Tobias Hemsel

Survey of the present state of the art of piezoelectric linear motors

Piezoelectric ultrasonic motors have been investigated for several years and have already found their first practical applications. Their key feature is that they are able to produce a high thrust force related to their volume. Beside rotary drives like the travelling wave motor, linear drives have also been developed, but only a few are presently commercially available. In the present paper, we first describe the state of the art of linear piezoelectric motors. The motors are characterized with respect to their no-load velocity, maximum thrust force, efficiency and other technical properties. In the second part, we present a new motor, which is judged to be capable of surpassing the characteristics of other piezoelectric motors because of its unique design which allows the piezoelectric drive elements to be pre-stressed in the direction of their polarization. The piezoelectric elements convert energy using the longitudinal d33 effect which allows an improved reliability, large vibration amplitudes and excellent piezoelectric coupling. Energy loss by vibration damping is minimized, and the efficiency can be improved significantly. Experimental results show that the motor characteristics can be optimized for a particular task by choosing the appropriate operating parameters such as exciting voltage, exciting frequency and normal force.

Frequency tuning of piezoelectric energy harvesters by magnetic force

A piezoelectric energy harvester is an electromechanical device that converts ambient mechanical vibration into electric power. Most existing vibration energy harvesting devices operate effectively at a single frequency only, dictated by the design of the device. This frequency must match the frequency of the host structure vibration. However, real world structural vibrations rarely have a specific constant frequency. Therefore, piezoelectric harvesters that generate usable power across a range of exciting frequencies are required to make this technology commercially viable. Currently known harvester tuning techniques have many limitations, in particular they miss the ability to work during harvester operation and most often cannot perform a precise tuning. This paper describes the design and testing of a vibration energy harvester with tunable resonance frequency, wherein the tuning is accomplished by changing the attraction force between two permanent magnets by adjusting the distance between the magnets. This tuning technique allows the natural frequency to be manipulated before and during operation of the harvester. Furthermore the paper presents a physical description of the frequency tuning effect. The experimental results achieved with a piezoelectric bimorph fit the calculated results very well. The calculation and experimental results show that using this tuning technique the natural frequency of the harvester can be varied efficiently within a wide range: in the test setup, the natural frequency of the piezoelectric bimorph could be increased by more than 70%.

Analytical determination of characteristic frequencies and equivalent circuit parameters of a piezoelectric bimorph

Piezoelectric structures are nowadays used in many different applications. A better understanding of the influence of material properties and geometrical design on the performance of these structures helps to develop piezoelectric structures specifically designed for their application. Different equivalent circuits have been introduced in the literature to investigate the behaviour of piezoelectric transducers. The model parameters are usually determined from measurements covering the characteristic frequencies of the piezoelectric transducer. This article introduces an analytical technique for calculating the mechanical and electrical equivalent system parameters and characteristic frequencies based on material properties and geometry for a cantilever bimorph structure. The model is validated by measurements using a cantilever bimorph and fits the experimental results better than previous models. The model gives a full set of piezoelectric transducer parameters and is therefore well suited for further theoretical investigations of piezoelectric transducers for different applications. The results also show that even small manufacturing tolerances have a considerable effect on the system parameters and characteristic frequencies. This might lead to intolerable deviations, especially in dynamic applications and should be avoided by careful design and production.

Model-based design of piezoelectric energy harvesting systems

In the design process of energy harvesting systems based on piezoelectric elements, achievable energy output is the most interesting factor. To estimate this amount a priori manufacturing of prototypes a mathematical model is very helpful. Within this contribution we will introduce a model based on electro-mechanical circuit theory. Its parameters are identified by measurements and the model is validated by comparison to experimental results. The model is designed to support the development-engineer in the dimensioning of energy harvesting units to specific application demands. Two main challenges in device design are investigated with the mathematical model: influence of the ambient excitation frequency, and influence of the load impedance. Typically, the equivalent model approach delivers models for piezoelectric elements that are driven in resonance by electrical excitation. In the case of energy harvesting the piezoelectric elements are excited mechanically and most often non-resonant. Thus, we first set up a mechanical equivalent model for base excited systems. In first approximation it represents an energy harvesting unit around one resonance frequency. The model is expandable for a wider frequency range using the superpositioning of multiple circuits. From the viewpoint of optimum energy transformation between mechanical and electrical energy it is favorable to drive piezoelectric elements at resonance or anti-resonance. Thus, an energy harvesting system should be tuned to the excitation frequency.

Piezoelectric transformers - state of the art and development trends

Piezoelectric transformers are well known since the publication of some patent applications at the end of the 1950s. But until today their only business use lies in the field of backlighting systems for LCDs. Due to key features as light-weight, flatness, high step-up at low volume and high efficiency piezoelectric transformers should be usable in a much broader range of applications. This contribution returns to mind their operating principle, shows how to model and to develop such devices as well as give some aspects for development trends that will lead to further applications.

