Fu_2019_J._Phys. _Conf._Ser._1345_032095

Journal of Physics: Conference Series
PAPER • OPEN ACCESS
A Design of Wide-range Frequency-tracking Ultrasonic Power Supply

To cite this article: Yu Fu et al 2019 J. Phys.: Conf. Ser. 1345 032095
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CISAT 2019 IOP Publishing
Journal of Physics: Conference Series 1345 (2019) 032095 doi:10.1088/1742-6596/1345/3/032095
A Design of Wide-range Frequency-tracking Ultrasonic Power

Supply
Yu Fu1, Tie Fu2 and Aimin Wang1*

1
School of Mechanical Engineering, Beijing Institude of Technology, Beijing, 100081,
China
2
School of Mechanical Engineering, Beijing Institude of Technology, Beijing, 100081,
China
*
Corresponding author’s e-mail: futie@bit.edu.cn
Abstract. Aiming at the problem that the frequency tracking range of commercial ultrasonic
power supply on the market is narrow, which makes the load of ultrasonic power supply, a
structure of transducer-horn-tool, difficult to match. This paper presents a kind of ultrasonic
power supply based on TMS320F28335, which can track the frequency in a wide range(15-
21kHz).The advantages, theory, software and hardware structure of the power supply are
introduced, which can realize the functions of wide range frequency tracking, power regulation,
human-computer interaction and so on. Experiments show that the power supply can well
match the ultrasonic vibration load with a wide range of resonant frequencies, and has good
human-computer interaction function.
1. Introduction
In recent years, ultrasonic vibration assistant processing has developed rapidly, and it has been proved
that it has more advantages than traditional processing in processing hard and brittle materials. In
order to study the technology of ultrasonic vibration assistant processing, the first step is to design the
equipment of ultrasonic vibration assistant processing. The frequency tracking range of commercial
ultrasonic power supply is low, so the structure of transducer-horn-tool used in experimental research
needs to be slightly changed several times to match the ultrasonic power supply, which leads to the
increase of the experimental period and costs. In serious cases, the horn-tool may be scrapped. From
the perspective of ultrasonic power supply instead of the traditional method of changing the structure
of transducer-horn-tool, this paper designed a large-scale frequency tracking ultrasonic power supply
matching the transducer-horn-tool, to reduce the experimental period, reduce costs and track the load’s
resonant frequency accurately.
2. Theory of the power supply

Ultrasonic vibration assistant processing system consists of ultrasonic power supply, transducer, horn,
tool, connect joint and so on. This paper used the system shown in figure 1. Connect joint can be
rotating joint or non-rotating joint.
The ultrasonic power supply provides the electric energy for the transducer to work in its resonant
frequency. Ultrasonic transducer can convert electrical energy into ultrasonic vibration and transmit it
to the tool, so the ultrasonic power supply should have the following functions:
A. Real-time tracking of resonant frequency of transducer-horn-tool;
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B. An output power negative feedback control is adopted and the output power can be continuously
adjusted.
C. The power supply can display the current resonant frequency and power in real time. It can
manually input power set value (0~300W). Power can be adjusted to the set value, track resonant
frequency roughly and precisely in the frequency tracking range.
Figure 1. Schematic diagram of ultrasonic vibration assistant processing system
2.1. Compose of the power supply

Ultrasonic power supply is mainly composed of AC-220V, rectifier circuit, BUCK circuit, half-bridge
inverter, transformer, matching circuit, voltage and current sampling circuit, control circuit, direct
digital synthesizer (DDS) AD9850, driving circuit, touch screen and so on, as shown in figure 2. The
control circuit takes the digital processor TMS320F28335 as the core to realize the PWM output, the
processing of voltage and current sampling data, and the control of AD9850 output.
Figure 2. Principle diagram of ultrasonic power supply

