Selecting Ultrasonic Transducers for Industrial Cleaning Applications

Ultrasonic cleaning systems consist of three parts: the ultrasonic generator, the transducer, and the cleaning tank. The generator produces an electric signal and the ultrasonic cleaning transducer converts the signal into compression waves into the cleaning solution. The waves then produce cavitation bubbles that do the scrubbing action of the components to be cleaned.

The role of the transducer is quite crucial for the cleaning of components, parts, and tools. It produces compression waves through the piezoelectric material that expands and contracts when subjected to the electric signal. The transducer changes the height of the piezoelectric material with the help of the electric signal that comes from the ultrasonic generator. That way, the transducer produces compression waves when its metal surface, tightly bonded to the surface, vibrates at a selected frequency.

Ultrasonic cleaning transducers need to be heavy, rugged and durable enough to withstand severe vibrations and immersion in cleaning solutions, as well as to generate powerful compression waves. Their surfaces must also be designed to resist pitting due to the action of cavitation bubbles.

Kaijo offers transducers that are heavy, rugged and durable. They are hermetically sealed in 316L polished stainless steel housing and are designed to withstand immersion in cleaning temperatures up to 100 degrees Centigrade.

Ultrasonic cleaning transducers are available in bolt-on, immersible or mounted versions. Immersible versions are independent units connected to the generator via a cable can be moved and placed anywhere in the cleaning tank. Mounted tranducers are integrated into cleaning tanks and are usually purchased for specially designed cleaning applications. Bolt-on transducers are similar to mounted, but are bolted onto the sides or bottom of cleaning tanks in single or multiple-unit configurations.

Kaijo’s ultrasonic cleaning systems range in frequencies from 26 kHz to 2MHz. Their variable power output has maximums of 600W or 1200W. Kaijo is able to evaluate a customer’s needs and propose the right custom solution. Learn more about the Kaijo ultrasonic transducers by reading “Selecting Ultrasonic Transducers for Industrial Cleaning Applications.” If you have any questions, want a free consultation or quote call at 408-675-5575 or send an email to info@kaijo-shibuya.com.

How a Megasonic Cleaning System Removes Submicron Particles from Delicate Components

Megasonic cleaning systems use high frequency generators and transducers to clean delicate components like silicon wafers and other microelectronic devices. Megasonic cleaning has proven to be a faster, more effective, and more thorough for removing submicron particles from delicate components compared to other cleaning methods.

So how does a megasonic cleaning system work to remove such particles?

Like the ultrasonic cleaning system, the megasonic cleaning system relies on cavitation bubbles which scrub and clean away impurities from the surface of delicate components.

As a megasonic wave enters the cleaning fluid, the wave troughs produce areas of low pressure where the bubbles form. When the pressure reaches its highest peak, the bubbles collapse and releases energy which acts to scrub and clean away the contaminants on the surface of the devices being cleaned.

When the system frequency increases, the waves become closer together and there is less time for the bubbles to form. As a result, higher frequencies generate smaller bubbles. These bubbles do the gentler cleaning action on delicate components as the collapsing bubbles become less energetic.

Submicron contaminants are quite difficult to clean away because they can be small enough to be lodged in the boundary between the solid wafer and the free-flowing cleaning solution. The megasonic cleaning system enables the bubbles to move straight to the submicron particles. As the bubbles collapse, the resulting energy becomes strong enough to dislodge the submicron particles off of the surface. This cleaning process proves to be more effective in dislodging even the smallest and the most stubborn submicron particles from delicate semiconductor components and results in fewer defects in the final product. Megasonic cleaning produces a current in the solution to ensure that the small particles won't attach to the surface of the semiconductor components again.

Kaijo has been providing a wealth of expertise and experience in manufacturing ultrasonic and megasonic cleaning systems for many years. These systems can be standardized or customized according to the clients' preference. The company's "Quava megasonic cleaning system" is a cost-effective solution that can operate at either lower or higher ultrasonic frequencies for several specific cleaning applications.

To learn more about our megasonic cleaning systems read the full article “How a Megasonic Cleaning System Removes Submicron Particles from Delicate Components”. If you have additional questions, feel free to call Kaijo Shibuya or send an email to info@kaijo-shibuya.com. 

7 Things to Consider When Selecting Ultrasonic Cleaners

Ultrasonic cleaners are a better alternative than traditional cleaning methods as they don't use harsh cleaning agents and can still clean items thoroughly and quickly. Ultrasonic cleaners use ultrasonic sound waves which generate microscopic cavitation bubbles which do the scrubbing and cleaning action.

