Ultrasonic Fog Generator

I don’t argue, you could buy a ready-made ultrasonic humidifier more quickly, but I had a spare part for me that it came out by itself. In the article I will show how and from what I made it, and at the end, I will tell you how I would do it now, based on the experience of the present run-in. In March, I received an ultrasonic nebulizer in a plastic case, I specifically prepared for In the summer, the structure was assembled, but once, the level sensor built into the ultrasonic head did not work, and as a result of working on a dry one, the sensor body melted, and in some places it went bankrupt, though I didn’t notice it right away - it cost. A week ago, The ultrasonic head has already come to me already in the metal case, and then I had to disassemble and rebuild the entire structure.

I’ll need

Ultrasonic Fog Generator
I had the following:
  • - 10-liter office bucket;
  • - 12 volt power supply;
  • - ultrasonic nebulizer in a metal case;
  • - black installation box with dimensions 100 x 60 x 25 mm;
  • - any incremental module,I had the Xl6009 module;
  • - 12 volt speed controller;
  • - impeller;
  • - power switch, several nests and plugs to them;
  • - handy trifle appeared during the assembly process;
  • - and also - the case from the faulty speed controller - you will see it later.

Visual connection diagram

Ultrasonic Fog Generator
I had to try so that all this did not look like porridge and was convenient for perception.
  • - the input 12 volts is increased by module to 22 volts and fed to an ultrasonic nebulizer;
  • - the input 12 volt is also supplied to the fan speed regulating unit;
  • - both are connected in parallel and are connected via a general power switch to the input socket.
Ultrasonic Fog Generator
A ready-made rev regulator immediately came to me faulty, and as it happens, it was deposited in a handful "until better times", its case went into action with four convenient mounting holes. You see what happened to the filling. For some time, the current was so high that the wiring leading to the socket on the ultrasound head burnt out and melted.However, both modules turned out to be serviceable and all that was needed was to replace the wiring.
Ultrasonic fog generator
At the end of the office basket, I drilled four holes for the installation of screws to which the control unit was attached, even lower, you see a hole for the wire to go to the ultrasonic head.
The first option, I collected in a hurry, and this decision revealed its shortcomings. If you look inside the basket, you can see that the screw heads were corroded.
Ultrasonic Fog Generator
To get rid of rust, it was necessary to transform it with tampons moistened with a strong solution of food citric acid
Ultrasonic Fog Generator
After brushing and drying, the heads were covered with clear acrylic glue from the hardware store.
Ultrasonic Fog Generator

Fan Assembly

It must be completely protected from splashes and after a short reflection,I decided to use a centrifugal impeller that I pasted in a black plastic box on strips of double-sided tape based on 1 mm.
Ultrasonic Fog Generator
Through a smaller opening in the bottom of the box, air flows into the basket. Note that the intake port on the upper side of the box and the outlet on the bottom will be located opposite to each other. Thereby, no splashes can reach the turbine engine. Along the perimeter of the resulting node, I pasted the sealing tape used for sealing the openings of the opening plastic windows, and to the turbine itself, a segment of the twisted cord was soldered from the plugs at the end. Brazed contacts were sealed with hot glue.
Ultrasonic Mist Generator

Cover Assembly

Reverse side. Ultrasonic fog generator
The lid of the office bucket, as you know, is equipped with a rotary valve, and it gave me the most inconvenience.
  • - at the beginning, I marked and made a hole for the exit of the water mist;
  • - then,I napped out a rectangular window for the fan assembly;
  • —To lock the valve, across the entire inside area of ​​the lid, I pasted foam rubber on waterproof glue;
  • - the workpiece, in order for it not to poison the steam, had to be well moistened with the same glue in several stages;
  • - after drying, I glued the workpiece from linoleum trimming to an almost water-repellent foam rubber workpiece.
In the cut, you can see which sandwich went out:
Ultrasonic Fog Generator
Cover on the front side. In the hole for the release of drizzle, inserted half of a chocolate egg. With some effort, it can rotate. I advise you to burn holes in it only on one side so that the flow of cold steam can be directed away from the fan assembly and the air intake opening.
Ultrasonic Mist Generator
As a result, the general view of the washed office basket without the installed fan assembly is like this. To give a less collective-farm look, I glued the remaining pressure tape along the contour of the slit of the rotary valve. Ultrasonic Fog Generator