AC-220V is converted into adjustable DC voltage through the rectifier circuit and BUCK circuit,
then the high frequency voltage which meets the load requirements can be obtained through the half-
bridge inverter. MOSFET is chosen as power switching device, which has the advantages of easy
driving, fast switching speed, high operating frequency and good thermal stability. IR21844 is a half-
bridge driver chip, which can realize that one signal input can output two complementary waveforms
with dead zone. An IR21844 can drive both the upper and lower arms of half-bridge inverters, so only
a small number of discrete components and one control signal can be used to realize the drive circuit
of the half-bridge inverter, which greatly reduces its cost and volume.
2
AD9850 contains 32-bit phase accumulator and high-speed comparator, which can realize
frequency synthesis controlled by full digital programming. The phase accumulator can output two
complementary sine waves and square waves after truncation, low-pass filtering and high-speed
comparator. The square waves can control the frequency of half-bridge inverter output by driving
circuit. Its output frequency resolution can reach 0.0291 Hz, which can effectively guarantee the
accuracy of frequency tracking.
The touch screen of Samkoon EA-043A is chosen, which integrates CPU unit, input and output
unit, display screen, memory and other modules to support serial communication. The configuration
software SATOOL can be used to realize the functions of picture configuration, driver setting and
control[1].
The core processor of the control circuit is TMS320F28335. TMS320F28335 is a 32-bit floating-
point DSP controller developed by TI Company. Its main frequency can reach 150 MHz, which
greatly improves the processing speed of the program. This ultrasonic power supply mainly uses the
general digital input/output (GPIO), enhanced pulse width modulation (ePWM), ADC conversion
module, serial communication module (SCI) of the chip. GPIO is mainly used to control the output
frequency of AD9850 and some components; ePWM module is mainly used to adjust the duty cycle of
BUCK circuit to regulate DC voltage; ADC module is mainly used to collect the voltage and current
sampling waveform after the sampling circuit, and prepare for data post-processing; SCI module is
mainly used for serial communication with touch screen to achieve specific data input and output.
2.2. Realizaion of human-computer interaction

The serial communication between TMS320F28335 and touch screen is based on MODBUS-RTU
protocol. TMS320F28335 is the main device and Samkoon touch screen is the slave device. After a
certain period of time, the request frame will be sent by TMS320F28335, then the touch screen will
return the response frame to realize information exchange. The touch screen can display the current
output frequency and power in real time, and input the power setting value to change the current
power.
2.3. Realization of wide range frequency tracking

a. Accurate sampling. Accurate sampling of voltage and current is vital for frequency tracking and
power control. The sampling circuit is required to accurately collect the magnitude and phase of output
voltage and current (frequency 15-21 kHz). Resistance sampling method is adopted here. The
schematic diagram of voltage and current sampling circuit is shown in figure 3. The sampling
resistance distribution diagram is shown in figure 4.
Figure 3. Sampling circuit giagram
3
Figure 4. Sampling resistance distribution diagram

The equivalent circuit of the load of the ultrasonic power supply near the resonant frequency is
shown in the dotted frame in figure 4[2], where C is the static capacitance, C is the dynamic
capacitance, L is the dynamic inductance and R is the dynamic resistance. The load can be either a
transducer or a transducer-horn-tool under light condition.
Voltage sampling resistors R2, R3 are in parallel with the output voltage U0 of the ultrasonic power
supply. The voltage U1-DGND between point 1 and DGND equals the output voltage U0. The current
sampling resistance R4 is connected in series with the load, and its voltage U3-DGND is proportional to
the current flowing through the load.
Band-pass filter allows waveforms in specific frequency bands to pass through and shield
waveforms in other frequency bands. The band-pass filter designed here allows waveforms at
frequencies of 15 to 21 kHz to pass through, which can effectively filter clutters in other frequency
bands and obtain high precision voltage and current sampling waveforms. The band-pass filter is a 12-
order band-pass filter. The theoretical amplitude-frequency and phase-frequency characteristics are
shown in figure 5. The red line represents the phase-frequency characteristic curve and the blue
represents the amplitude-frequency characteristic curve.
b. Rough tracking. Rough tracking is based on the principle that the impedance of the load is the
smallest near the resonant frequency[3]. When the power supply is turned on, it sweeps the frequency
in the frequency range of 15-21 kHz and sets the frequency of maximum current as the current output
frequency. It is noticed that its output frequency is not the resonant frequency.
c. precise tracking. The resonant frequency of transducer-horn-tool drifts with the change of
working condition[4]. The real resonant frequency when the load of transducer-horn-tool is working is
different from the result of rough tracking. The method of precise tracking is to process the data after
FIR and FFT and extract the phase difference, and to change the current frequency by a fixed
frequency step according to the phase-frequency characteristic of transducer-horn-tool.
Figure 5. Frequency characteristic chart of band-pass filter
4
2.4. Realizaion of power control