Facility managers and decision makers should be familiar with ultrasonic cleaning system characteristics so that they can choose what type of cleaners will meet their own application requirements. Below are seven things to consider when selecting ultrasonic cleaners.

1. Frequency - The frequency power determines the size of the cavitation bubbles. Low frequencies (down to 20 kHz) generate comparatively bigger bubbles for robust cleaning action, while higher frequencies (200 kHz or more) generate smaller bubbles which clean more delicate parts.

2. Cleaning power - The ultrasonic cleaning system's power in watts determines the overall cleaning capacity. Bigger tanks, obviously, need more power.

3. Tank size - Kaijo's ultrasonic cleaning system has tanks that range from the standard size to customized ones.

4. Basket - Baskets fit inside the tank and hold the parts to be cleaned away from the surface of the tank. This is to ensure that the walls and the floor of the tank won't be damaged by the components during the cleaning process.

5. Heating – Heating the cleaning solution will improve the removal of certain contaminants like grease and oil. There are some contaminants that are not affected by heat, so heating the cleaning solution will be of little benefit in this case.

6. Cleaning solution - Generally industrial ultrasonic cleaning systems need only plain water to clean the contaminated components. Mild detergents are sometimes added to improve cleaning performance.

7. Do you need sweep mode? - Sweeping the frequency helps prevent the problems of fixed frequencies which may cause damage to the parts to be cleaned.

Kaijo takes these factors to make sure that customers are getting the ultrasonic cleaning system that will meet their specifications and requirements. Read the complete article “7 Things to Consider When Selecting Ultrasonic Cleaners” and then send an email to info@kaijo-shibuya.com if you have questions about selecting the best ultrasonic cleaner for your cleaning application. 

Using Ultrasonic Cleaning Technology for Food Plants

Cleanliness is an absolute must especially for companies that prepare or process food. Food processing requires companies keep their tools clean and sanitized. These issues can be addressed with ultrasonic cleaning systems such as those offered by Kaijo.

Kaijo's ultrasonic cleaning systems are a better alternative to conventional cleaning methods. These systems generate ultrasonic sound waves in the liquid of a cleaning tank where the parts are placed for cleaning. The ultrasonic sound waves create cavitation bubbles in the cleaning solution. This collapsing of bubbles creates a strong scrubbing action that removes impurities and contaminants from the surfaces to be cleaned.

The intensity of the cleaning action can be adjusted by changing the ultrasonic frequency. Machines and tools that prepare and process food are often contaminated with oil, grime, and food residue from frequent use. For this, parts should be generally cleaned at low frequency levels, which generate bigger cavitation bubbles that do the more robust cleaning. Even the food itself can be cleaned by the ultrasonic cleaning method. Delicate food, as well as the delicate plastic parts used to process food, is generally cleaned at higher frequency levels. These higher frequency levels produce smaller bubbles for a gentle cleaning action.

Some of the reasons why food plants use ultrasonic cleaners for the preparing and processing food include:

·         Faster than traditional cleaning methods

·         More efficient and effective in cleaning many types of parts -- even parts that have complicated shapes as well as holes and crevices

·         Less labor-intensive

·         Eliminates the use of harsh cleaning chemicals and solvents

·         Cost-effective

·         Environment-friendly

With the advantages above, Kaijo's advanced ultrasonic cleaning systems will significantly increase productivity in food plants and increase their bottom line in the process.

Learn more about Kaijo’s ultrasonic cleaning systems by reading our complete article “Using Ultrasonic Cleaning Technology for Food Plants.” If you have questions, please send an email to info@kaijo-shibuya.com.

Using Ultrasonic Cleaning Technology for Medical Device Implants

Medical device implants need to be cleaned and sterilized according to FDA and other requirements before they can be used in a patient. Some of these medical device implants are delicate and high-value. They need to be cleaned thoroughly but also gently at the same time. If they aren’t, these implants may introduce contaminants, or they may suffer damage from rough scrubbing or cleaning with harsh chemicals.

That's why industrial ultrasonic cleaners are the ideal alternative to conventional cleaning methods. These systems rely on cavitation bubbles to clean a variety of parts and the intensity of the cleaning action can vary by adjusting the ultrasonic frequency.

Kaijo offers a range of ultrasonic cleaning systems ideal for medical cleaning applications, specifically the cleaning of medical device implants. These systems do not use mechanical scrubbing or the use harsh chemical solvents. Instead, Kajio's ultrasonic cleaning system uses ultrasonic sound waves which create microscopic cavitation bubbles in a cleaning tank. These bubbles provide the scrubbing action on the surfaces to be cleaned.