Improving the bond quality of copper wire bonds using a friction model approach

In order to increase mechanical strength, heat dissipation and ampacity and to decrease failure through fatigue fracture, wedge copper wire bonding is being introduced as a standard interconnection method for mass production. To achieve the same process stability when using copper wire instead of aluminum wire a profound understanding of the bonding process is needed. Due to the higher hardness of copper compared to aluminum wire it is more difficult to approach the surfaces of wire and substrate to a level where van der Waals forces are able to arise between atoms. Also, enough friction energy referred to the total contact area has to be generated to activate the surfaces. Therefore, a friction model is used to simulate the joining process. This model calculates the resulting energy of partial areas in the contact surface and provides information about the adhesion process of each area. The focus here is on the arising of micro joints in the contact area depending on the location in the contact and time. To validate the model, different touchdown forces are used to vary the initial contact areas of wire and substrate. Additionally, a piezoelectric tri-axial force sensor is built up to identify the known phases of pre-deforming, cleaning, adhering and diffusing for the real bonding process to map with the model. Test substrates as DBC and copper plate are used to show the different formations of a wedge bond connection due to hardness and reaction propensity. The experiments were done by using 500 μm copper wire and a standard V-groove tool.

Improved Process for Hydrothermal Lead-Free Piezoelectric Powders and Performances of Sintered (K0.48Na0.52)NbO3 Ceramics

In this study, we report some improvements in a hydrothermal method for lead-free piezoelectric powders and the performance of the sintered (K0.48Na0.52)NbO3 ceramics. To increase the obtained powder weight per source solution volume, the hydrothermal reaction conditions were modified. This improvement is important for mass production; however, it resulted in a larger particle size dispersion. Therefore, we examined to introduced the ball milling process that is useful for dense (K0.48Na0.52)NbO3 ceramics. When a large amount of powder was obtained, it took a long time to eliminate the residual alkaline ions in the hydrothermal powders by a washing process. Therefore, a neutralization was conducted in the powder washing process. Using this powder, a solid solution of (K,Na)NbO3 ceramics was synthesized. The relative density was successfully increased. Concerning the electrical properties, the relative permittivity was improved, and the piezoelectric constant d33 was also increased from 114 to 130 pC/N.

Study on optimizing ultrasonic irradiation period for thick polycrystalline PZT film by hydrothermal method

The hydrothermal method utilizes a solution-based chemical reaction to synthesize piezoelectric thin films and powders. This method has a number of advantages, such as low-temperature synthesis, and high purity and high quality of the product. In order to promote hydrothermal reactions, we developed an ultrasonic assisted hydrothermal method and confirmed that it produces dense and thick lead-zirconate-titanate (PZT) films. In the hydrothermal method, a crystal growth process follows the nucleation process. In this study, we verified that ultrasonic irradiation is effective for the nucleation process, and there is an optimum irradiation period to obtain thicker PZT films. With this optimization, a 9.2-μm-thick PZT polycrystalline film was obtained in a single deposition process. For this film, ultrasonic irradiation was carried out from the beginning of the reaction for 18 h, followed by a 6 h deposition without ultrasonic irradiation. These results indicate that the ultrasonic irradiation mainly promotes the nucleation process.

Modelling the friction contact in an inertia motor

Piezoelectric inertia motors, also known as stick–slip drives or (smooth) impact drives, use the inertia of a body to drive it by a friction contact in small steps, in the majority of motors composed of a stick phase and a slip phase between the friction partners. For optimizing inertia motors, it is important to understand the friction contact correctly and to measure its properties appropriately. This contribution presents experimental set-ups for measuring the contact force, friction force and relative displacement in an actual inertia motor with a dry friction contact and numerical simulations of the motor operation. The motor uses a pre-stressed multilayer actuator with a displacement in the range of 20 µm. It is shown that a previously postulated condition for the applicability of simple kinetic friction models is well fulfilled for the investigated motor. The friction contact in the motor is simulated using different kinetic friction models. The input for the friction models is the measured motion of the rod. The models qualitatively reproduce the measured motion but show quantitative deviations varying with frequency. These can be explained by vibrations of the driving rod that are experimentally investigated.

Self-sensing ultrasound transducer for cavitation detection

Cavitation monitoring is desired to optimize the sonication for diverse sonochemical processes and to detect changes or malfunctions during operation. In situ cavitation measurements can be carried out by detection of the acoustic emissions of cavitation bubbles by sensors in the liquid. However, in harsh environments sensors might not be applicable. Thus, the impact of cavitation on the electrical signals of a piezoelectric transducer has been analyzed as alternative method to measure the threshold, strength and type of cavitation. The applicability has been tested in three different setups to evaluate the generalizability of extracted indicators. In all setups indicators for the cavitation thresholds could be derived from the current signal. In two setups features showed two thresholds that may be linked to the types of cavitation. However, only one feature derived from the current signal in one particular setup correlated to the strength of cavitation. Cavitation detection based on the current signal of the transducer is a useful method to detect cavitation in harsh environments and without perturbing the sound field. Once applicable indicators have been identified, they may easily be tracked during the process. However, for more detailed studies about the cavitation activity and its spatial distribution, measurements with in situ sensors are recommended.