Incremental PI method is used for power feedback. When the current working frequency is the
resonant frequency of the load, the power feedback will trigger, because the power feedback has a
great relationship with the load impedance, and the load impedance is the smallest near the resonant
frequency[5].
3. Demonstration of experimental results

Here are the labeled loads and the ultrasonic power supply, as shown in figure 6 and figure 7. The two
results of resonance frequency F analyzed by impedance analyzer and F got in conditions where the
power supply is switched on with 5% duty cycle of BUCK circuit are shown in table 1, proving that
the power supply can track the load resonant frequency in a wide frequency range.
Figure 8 is the impedance analysis result of load No. 4. Figure 9 shows the waveforms of voltage
U1-DGND and voltage U3-DGND when the load is No. 4. The two waveforms are in phase. According to
figure 4, the waveforms reflect the real output voltage and current, that means the output voltage and
the load current are in phase, that is, the matching circuit and the ultrasonic load reach the resonance
state. The U1-DGND positive amplitude decreases gradually and slightly because central voltage drift of
two voltage divider capacitors in the front of half-bridge inverter.
Table 1. The resonant frequency of the loads.
The label 𝐹 /Hz 𝐹 /Hz

1 20496 20455
2 19785 19705
3 18512 18446
4 19830 19821
4. Conclusions and future work

This paper presents a wide range frequency tracking power supply, and proves that it can track and
maintain the resonant frequency of the load in a wide range. The disadvantage of power supply lies in
the midpoint voltage drift of the half-bridge inverter, and it will be improved later by replacing it with
a full-bridge inverter. In the future, the ultrasonic vibration system based on the power supply will be
developed and more experiments will be carried out.
Figure 6. The loads of the ultrasonic power Figure 7. the ultrasonic power supply
5
Figure 8. The impedance analyzer result Figure 9. Waveforms of sampling resistors
Acknowledgments
This work has received a lot of help, suggestions and guidance. Mr.Wang, Mr.Fu and Mr.Liu really
helped me a lot, and I appreciate that.
References
[1] Zhang X H , Xia H B , Lin R . Communication Interface Design of Mitsubishi Touch Screen
and DSP[J]. Applied Mechanics and Materials, 2014, 687-691:4174-4179.
[2] Bao HS, Wang YD. Impedance matching circuit of ultrasonic cleaning machine. Washing
Technology 2(5): 11-14, 2004. (in Chinese)
[3] Liu LH, Gu YJ, Yang K. Development of intelligent power ultrasonic generator. Chinese
Journal of Electron Devices 25(1): 67-70, 2002. (in Chinese)
[4] Kuang Y , Jin Y , Cochran S , et al. Resonance tracking and vibration stablilization for high
power ultrasonic transducers[J]. Ultrasonics, 2014, 54(1):187-194.
[5] A. Ramos-Fernandez et al., Automatic system for dynamic control of resonance in high power
and high Q ultrasonic transducers, Ultrasonics 23 (1985) 151–156.

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Journal of Physics: Conference Series

PAPER • OPEN ACCESS

A Design of Wide-range Frequency-tracking Ultrasonic Power Supply

View the article online for updates and enhancements.

This content was downloaded from IP address 1.4.226.19 on 22/11/2020 at 14:13

A Design of Wide-range Frequency-tracking Ultrasonic Power

Yu Fu1, Tie Fu2 and Aimin Wang1*

2. Theory of the power supply

Figure 1. Schematic diagram of ultrasonic vibration assistant processing system

2.1. Compose of the power supply

Figure 2. Principle diagram of ultrasonic power supply

2.2. Realizaion of human-computer interaction

2.3. Realization of wide range frequency tracking

Figure 3. Sampling circuit giagram

Figure 4. Sampling resistance distribution diagram

Figure 5. Frequency characteristic chart of band-pass filter

2.4. Realizaion of power control

3. Demonstration of experimental results

The label 𝐹 /Hz 𝐹 /Hz

4. Conclusions and future work

Figure 8. The impedance analyzer result Figure 9. Waveforms of sampling resistors

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