a V-shaped sound path in the test material. Essentially, the transmit and receive beams cross under the examination surface. This creates a pseudo-focus effect, which enhances resolution in the focal zone.
The increased sensitivity from the pseudo-focus effect is particularly helpful for examining parts with rough backwall surfaces—making these transducers the industry standard for measuring remaining wall thickness in corrosion applications.

 

Contact Transducers
As the name implies, a contact transducer is used for direct contact inspections. This single element transducer has a wear-resistant surface optimized for contact with most metals—making it durable for use in rugged industrial environments.
This transducer type is available in a variety of styles and configurations, such as fingertip for difficult-to-access areas.

 

Angle Beam Transducers
An angle beam transducer is a single element transducer used with a wedge to introduce a refracted shear wave or longitudinal wave into a test piece. The removable or integral wedge introduces sound at an angle into the part.
Inspectors commonly use angle beam transducers to test weld integrity, because weld inspection requires you to aim sound waves at an angle. Other common industrial applications include flaw detection and crack sizing techniques.
Wedges come in a variety of sizes to meet specific needs. For instance, some wedges offer a shorter approach distance while others are suited for high-temperature applications. You can also customize select wedges to create nonstandard refracted angles and contours.

 

Delay Line Transducers
A delay line transducer is a single element transducer designed for use with a replaceable delay line. As the name suggests, this transducer introduces a time delay between the generation of the sound wave and the arrival of the reflected waves, helping to improve the near-surface resolution.
The higher transducer frequency is ideal for inspecting or measuring thin materials, as well as locating small flaws while using the direct contact method. With the replaceable delay line, this transducer is well-suited for a variety of industrial applications.

 

Immersion Transducers
An immersion transducer is a single element transducer designed to operate in water. Rather than making direct contact with a test piece, these transducers use a column or bath of water to couple sound energy into the material.
The immersion technique enables uniform, fast coupling so inspectors can quickly scan parts. Inspectors can choose focused transducers to increase sensitivity and performance in a specific area of a part.
Immersion transducers are often used for in-line or in-process tests on moving parts, automated scanning, and optimizing sound coupling into sharp radiuses, grooves, or channels in test pieces with complex geometry.

 

Application of Ultrasonic Transducer

 

超声波压电换能器

Role in Measurement and Control Systems

Ultrasonic transducers are fundamental components in measurement and control systems, enabling accurate monitoring and regulation of physical parameters such as temperature, pressure, and flow rate. In industrial settings, transducers ensure precise control of processes, leading to enhanced productivity and quality assurance.

 
15KHz 20KHz超声波焊接传感器，用于无纺布面罩焊接

Aerospace and Defence Applications

Ultrasonic transducers are vital components in aerospace and defence systems, ensuring reliable operation under extreme conditions. In aircraft, transducers monitor engine performance, altitude, and airspeed, while in defence applications, they facilitate surveillance, target tracking, and missile guidance.

 
15kHz超声波焊接换能器，带增压器

Contribution to Medical Technology

In the medical field, ultrasonic transducers play a critical role in diagnostic imaging techniques like ultrasound, MRI, and CT scans. Transducer-based sensors enable non-invasive monitoring of vital signs such as heart rate, blood pressure, and oxygen saturation, facilitating early detection of health conditions and guiding medical interventions.

 
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Environmental Monitoring and Research

Ultrasonic transducers play a crucial role in environmental monitoring and research, enabling the collection of data on air quality, water pollution, and climate change. Weather stations use transducers to measure temperature, humidity, and atmospheric pressure, while sensors deployed in oceans and forests monitor ecosystem health and biodiversity.

 

 

Factors To Consider When Choosing Ultrasonic Transducer

 

 

Material Type
Different types of materials transmit ultrasonic sound waves in different ways. Some materials such as metals, glass, and ceramics, which are used in many engineering applications are efficient ultrasound transmitters and can be measured easily no matter the thickness of the materials. Moreover, some composites such as rubber and fiberglass are more attenuating and will need you to use transducers with lower frequencies and high penetration. Other materials like plastics have a limited maximum thickness range because they absorb ultrasonic energy quicker, but ultrasonic testing can still be done on them efficiently in industrial settings.

 

Defects Type
Generally, ultrasonic testing can detect more defects than other kinds of material testing. But this does not come automatically. The type of transducer used in UT greatly affects the kind of information that the technician gets after testing.
Some probes are able to detect even the small and hard-to-find flaws such as the phased array transducers. While some other probes are only able to detect obvious surface and subsurface abnormalities.

 

Frequency
The probe frequency is an important factor that affects the accuracy of test results in ultrasonic testing. Most ultrasonic transducers have frequencies that range from 0.1MHz to 15MHz, while some can be customized up to 50MHz frequency, for special precision testing. Low frequencies are ideal for measuring thick components while higher frequencies are good for thinner materials.

