Time Vs. Money: How an Ultrasonic Cleaning System Saves Both

Ultrasonic cleaning systems can clean parts and components quickly and thoroughly and provide a superior option compared to traditional methods that use harsh chemicals and mechanical brushing. Plus, these systems help reduce cleaning costs considerably, they also save time and increase the efficiency of many production lines or manufacturing processes.

Ultrasonic cleaning process works by placing the items to be cleaned in a cleaning liquid of a cleaning tank. The sound waves generate cavitation bubbles in the cleaning liquid. These microscopic bubbles dislodge contaminants from the surfaces of the items being cleaned.

Ultrasonic cleaning saves time because the items do not need to be soaked in the cleaning liquid in order to soften the dirt. Subsequent manual scrubbing with pressure sprays is also no longer needed. In ultrasonic cleaning, the bubbles do the cleaning and scrubbing action, and they could clean even the more complicated parts, shapes, holes, and crevices of the items, resulting in quick but thorough cleaning.

The cost savings come from various sources. Because of the high performance of the ultrasonic systems, the need for water and power are reduced and the use of harsh chemicals is eliminated. Depending on the cleaning chemicals previously used, various chemical handling equipment and processing may no longer be needed.

High performance ultrasonic cleaning systems save on power usage since a typical system uses up to 1200 Watts, lower than the power used by conventional cleaning systems. Water use is also reduced because only one tank is needed for cleaning. These reductions translate into bigger savings.

You can learn more about Kaijo’s ultrasonic cleaning systems by reading the complete article titled “Time Vs. Money: How an Ultrasonic Cleaning System Saves Both.” Contact Kaijo for a free consultation or quote at info@kaijo-shibuya.com or call 408-675-5575.

How an Ultrasonic Generator Works

The ultrasonic generator is the heart of an ultrasonic cleaning system. It generates the high-frequency signal, which the ultrasonic transducers convert to sound waves of the cleaning solution within a cleaning tank. In addition to generating the signal, the ultrasonic generator controls the frequency and the power levels to produce several or a range of frequencies as part of an integrated, turnkey solution or independently to power separate transducers.

As the sound waves go through the cleaning liquid, the cavitation bubbles start to emerge in the low-pressure troughs of the waves, then collapse in high-pressure peaks. This action of the microscopic bubbles leads to a powerful scrubbing action that helps dislodge the dirt and particles off the surfaces of parts (in the cleaning liquid of the cleaning tank). The bubbles can even clean hard-to-reach places like holes and crevices, leaving the item thoroughly cleaned. Ultrasonic cleaning systems are generally considered superior to other traditional methods that use chemicals or mechanical scrubbing.

Apart from producing the high-quality signal, Kaijo’s ultrasonic generators provide the frequency needed to optimize cleaning performance for the specific cleaning application. Setting the right frequency is the key factor for an effective cleaning:

·         Low frequency (26 kHz to 38 kHz range) - This frequency produces large, energetic cavitation bubbles, making them suitable for cleaning machined parts, glass, and wires.

·         Mid-range frequency (78 kHz to 160 kHz) - The bubbles become smaller and the cleaning action is gentler. Suitable for cleaning hard disk drives, solar panels, and ceramic parts.

·         High frequency (450 kHz to 950 kHz) - The bubbles become even smaller and the cleaning action is at its most delicate. Suitable for cleaning semiconductors, LED's and fragile medical components.

If an Ultrasonic generator is used with a single process to always clean the same parts, selecting a single-frequency model is a good choice. For general-purpose usage, where the ultrasonic cleaning system may be used in a wide variety of cleaning applications, a generator that can produce a range of frequencies is the best option.

Read the complete article titled “How an Ultrasonic Generator Works” for additional information. If you have questions, want a free consultation or quote, contact Kaijo at 408-675-5575 or send an email to info@kaijo-shibuya.com.

How to Design an Ultrasonic Cleaning System for Your Application

Ultrasonic cleaning systems are an ideal solution for many industrial cleaning applications although the various components need to be selected according to the specific application they are used in. Both the operating frequencies of the system and the tank size are critical factors in selecting the right system. In addition, the power of the system, and the type of transducers used will impact how the system performs for a specific application.

Choosing the right type of ultrasonic cleaning system is important. Ultrasonic cleaning systems are made up of an ultrasonic generator which produces the ultrasonic signal and the transducers that convert the signal into sound waves in the cleaning solution of the cleaning tank. The components can be purchased separately or as a complete turn-key ultrasonic cleaning system that incorporates three components into one integrated package. Transducers can either be immersible units that can be moved or versions that are mounted or bolted onto the cleaning tank.

The size and shape of the parts determine the size of the cleaning tanks and the type of basket needed. The bigger the cleaning tank and part being cleaned, the more power will be required. Large numbers of smaller components may also need a bigger cleaning tank. A large tank need more power and may require several ultrasonic transducers to cover the whole tank.

The type of part material being cleaned and the nature of the contaminant determine the level of the frequency needed for the cleaning application. Low frequencies (20 kHz to 40 kHz) are best for cleaning heavy dirt from rugged parts (like metals and glass), while high frequencies (100 kHz) are ideal for removing dirt from delicate components (like solar cells, and fragile machine parts). Choosing the wrong frequency can result in either slow or ineffective cleaning, or even damage to the parts being cleaned.

Kaijo can help you choose the best system for your needs. Read the complete article “How to Design an Ultrasonic Cleaning System for Your Application” for more details. If you have questions or want a free consultation or quote call 408-675-5575 or send an email to info@kaijo-shibuya.com.