Ultrasonic cleaning systems are available in a wide range of frequencies that can be adjusted for specific cleaning applications. Lower ultrasonic frequencies generate larger bubbles for more intense cleaning, while higher ultrasonic frequencies create smaller bubbles which are ideal for cleaning delicate parts including delicate device implants. These bubbles can also clean complicated shapes, holes, and crevices on many different types of parts and devices, something that mechanical scrubbing could not reach.

Traditional cleaning methods used on medical device implants require rinsing to completely remove contaminants that may be left from cleaning. Even if the parts have been cleaned in water with ultrasonic cleaning, they still need to be rinsed because the water used in the ultrasonic cleaning may have become contaminated with foreign matter the ultrasonic cleaner has removed.

Kaijo's industrial ultrasonic cleaners deliver improved performance and better results compared to traditional cleaning methods. This makes them the perfect solution for cleaning delicate and intricately-shaped medical implants.

Learn more by reading the complete article titled “Using Ultrasonic Cleaning Technology for Medical Device Implants” or call 408-675-5575 to have your specific questions answered.

Why Plastic Manufacturers Use Ultrasonic Cleaning Systems

Plastic product manufacturers need effective and reliable cleaning solutions to keep their fabrication processes running efficiently. For many decades they've been using the traditional cleaning methods which involve the use of harsh chemicals and mechanical scrubbing of molds used in creating plastic shapes as well as tools used in finishing plastic products. These methods can be time-consuming and costly, not to mention they may also damage tools and mold surfaces.

Ultrasonic cleaning systems provide a solution to these cleaning challenges. How do they work? Manufacturers use a tank which contains a mild cleaning solution. The ultrasonic transducer may be immersed into the tank or may be bolted onto the tank. The transducer receives high-frequency electrical signals generated by the ultrasonic generator and then converts these signals into sound waves that travel through the cleaning solution in the tank.

The sound waves generated by ultrasonic cleaning systems create tiny bubbles that do the cleaning action of removing dirt, contaminants or any other impurities from the surface. The scrubbing action of these bubbles is so powerful that they can also clean items with complicated shapes, holes, and crevices that mechanical scrubbing cannot reach. Within ten to fifteen minutes, the parts will be cleaned down to their original surface.

Apart from being effective and quick in cleaning components like molds and tools, ultrasonic cleaning systems are also cost-effective, require less continuous monitoring, are environmentally safe, leave no contamination or residue along with other benefits.

Kaijo's ultrasonic cleaning systems are available in a wide range of options that include both turnkey systems and individual system components. These systems typically operate in a wide range of frequencies for various cleaning applications without affecting or damaging the surfaces of the molds and tools to be cleaned.

Read our complete article “Why Plastic Manufacturers Use Ultrasonic Cleaning Systems” to learn how the ultrasonic cleaning system can be used by plastic manufacturers. You can call Kaijo for a free consultation or quote or email them at info@kaijo-shibuya.com.

How Ultrasonic Cleaners are Used in Automotive Cleaning Applications

Ultrasonic cleaners use high-frequency sound waves to remove impurities and contaminants from metal and plastic components. They are seen as the better solution to the traditional cleaning methods which uses harsh chemicals and mechanical scrubbing which can damage the components.

Ultrasonic cleaners are especially useful in automotive shops working with used engine parts and restoration facilities working on classic cars. A lot of automotive parts have unusual and complicated shapes, curves, holes, and crevices which mechanical scrubbing simply cannot reach. Some areas may get more mechanical scrubbing than other areas (especially the less visible ones), where the contaminants may remain.

Ultrasonic cleaners use ultrasonic signals generated in the cleaning bath which creates millions of tiny bubbles which do intensive cleaning. These bubbles help in removing oil, dirt, grease, and grime throughout the bath. While the bubbles are intensive enough to dislodge all the contaminants they will not cause damage to the metal surfaces. In addition these bubbles will clean irregularly-shaped components, holes, and crevices that are considered to be inaccessible by mere mechanical scrubbing.

Ultrasonic cleaning systems can also be changed to operate at a higher frequency to produce smaller, finer bubbles, which clean more delicate components. As a result, the ultrasonic cleaning method cleans the automotive parts thoroughly and quickly without damaging them.

Kaijo's ultrasonic cleaners can meet a wide variety of automotive cleaning needs. They provide adjustable frequencies that can be set according to the requirements of the automotive cleaning application. Kaijo's ultrasonic cleaners are cost-effective, save cleaning time, and are environmentally-friendly as well.

Contact Kaijo to learn more about their ultrasonic cleaners or read the complete article on this topic titled “How Ultrasonic Cleaners are Used in Automotive Cleaning Applications.”