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Ultrasonic sensor
Tuesday, 21 November 2006

An ultrasonic sensor typically utilizes a transducer that produces an electrical output in response to received ultrasonic energy. The normal frequency range for human hearing is roughly 20 to 20,000 hertz. Ultrasonic sound waves are sound waves that are above the range of human hearing and, thus, have a frequency above about 20,000 hertz. Any frequency above 20,000 hertz may be considered ultrasonic. Most industrial processes, including almost all sources of friction, create some ultrasonic noise. The ultrasonic transducer produces ultrasonic signals. These signals are propagated through a sensing medium and the same transducer can be used to detect returning signals. In most applications, the sensing medium is simply air. An ultrasonic sensor typically comprises at least one ultrasonic transducer which transforms electrical energy into sound and, in reverse, sound into electrical energy, a housing enclosing the ultrasonic transducer or transducers, an electrical connection and, optionally, an electronic circuit for signal processing also enclosed in the housing. Ultrasonic sensors have typically been used in applications such as detecting and identifying solid objects, measuring the shape and orientation of a workpiece, detecting possible collisions between objects to avoid the collisions, room surveillance, flow measurement, and determining a type of material by measuring the absorption of sound. Ultrasonic sensors have been used for proximity or distance measurement. These devices typically transmit a short burst of ultrasonic sound toward a target which reflects the sound back to the sensor. The system then measures the time for the echo to return to the sensor and computes the distance to the target using the speed of sound in the medium. Sensors are devices which are designed so that they can detect or quantitatively determine physical parameters such as pressure, temperature, position or velocity over a measuring range. In automated industrial applications, sensors are used for numerous purposes. Sensors are used for a variety of applications including sensing the presence or absence of articles and sensing a distance or proximity of an article to the sensor, such as may be required for a process control application. Ultrasonic sensing systems provide a much more efficient and effective method of longer range detection. Ultrasonic sensors are widely used for numerous sensing applications for process control of production and packaging operations. Such sensing applications include container presence/absence detection, container size detection, product level detection, container orientation detection, container counting operations, material web control, tamper/safety seal detection, and surface coating detection.

Ultrasonic sensors typically have a piezoelectric ceramic transducer that converts an excitation electrical signal into ultrasonic energy bursts. The energy bursts travel from the ultrasonic sensor, bounce off objects, and are returned toward the sensor as echoes. Transducers are devices that convert electrical energy to mechanical energy, or vice versa. The transducer converts received echoes into analog electrical signals that are output from the transducer. Ultrasonic transducers operate to radiate ultrasonic waves through a medium such as air. Transducers generally create ultrasonic vibrations through the use of piezoelectric materials such as certain forms of crystals or ceramic polymers. Piezoelectric materials vibrate in response to alternating voltages of certain frequencies applied across the material. Piezoelectric elements are similar to common analog capacitors in that piezo elements generally include two electrodes separated by a piezoelectric material that functions as a dielectric. The overall capacitance of a transducer is dependent upon the area and the thickness of the piezo material. Ultrasonic transducers are available in various technical forms. Ultrasonic transducers are typically formed of either piezoelectric elements or of micro-machined ultrasonic transducer (MUT) elements. For industrial use, solid-state transducers are usually used, because of their robustness. They basically include a piezoceramic device as an element for converting between electric signals and acoustic signals and a resonant adapter layer, with which the transfer of sound to the air is optimized. The piezoelectric elements typically are made of a piezoelectric ceramic such as lead-zirconate-titanate (PZT), with a plurality of elements being arranged to form a transducer. Piezoceramic ultrasonic transducers are the transducers of choice for rugged, industrial applications because they are efficient and environmentally robust. These sensors have been used in industry for numerous applications; however have not been capable of short range object detection until recently. A micro-machined ultrasonic transducer (MUT) is formed using known semiconductor manufacturing techniques resulting in a capacitive ultrasonic transducer cell that comprises a flexible membrane supported around its edges over a silicon substrate. The membrane is supported by the substrate and forms a cavity. The MUT may be electrically energized to produce an appropriate ultrasonic wave. Similarly, when electrically biased, the membrane of the MUT may be used to receive ultrasonic signals by capturing reflected ultrasonic energy and transforming that energy into movement of the electrically biased membrane, which then generates a receive signal. Capacitive micromachined ultrasonic transducers (cMUTs) are tiny diaphragm-like devices with electrodes that convert the sound vibration of a received ultrasound signal into a modulated capacitance. For transmission the capacitive charge is modulated to vibrate the diaphragm of the device and thereby transmit a sound wave. In general, ultrasonic transducers are constructed by incorporating one or more piezoelectric vibrators which are electrically connected to pulsing-receiving system.

Ultrasonic sensing techniques have earned a pre-eminent position in a variety of fields including medicine, nondestructive testing and process monitoring, geophysics, and sonar surveillance. Ultrasonic flow sensors have been employed for a number of years for performing intraoperative or extracorporeal blood flow measurements. Intraoperative flow measurements are typically conducted to monitor blood flow in various vessels during vascular, cardiac, transplant, plastic and reconstructive surgery. Transit-time ultrasonic flow sensors detect the acoustic propagation time difference between the upstream and downstream ultrasonic transmissions in a moving fluid and process this information to derive a fluid flow rate. Ultrasonic array transducers rely on wave interference for their beam forming effects, and typically include a plurality of individual transducer elements organized as either a one-dimensional (linear) array or a two-dimensional array. Ultrasound is used as a non-invasive technique for obtaining image information about the structure of an object which is hidden from view, and is widely known as a medical diagnostic tool as well as a tool for non-destructive testing and analysis in the technical arts. Ultrasound diagnostic imaging systems are in widespread use for performing ultrasonic imaging and measurements. Ultrasonic imaging sensors act as both transmitters and receivers of ultrasonic energy. The sensor first acts as a transmitter; emitting ultrasonic energy in a train of high frequency pulses, typically in the range of 2 to 10 Mhz. Then the transmitter is turned off and the sensor acts as a receiver, which listens for returned echoes at the transmitted frequency. Ultrasonic sensors are used to make remote distance measurements. One particular use of ultrasonic sensors is within a vehicle occupant protection system within a vehicle. Ultrasonic range finders typically use ultrasonic frequencies which are inaudible to the human ear. These high frequencies have inherently shorter wavelengths, which lead to greater positional accuracy than audible frequencies. Parking aid systems of today usually consist of an electronic control unit and several ultrasonic sensors. Each ultrasonic sensor possesses a separate data line, since, in order to improve evaluation, echo information from several ultrasonic sensors is required at a certain instant. Thus, the evaluation of several ULS on the basis of one transmitted sound wave permits more precise conclusions to be made about the position of and the range of the obstacle. Ultrasonic sensors are equipped in robots and used for detecting objects positioned along a robot travel path. Such ultrasonic sensors are adapted to convert a pulse signal into an ultrasonic wave energy which is, in turn, radiated at a search area.