Ultrasonics · 3 min read
Thermal and Protection Considerations in Ultrasonic Drive Circuits
Ultrasonic generators work hard, continuously, into a changing load. Thermal design and protection decide how long they last.
NANOSOFT Engineering Insights
Where the heat comes from
Switching devices dissipate conduction and switching losses; transformers and inductors add core and copper losses. Operating off-resonance increases reactive current and losses significantly.
Thermal design
- Estimate losses at worst-case operating points
- Size heatsinks for the enclosure's real airflow
- Use copper area and thermal vias under power devices
- Place temperature sensing close to the hottest components
Protection functions
Over-current
Fast hardware detection that shuts down switching within microseconds protects devices from shoot-through or short circuits.
Over-temperature
Thermal sensing triggers power reduction or shutdown before limits are reached.
Abnormal load
Detecting a dry tank, disconnected transducer or failed element prevents damage and informs the user.
Graceful behaviour
Good protection is not only about shutting down. Soft-start, automatic power reduction and clear fault indication make the product safer and easier to service.
Frequently asked questions
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