Float Assembly

I cut a round float from polyethylene foam, displays and TVs "wear" into a frame of such material. A yogurt cup is inserted into the float, into which an ultrasonic nebulizer is inserted.
Ultrasonic Fog Generator
The first tests immediately showed that the ultrasonic head should be sunk beneath the surface of the water, to the depth of the phalanx of the finger, but at the same time, some splashes still flew out of the mist fountain. So I had to think about the drip tray. It is made of a foam bottle cap, and fortunately, it had an eyelet with a hole for the foam tube.
Ultrasonic Fog Generator
Traces of rust are due to the fact that instead of nylon cable ties, I used a metal pin, and after soaking in citric acid, during final assembly, I will use them.
Actually, everything-cleaning is finished, then a series of photos will go with explanations, in which you will see the process of the final compilation of spare parts. Behind her, I will share my thoughts on what I would have done differently and the video of the work of the humidifier assembly.

Electronics hub

The wires were soldered. At the same time, on the left, you see the socket for connecting the fan unit.
Ultrasonic Fog Generator
And the lid is closed. Two bottom sockets. The right, the output to the ultrasonic head, the left jack is intended for connecting an external power supply unit +12 volts.
Ultrasonic fog generator

Ultrasonic head and float system

I had to cut off the standard wire due to its poor flexibility and splice it with flexible conductors in a silicone shell . Soldering sites were generously sealed with hot glue. And, pay attention - the wire is passed through a silicone cap which is corked with jars of antibiotics. You have seen a through hole in the office basket, a lid with a wire at its center will be inserted into it, which will not only be an obstacle to the release of fine mist, but will also allow you to remove this entire node without biting the conductors.
Ultrasonic Fog Generator
But the floating platform had to be completely changed.The metal sprayer was heavy for her and the buoyancy was negative. I took, as you see foam plastic, I was lucky, it is dense foam plastic from the same foam box with a width of 24 mm and 100 by 115 mm sides. Basket for The ultrasonic head also had to be replaced with a whole glass from under the yogurt. The sprayer was firmly pressed into the cup to the bottom, and with a soldering iron, the holes for water access inside this small container were burned. You will have to experimentally find out the buoyancy of the platform, but I’ll say right away that there is no alternative to foam plastic.
Ultrasonic fog generator

Test run

Water is poured into the basket, the ultrasonic node is lowered to the surface, the plug of the ultrasonic node passes the wall of the office basket through the silicone lid. You also see that the same sealing cord is glued on the inner perimeter of the basket.
Ultrasonic fog generator
The system is at medium speed.
Ultrasonic fog generator
System consumption was at maximum fan speeds and with an external power source of 12V - 1.92A.Without a fan 1.72A. So I changed now. First of all, the cover, it seems to me that it’s not quite successful. Climb up to the picture, which I showed an inverted lid. It would be better if you cut a blank from the solid sheet of plastic with the inner side (step) of the cover. After sizing and checking for sealing, the fan assembly can be placed in the space formed under the rotary valve of the office basket lid. I think that in the same place there was enough space for other electronics. What? For example - a humidity sensor. There are modules with humidity sensors combined with a relay, and after calibrating and installing the module at a humidity of 40%, you can forget about playing with a switch. Humidity will always be automatically maintained at the optimum level. Secondly, the safety system. I guess why the former fog generator in a plastic case has burned out. On it (as well as on this one), a capacitance sensor is installed in the form of a bracket and, probably, the fog generator is skewed — the capacitance sensor is in the water, and the piezo membrane is part of the air, which caused the entire head to overheat.On the TTP223 chip, compact capacitance sensors are released, it can and should be glued at the minimum water level in the basket from the outside, at which guaranteed, this ultrasonic head, albeit heavy, but still, would be in water. The sensor itself can control the boost module, the boosting module has a controlled input. Third, the boost module can be cheaper, not necessarily the one I used - there was nothing else near at hand. The approximate cost of the entire set:
  • - office basket - $ 2.5.
  • - ultrasonic nebulizer - $ 5.6.
  • is a boosting module Xl6009, which may be different - $ 0.80.
  • - impeller - $ 1.43.
  • - black box 100x60x25 mm - 1.08 dollars .
  • - ready speed regulator - $ 1.32 lars.
Total: about 12 dollars. Everything else I had in stock. I believe that this homemade dress, which does not pretend to be a samovar at the center of the festive table, nevertheless has all the necessary consumer qualities, which, for the money, is most likely not to be found in the finished version. Thank you for your attention. Ruslan.

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