Important Questions Customers Ask about Ultrasonic Cleaners (Part One)

The following are some of the key questions that customers asked about selecting and using industrial ultrasonic cleaners, especially when they use them for their specific applications.

1) “When should I use an ultrasonic cleaner?”

You should use an ultrasonic when you want a quick, thorough and more efficient cleaning action without the use of harsh cleaning chemicals or mechanical scrubbing. It is important to choose the right power, frequency, type of transducer and the size of the unit to arrive at an ideal and desirable cleaning result. It also takes the right type of ultrasonic cleaning system to do it.

2) “How do ultrasonic cleaners work?”

The ultrasonic generator produces a high-frequency electric signal which is converted to ultrasonic waves in the cleaning solution by the transducer. The cavitation bubbles form in the ultrasonic waves. When the bubble collapse, they deliver a powerful scrubbing and cleaning action that dislodges dirt from the surfaces of the parts that are being cleaned.

3) “How do I select the right equipment?”

The best way for you to select the right industrial ultrasonic cleaning system is to discuss your requirements with your manufacturer/supplier. They should have extensive experience and be willing to offer advice on how to achieve your cleaning goals. Can existing tanks be re-used? Do you clean one kind of part or multiple parts? Do you need additional measures like heat or mild cleaning solvent? There are many factors that can influence your decision in choosing the best solution for you.

4) “How do I specify equipment size?”

Parts to be cleaned must be immersed within a cleaning solution in a cleaning tank large enough to hold the parts. Oddly shaped parts may require the use of a custom tank size depending on the size and shape of the part.  But if you clean mostly small parts or delicate parts that can easily break, you will need a parts basket to support them and to prevent them from touching the bottom and sides of the tank as the vibration might cause breakage. If you clean with many different types of parts of various sizes, the tank needs to accommodate the largest part.

See more answers to questions often asked by reading our complete article “Important Questions Customers Ask About Using Ultrasonic Cleaners.” If you have questions not included, or would like to set up a free consultation, call 408-675-5575 or send an email to info@kaijo-shibuya.com.

Using Industrial Ultrasonic Cleaners to Clean Disk Drives

Disk drives and components that include aluminium disk platter blanks and metal read/write heads are usually manufactured in standard industrial facilities. The processes used in their fabrication includes machining, stamping, punching, polishing, and molding using industrial chemicals for cooling, lubrication and as abrasives.

Before they are sent to special facilities for assembly, the hard drive components arriving from the industrial manufacturer must be cleaned thoroughly. Traces of industrial chemicals, contaminants added during shipment and particles adhering to platter surfaces must be removed completely. The components of hard disk drives must be especially clean, since the heads float very close over the platter surface and excessive contamination will not allow them to gather and store data.

High performance industrial ultrasonic cleaners can perform these types of cleaning tasks quickly and effectively. An industrial ultrasonic cleaning system produces microscopic cavitation bubbles in the solution of a cleaning tank. The bubbles form and collapse in time with the ultrasonic frequency. When a bubble collapses by the surface of a hard disk component, it produces a scrubbing action that removes dirt and contaminants. The bubbles form wherever the cleaning solution can penetrate, even around crevices, tinier holes and irregular shapes of disk read/write head.

To achieve optimum cleanliness, hard disk drive manufacturers usually use several frequencies to clean various components to remove specific contaminants. Deionized water is the preferred cleaning solution since cleaning agents leave traces that then have to be removed as well. For components that have surface lubricants, a mild detergent and/or heating the cleaning solution may make complete removal easier.

Kaijo offers free consulting to help customers choose the right industrial ultrasonic cleaners that will meet their requirements. Read the complete article “Using Industrial Ultrasonic Cleaners to Clean Disk Drives” to learn more. If you would like a free consultation or have questions, contact Kaijo at 408-675-5575 or email info@kaiijo-shibuya.com.

Why Are Higher Ultrasonic Cleaning Frequencies Required?

Choosing the right high frequency ultrasonic cleaner is the key to successfully cleaning parts that have a delicate physical structure. However, if the ultrasonic cleaning system frequency is set too high, cleaning could take longer and become less effective. If the frequency is set too low, it could damage the more delicate parts. Ultrasonic cleaning systems are extremely versatile and effective in most cleaning applications, but only if the operating frequency matches the tasks to be performed.

Ultrasonic cleaning systems generate a high-frequency electric signal that is converted into sound waves by an ultrasonic transducer. The transducer is submerged in the cleaning tank filled with water and generates sound waves in the liquid. Microscopic cavitation bubbles appear wherever the cleaning solution can penetrate. They form in the low-pressure troughs and collapse in high-pressure peaks.