 

Crystal Diameter
A bigger crystal diameter results in lower frequencies, and high sensitivity, while a smaller crystal diameter leads to high frequencies and less sensitivity. You can choose a crystal diameter size depending on the kind of UT data you are interested in. Transducer crystal diameters vary depending on the type of transducer. For example, in array transducers, while you might be confused by the overall sizable diameter, it is a probe that comprised several small diameter crystals in one.

 

The Thickness Of Test Parts
Most ultrasonic testing instruments work efficiently on any size/ thickness of the material, it all comes down to the kind of transducer that is used for measurement. As mentioned, lower frequency transducers are ideal for measuring thick test parts and high frequencies are ideal for thinner parts. On some rare occasions, you might need to combine several types of transducers in order to measure very thick or multiple layer materials.

 

The Shape Of Test Parts
The coupling effectiveness between a probe and the surface to be tested is affected by the shape of test parts. A flat surface can be scanned efficiently using either small or large diameter transducers.
However, curved surfaces like narrow pipes and components with convex and concave shapes require either special transducers such as non-contact immersion transducers or small diameter probes to get proper coupling and therefore accurate and efficient results.

 

The Temperature Of Test Parts
Every transducer comes with information on the minimum and maximum operational temperatures, with most of them enabling a maximum temperature of 50 degrees Celsius. Depending on your operational temperatures, choose a probe that will work efficiently. High temperatures may cause probe parts to expand and permanently damage the probe, while very low temperatures may cause it to malfunction.

 

 
FAQ

 

Q: How does an ultrasonic transducer work?

A: When the electrical signals are transmitted to the target by an ultrasonic transducer, the signal hits the item and returns to the transducer. The object’s distance is estimated rather than the signal’s loudness or sound quality. These transducers can be used to calculate a few other characteristics depending on where and how to use ultrasonic transducers, but they’re most commonly used to measure distance.
The sensitivity or resolution of the transducer is important to learn how to use ultrasonic transducer. Resolution refers to the transducer’s capacity to separate signals created by two close reflectors. Sensitivity refers to the transducer’s capacity to detect a flaw in the material. The reflected signal is reduced by using a very damped transducer, which allows the transducer to investigate faults that are closely spaced. To effectively know how to use ultrasonic transducer, the transducer must have greater high sensitivity with big polarised composite material and crystals.

Q: How to determine the efficiency of an ultrasonic transducer?

A: To know how to use ultrasonic transducer, the efficiency of the transducer is determined first, by the wafer manufacturing method, which should have a high sensitivity and a high electromechanical coupling coefficient. The resonance frequency of the piezoelectric material used is the operating frequency of this transducer. The resonance frequency of the microchip with the maximum output energy and sensitivity is equal to the frequency of the applied AC voltage.
Because piezoelectric materials have a high Curie point, the transducer utilises minimal wattage and operates at a low temperature for diagnosis, allowing it to operate for extended periods of time without causing circuit damages.

Q: What is the working principle of ultrasonic transducer?

A: An electric signal applies to an ultrasonic transducer and vibrates through a specified range of frequencies to generate sound waves. These waves transmit and send back the data to the transducer if any hurdle appears. That’s how the data is transformed into electrical signals.
The transducer also tracks the time interval between the transmitted sound wave and the signals received by the object. In other terms, the ultrasonic transducer working principle is wholly based on transforming one energy form to another.
At 40KHz, the ultrasonic signals are transmitted by the ultrasonic transducer that transmits by air. These ultrasonic transducers aren’t influenced by dust, black materials, etc. Thus, they are preferred over any other infrared sensor. Based on the ultrasonic transducer working principle, the device works efficiently to suppress noise distortion.
Ultrasonic transducers use ultrasonic waves to calculate the distance and use the following formula: D = ½ * T * C.
Where ‘D’ in this formula stands for ‘Distance,’ ‘T’ signifies the time gap between transmitting and receiving signals from the transducer. And, ‘C’ solely stands for sonic velocity.

Q: What is the frequency of the ultrasonic transducer?

A: The frequency of ultrasonic transducers can vary widely depending on their intended application. Typical frequencies range from a few kilohertz (kHz) to several megahertz (MHz). For example, medical ultrasound transducers often operate in the range of 1–15 MHz, while industrial applications might use lower frequencies in the kHz range for thicker materials.

Q: Are there any emerging technologies in ultrasonic transducers?

