Characterization and Modeling of a Novel Ultrasonic Transducer with Integrated Temperature and Amplitude Sensors for Manufacturing Applications

Ultrasonic transducers play a pivotal role in various industrial manufacturing processes, including welding, cutting, and machining, owing to their ability to generate high-frequency vibrations. The heart of these applications is the ultrasonic transducer, which converts electrical AC voltage into the required high-frequency vibration amplitude. Precise control over the vibration amplitude is crucial for maintaining consistent process quality, efciency, and transducer longevity. However, conventional transducers lack direct amplitude measurement capabilities, relying instead on indirect electrical parameter calculations prone to inaccuracies. A new ultrasonic transducer design incorporating sensor disks for amplitude and temperature measurement has been developed. This study undertakes detailed modeling and experimental characterization of the novel transducer dynamics. Impedance spectroscopy combined with Butterworth-Van Dyke modeling was employed to experimentally characterize the piezoelectric actuators and develop accurate equivalent circuit representations. The integrated PZT-802 and alpha-quartz sensor disks were correlated with external laser Doppler vibrometer and thermal measurements to enable direct vibration amplitude and temperature monitoring. The validated equivalent circuits for actuators and sensors were incorporated into a comprehensive LTspice simulation model capable of predicting the overall electro-mechanical-thermal behavior of the integrated transducer system. Extensive model verifcation was performed by comparing LTspice predictions with measured impedance spectra, vibration characteristics, thermal profles, and sensor responses across a wide range of operating conditions. The modeling approach demonstrated agreement with experimental data, enabling accurate performance prediction for impedance. This validated model facilitates optimal design refnement and implementation of the sensor-integrated ultrasonic transducer across industrial applications demanding precise amplitude regulation, robust thermal management, and extended transducer lifetimes under demanding operating conditions.