This collapse of the bubbles is responsible for the cleaning action of an ultrasonic cleaning system. The bubbles can clean inside hollow tubes, in the thread of bolt holes, inside dead-end holes, and in cracks.

Low frequency — have longer cycle times and the wave troughs are wider resulting in bigger bubbles. Typical candidates for low-frequency cleaning include automotive parts such as cylinder valves and carburetors.

High frequency — have smaller bubbles because there is less time for them to grow in the comparatively narrow troughs. Using a high frequency ultrasonic cleaner is required for cleaning delicate parts such as medical instruments, semiconductor components, and computer parts. The selection of the ultrasonic frequency has to balance between the need for reduced cleaning power due to the fragility of the parts and the type of contamination that is being removed.

Kaijo has a full product line of industrial ultrasonic cleaning equipment and has extensive experience in the field of ultrasonic cleaning. For more information read the complete article “Why Are Higher Ultrasonic Cleaning Frequencies Required?”. If you have questions or would like to set up a free consultation to discuss your industrial cleaning requirements, contact Kaijo Shibuya at 408–675–5575 or email info@kaijo-shibuya.com.

Kaijo's New Phenix+ Ultrasonic Generator Optimizes Cleaning Performance

Kaijo's new Phenix+ industrial ultrasonic generator improves the functions used in the ultrasonic cleaning system’s performance. It provides better efficiency and takes ultrasonic cleaning control to whole new level.

Kaijo analyzed the possible sources of problems with using ultrasonic generators and used this to design the Phenix+ ultrasonic generator. It includes features that make the units easier to use, more efficient and offer better control of ultrasonic cleaning system functions.

The Phenix+ ultrasonic generator includes the following features:

• Touch panel controls for easy-to-use operator interface.
• Improved power output monitoring and control.
• Advanced automatic turning for changed process environment or a changed transducer.
• A standard frequency modulation mode which ensures an even and uniform ultrasonic wave distribution.
• More efficient cooling of the generator unit for increased efficiency.
• Reduced power use due to a more efficient power circuit.

These features make the Phenix+ ultrasonic generator an ideal source to create a high-frequency electrical signal used within an ultrasonic cleaning system. Operators can use the additional functions to control the cleaning process more precisely and deliver optimum cleaning performance.

Touch panel controls, automatic adjustment for the cleaning environment, uniform ultrasonic wave distribution, and increased efficiency from cooling requirements make the new Phenix+ industrial ultrasonic generator a great choice.

As a leading ultrasonic equipment manufacturer, Kaijo is focused on continuously improving their ultrasonic cleaning system components. They are committed to bringing the most advanced and cost-effective ultrasonic cleaning solutions to their customers.

For further details read the complete article, “Kaijo’s New Phenix+ Ultrasonic Generator Optimizes Cleaning Performance”. Contact Kaijo Shibuya at 408-675-5575 or email to info@kaijo-shibuya.com if you have questions or would like to set up a free consultation.

How Ultrasonic Cleaners Effectively Clean Industrial Machined Parts

Machined parts that come directly from a production environment will be contaminated with a variety of substances. These parts may have picked up contaminants from the shop environment and machining can often leave particles on the machined surfaces. Industrial ultrasonic cleaners offer an efficient and cost-effective solution to meet these types of cleaning needs.

Contamination can be harmful especially if machined parts are used in systems which have high levels of cleanliness. These requirements are needed in certain industries such as food, pharmacy, and medicine.

There are many ways to clean machined parts. Cleaning and rinsing machined parts with solvents may remove the contaminants with simple geometries but they cannot clean the intricate crevices and holes. Plus, rinsing may leave residues as well. Manual scrubbing, another cleaning option, may remove contaminants but may damage the machined surfaces.

That's why ultrasonic cleaning is the best alternative to these traditional cleaning methods, since it effectively removes all grease, oil, dirt, particles and all other sorts of contaminants.

Ultrasonic cleaning starts with the ultrasonic generator which sends an electric high-frequency signal to the ultrasonic cleaning transducers immersed in the cleaning solution. The ultrasonic waves create cavitation bubbles which form in their troughs and collapse in the wave peaks. This formation and collapse of bubbles in the liquid result in a powerful scrubbing and cleaning action as the bubbles effectively dislodge dirt and other foreign particles from the machined surfaces.