A: Some emerging technologies in the various types of transducers.
Flexible and Wearable Transducers: Research into flexible and wearable ultrasonic transducers for medical and health monitoring applications.
High-Frequency Transducers: Development of transducers operating at even higher frequencies for improved resolution in medical imaging and materials testing.
MEMS-based Transducers: Integration of microelectromechanical systems technology to create smaller and more precise ultrasonic transducers.
Multi-Modal Imaging: Combining ultrasound with other imaging modalities like photoacoustic imaging or elastography for enhanced diagnostics.

Q: What are the typical applications of piezo ultrasonic transducers?

A: Piezo ultrasonic transducers are used in a wide range of applications. In both commercial and industrial environments, these devices allow ultrasonic cleaning apparatus to work effectively — even in the most demanding and delicate of activities, such as in ultrasonic jewelry cleaning.
In healthcare applications, piezo ultrasonic transducers provide capabilities such as the ultrasonic breaking up of kidney stones and the removal of dental plaque. In addition, they're used to conduct precise measurements to identify flaws and other anomalies detected between the transmitters and receivers of ultrasonic waves.

Q: What are the benefits of ultrasonic transducers?

A: Ultrasonic transducers have several benefits and advantages. Some of these are mentioned below:
Ultrasonic transducers are even better than infrared sensors. These are not hampered by dust, black particles, water, smoke, and even temperature variations. Thus, ultrasonic transducers suppress background interference better than other infrared devices.
Ultrasonic transducers are used for accurate measuring of different elements like minute defects, low depths, and high distances.
Ultrasonic transducers can work in several types of mediums, materials, and environments. These are easy to carry and can be taken to difficult-to-reach sites without any hassles or difficulties.

Q: What are the system components of ultrasonic transducers?

A: It is composed of sending transducer (or wave transmitter), receiving transducer (or wave receiver), control part, and power supply part. The transmitter transducer is composed of a transmitter and a ceramic vibrator transducer with a diameter of about 15mm. The function of the transducer is to convert the electric vibration energy of the ceramic vibrator into super energy and radiate into the air; while the receiving transducer is transduced by the ceramic vibrator The transducer is composed of an amplifier and an amplifier circuit. The transducer receives the wave to produce mechanical vibration and converts it into electrical energy, which is used as the output of the transducer receiver to detect the transmitted super. In actual use, the ceramic vibrator of the transmitter is also used. It can be used as the ceramic vibrator of the receiver transducer company. The control part mainly controls the pulse chain frequency, duty cycle, sparse modulation, and counting and detection distance sent by the transmitter. The ultrasonic transducer power supply (or signal source) can be DC12V ± 10% or 24V ± 10%.

Q: How do you test ultrasonic transducer?

A: When testing ultrasonic transducers, you should start with the basic physical dimension measurements. You should then follow this with tests to the continuity, shorts and opens of the transducer. Also, to ensure that your transducer does not have any major defect, be sure to test capacitance and loss.
Once done with the basic testing, the next step should be functional testing. Ideally, this should be at ambient conditions which are usually the most optimal. Functional testing often consists of pulse-echo measurement at a specified distance and reflecting off a specified predetermined target.
It involves driving the transducer with a wave from an industry-standard pulse receiver. An oscilloscope is used to monitor the pulse and return signal. Numerical measurements you can make from this include the ring-down, bandwidth and sensitivity. Also measured during functional testing is Total Acoustic Power (TAP) output.

Q: What characteristics are used to evaluate ultrasonic transducer testing?

A: Frequency Response
There are two procedures that you can use to obtain the frequency. These are sinusoidal burst and shock excitation. Both procedures work well but some manufacturers may specify an optimal procedure for their transducers. This is defined by the peak frequency and the range of frequencies within which the transducer operates. The choice of transducer sensitivity and bandwidth is made based on the application’s needs.
Relative Pulse-Echo Sensitivity
You can also obtain value from the sinusoidal burst procedure’s frequency response data. Typically, the relative pulse-echo sensitivity comes from the relationship of the applied voltage’s amplitude and the specified target’s pulse-echo signal.
Time Response
This is a way of describing the radio frequency response of the waveform and is obtained using a shock excitation, pulse-echo procedure. Depending on the type of ultrasonic transducer under evaluation, specific targets provide the time or waveform responses.
Complex Electrical Impedance
The value of the complex electrical impedance may provide the magnitude and the impedance of the search unit over its operating frequency range. You may also obtain the value of the magnitude of this characteristic using values gotten from the sinusoidal burst. These measures are made using commercial impedance measuring instruments often in accordance with manufacturer specifications.
Sound Field Measurements
You can achieve this by scanning the sound field using a hydrophone transducer to map the sound field in a three-dimensional space. The goal is to create important parameters like the on-axis and transverse sound beam profiles for immersion. It applies to both flat and curved transducers.

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