Use Cases
Amplitude monitoring of vibrating sonotrodes
in industrial peening
Summary
When Vibration Drives the Process, Sonotrode Control Is Critical
In ultrasonic shot peening, the energy delivered to the component depends entirely on the controlled vibration of a sonotrode. The precision of this amplitude—typically in the micrometer range—is key to achieving the desired surface treatment effect while ensuring process repeatability, tool longevity, and operational safety.
Measurement Solution for Reliable, High-Precision Vibration Control in Ultrasonic Shot Peening Machines with Fogale Sensors
The challenge
In ultrasonic surface treatment systems, particularly in shot peening, maintaining the correct vibration amplitude of the sonotrode is essential. But several factors introduce variability:
- Thermal effects, aging of transducers, and mechanical tolerances cause amplitude drift over time.
- Closed-loop control is impossible without real-time displacement feedback.
- OEMs require high-speed, compact, and stable sensors that integrate without impacting system performance.
- Accurate amplitude feedback is essential for ensuring consistent energy transfer to the treated surface.
TYPICAL APPLICATIONS IN ULTRASONIC MACHINERY
- Shot Peening by Sonotrode Oscillation – Controlling the impact energy via amplitude measurement ensures consistent surface strengthening.
- Ultrasonic Cleaning Systems – Ensures optimal oscillation for uniform cavitation.
- Ultrasonic Bonding & Cutting – Verifies that amplitude remains within required limits for efficiency and tool life.
The solution
Fogale provides OEMs with a high-resolution, capacitive displacement measurement chain tailored specifically to monitor the vibration amplitude of ultrasonic sonotrodes. This enables real-time, micrometer-precise monitoring of oscillation amplitudes—even at ultrasonic frequencies.
What Fogale supplies:
- Capacitive sensors
Mounted close to the vibrating sonotrode tip to measure dynamic displacement directly. - Capacitive signal conditioners
Rugged, miniature, and high-bandwidth electronics to extract clean amplitude signals with excellent repeatability. - Custom-length cables
Adapted to each machine configuration to maintain signal integrity, from sensor to conditioner.
This modular, OEM-ready solution is fully integrated into the machines, helping ensure precise, stable operation over time.
KEY ADVANTAGES OF FOGALE’S SONOTRODE MONITORING SOLUTION
| Feature | Benefit |
|---|---|
| Direct, Real-Time Amplitude Measurement | Guarantees process reliability and consistency |
| Micron-Level Accuracy | Essential for ultrasonic frequency applications |
| High Bandwidth Conditioning Electronics | Accurately tracks high-speed sonotrode movement |
| OEM Integration Ready | Compact, robust, and field-proven by OEMs like Sonimat |
| Customizable Cable Configurations | Adaptable to any machine layout and shielding requirements |
The results
FOGALE’s capacitive sensor solution enables precise, stable, and long-term monitoring of sonotrode vibration amplitude, ensuring the highest standards in ultrasonic shot peening and related applications. Trusted by OEMs, this solution provides the essential feedback loop that drives process quality and production efficiency.