One of the primary benefits of using industrial ultrasonic cleaners is that the bubbles work where there is a cleaning solution, and you can select the frequency range as to how intense the cleaning you would like it to be. As a result, cleaning is thorough and effective around both simple surfaces and more intricate crevices, holes and along the ridges. No need to use harsh chemicals that may leave residues, or mechanical scrubbing that may damage the machined parts.

The article “How Ultrasonic Cleaners Effectively Clean Industrial Machined Parts” explains more details. For more information or to get a free consultation on how ultrasonic cleaners can be used for your cleaning application, contact Kaijo at 408-675-5575 or by email at info@kaijo-shibuya.com.

How to Specify Equipment Size and Options for an Ultrasonic Cleaner

Selecting the right equipment size and options for industrial ultrasonic cleaners is just as important as using the right frequency to obtain optimum cleaning performance. Depending on the cleaning application requirements, either a flexible system or a system designed for one particular task may work best.  Also selecting the corresponding options will influence how the system can be used.

In ultrasonic cleaning systems, the parts to be cleaned are immersed in a solution contained within ultrasonic cleaning tanks. The tank should be big enough to hold the largest parts or parts with unusual shapes (for tanks of custom shapes), but the power of the system also has to be adequate to fill the tank with ultrasonic sound waves.

Small or delicate parts may be easily damaged by vibrations if they come into contact with the walls and/or bottom of the tank. Placing the parts in a basket will help in reducing the possibility of vibration damage, so the basket has to be large enough to hold the parts and the tank has to be large enough as well to hold the basket.

Ultrasonic transducers can be immersible, bolt on or permanently installed on the cleaning tank. Among the three, immersible transducers are the most flexible because they are independent units that can be placed into any cleaning tank, whenever they are needed. Bolt-on transducers can be removed or replaced when needed, while mounted transducers are usually the part of a turn-key ultrasonic system that can’t easily be changed.

Ultrasonic cleaning generators produce an electrical signal at the selected ultrasonic frequency. A generator can be designed to produce just one frequency, several frequencies or a wide range of frequencies. Depending on the cleaning requirements and the application, an ultrasonic system may need a generator that produces one or multiple frequencies.

Customers can choose industrial ultrasonic cleaners that are turn-key, or they can have them assembled from the individual components to meet their requirements.

Read the complete article, “How to Specify Equipment Size and Options for an Ultrasonic Cleaner” to learn more. For questions or to schedule a free consultation, contact Kaijo at 408-675-5575 or email info@kaijo-shibuya.com.

Tuning into the Right Frequency for Your Ultrasonic Cleaning Application

Ultrasonic cleaning is an excellent solution for removing contaminants from a variety of components and parts without the use of strong, corrosive cleaning chemicals or mechanical brushing. It provides a faster, safer and a more effective solution for many different cleaning applications.

The key to successful ultrasonic cleaning is choosing the right operating frequency. This is to avoid damage of the parts to be cleaned and for rapid and complete removal of contaminants.

An ultrasonic cleaning generator produces the selected frequency for the system. When the ultrasonic waves pass through the cleaning solution, they produce cavitation bubbles that form and collapse quickly. As these bubbles collapse, they produce a powerful jet that dislodges dirt, contaminants and other foreign matter from the surface of the parts that are being cleaned. It is important to choose the right ultrasonic generator for the application to optimize the cleaning power but avoiding damaging the part being cleaned.

Low frequency (25 kHz) – the lowest ultrasonic frequencies produces bigger cavitation bubbles, stronger jets, and a powerful cleaning action. This is used for removing heavy contaminants from parts with hard and durable surfaces. This frequency is not recommended for delicate parts as they could be damaged and soft surfaces could suffer pitting.

Intermediate frequency (40 kHz) – suitable for any common cleaning applications, the bubbles are smaller compared to those generated by low frequency and therefore this frequency is suitable for cleaning glass, jewelry, and machined parts.

High frequency (80 kHz) – this frequency produces smaller cavitation bubbles and a gentler cleaning. This is ideal for cleaning more delicate parts with a fragile surface finish, such as hard disc drives, LCD's and aluminum parts. The gentle cleaning action avoids pitting or roughening of softer parts.

Highest frequencies (130-160 kHz )- the highest frequencies are used for very fragile parts or parts that have soft surfaces. The cleaning action is light but effective for applications that include electronic components, semiconductors, and delicate medical instruments.

The complete article titled “Tuning into the Right Frequency for Your Ultrasonic Cleaning Application” provides more details on choosing the ultrasonic cleaning generator. Contact Kaijo at 408-675-5575 or email info@kaijo-shibuya.com if you have questions or would like to discuss your particular cleaning requirements.