How Custom Designed Ultrasonic Cleaners Meet Automotive Industry Needs

 

The automotive industry has varied cleaning requirements for automotive parts and re-built components. Cleaning applications range from rugged engine parts to more fragile parts with special coatings or finishings.

Automotive ultrasonic cleaners can be custom designed to handle special cleaning applications, and customized systems often deliver optimum cleaning results.

Businesses use customized automotive ultrasonic cleaners that are designed with basic parameters that ideally match the cleaning application. For instance, low frequencies (such as 26 kHz and 38 kHz) clean robust, heavily contaminated parts. In comparison, higher frequencies (such as 78 kHz) are best for cleaning more delicate components such as aluminum parts.

Another important consideration is the cleaning tank, which hold the cleaning solution and the parts being cleaned. Standard tanks are gloss polished 12-gauge stainless steel, but other materials can be used when the specific cleaning applications require it. Tanks can be ambient temperature or heated, and they can include circulating pumps and filtration. Heating in the cleaning solution can soften more challenging and more stubborn dirt (such as caked grease), thus speeding up the cleaning process. Filtration can remove dirt as it is loosened from the automotive parts.

Transducers convert the electrical signal from the ultrasonic generator into sound waves that travel through the cleaning solution. Transducers can be permanently installed, bolt-on, or immersible, as needed by cleaning application.

Some automotive production lines require cleaning for a specific part, while others may have large volumes of several parts to be cleaned regularly. The level of contamination may be predictable or may vary, depending on the job. These factors influence how the parts should be cleaned, and therefore they may require extensive customization.

Other possible factors for customization of automotive ultrasonic cleaners include physical characteristics and special processing options. For example, the physical arrangement can be adapted to existing available space, and components (such as transducers) can be customized to be placed in existing tanks.

For more details read the complete article, “How Custom Designed Ultrasonic Cleaners Meet Automotive Industry Needs.” If you have questions, or would like to set up a free consultation, contact Kaijo by calling 408-675-5575 or email info@kaijo-shibuya.com.

How Ultrasonic Cleaners Safely and Effectively Clean Without Chemicals

Traditional cleaning of industrial parts, mechanical components, and electronics has typically involved manual scrubbing, pressure washing, and soaking in aggressive chemicals. These cleaning methods can damage the surfaces of the parts being cleaned and they do not guarantee thorough cleaning.

Ultrasonic cleaners work without the use of harsh chemicals and clean parts quickly and completely. Eliminating chemicals and reducing the use of water saves money and also provides a safer work place. The effective use of industrial ultrasonic cleaners requires selecting the right frequency and power which an ultrasonic cleaner manufacturer can provide based on the specific cleaning application.

Ultrasonic cleaners work by generating millions of microscopic bubbles in the cleaning solution. An ultrasonic generator produces a high-frequency electric signal for an ultrasonic transducer. The transducer is immersed in the cleaning bath and vibrates in tune with the electric signal. The transducer vibrations produce ultrasonic sound waves throughout the cleaning action.

Ultrasonic sound waves have high-pressure peaks and low-pressure troughs. The microscopic cavitation bubbles form in the low-pressure troughs and collapse in the high-pressure peaks. When the bubbles collapse, they emit a tiny high-pressure jet that hits the parts' surface to be cleaned and dislodges dirt and contaminants. These jets deliver a powerful mechanical cleaning action that works faster and better than traditional manual scrubbing or cleaning with chemicals.

Ultrasonic cleaners also clean the parts more thoroughly compared to traditional cleaning methods. They can also be fine-tuned for the specific cleaning application. The selection of the right frequency is critical to produce the best cleaning results. Low frequencies (20 to 30 kHz) produce comparatively large cavitation bubbles that make tiny, powerful jets. These frequencies are best suited for parts with hard surfaces. As the frequencies increase, the cavitation bubbles become smaller, and the cleaning action becomes less intense. Higher frequencies of several hundred kHz are suitable for cleaning delicate and fragile parts.

Once the right frequency is chosen, the ultrasonic sound waves penetrate everywhere throughout the cleaning solution. The jets from the collapsing bubbles clean inside holes, along with cracks and over rough surfaces, which traditional cleaning methods cannot do. Dirt and contaminants are removed completely, resulting in parts that are thoroughly cleaned.

With extensive experience with industrial ultrasonic cleaning equipment, Kaijo has the expertise to carry out the design and manufacturing in-house.

For more details, read the complete article “How Ultrasonic Cleaners Safely and Effectively Clean without Chemicals.” If you have questions or would like to set up a free consultation to discuss your particular needs, contact Kaijo at 408-675-557 or email info@kaijo-shibuya.com.

How Ultrasonic Cleaners Are Used to Provide Effective Infection Control

Invasive surgical techniques are being used more frequently, and the tools and instruments used in these procedures can't be easily cleaned or sterilized with high temperatures. Many of these tools and instruments are hard to clean and many are temperature sensitive. They also have complex shapes and features that can harbor contamination and pathogens.

Manual ultrasonic cleaners are used to clean these kinds of tools and instruments. Ultrasonic cleaning performance is excellent but does not, by itself, guarantee that an instrument or tool is sterile. However when the appropriate amount of disinfectant is added to the cleaning solution, the action of the ultrasonic cleaning forces the liquid into crevices and holes where it can kill microbes on contact. The sound waves clean the surfaces of tools and instruments and the dislodged matter is removed, leaving the disinfected parts. Together with a disinfecting cleaning solution, an ultrasonic cleaner is a better alternative to steam sterilization.

Ultrasonic cleaners work by using an ultrasonic transducer to convert a high-frequency electrical signal to ultrasonic sound waves in the cleaning solution. The transducer (mounted in the tank) vibrates in tune with the electrical signal to create sound waves throughout the cleaning bath. Microscopic cavitation bubbles are created in the low-pressure troughs of the ultrasonic waves and collapse in the high-pressure peaks.

As each of the cavitation bubbles collapses, it creates a powerful suction effect that dislodges microbes and contaminates particles from the parts' surfaces to be cleaned. Once dislodged, the microbes are fully in contact with the cleaning solution's disinfectant and are killed. You can find details of the type of disinfectant that works best for ultrasonic cleaning by referring to the website "Infection Control Today".

Here are the key factors to consider when using medical ultrasonic cleaners to clean surgical tools and instruments:

• Size of the cleaning tank – It should be sized with the largest dimension longer than the length of the largest part. Often, a basket is used to hold the smaller components and keep them from vibrating against the tank's sides.
• Power required – The ultrasonic cleaning system should have enough power to fill the cleaning tank with the ultrasonic waves.
• Frequency – Choosing the wrong frequency can lead to damage to these surgical tools and instruments, many of which contain soft, delicate, or fragile parts and components. Low frequencies produce comparatively bigger cavitation bubbles and a robust cleaning action, which can damage fragile parts.

For more details, read the complete article, “How Ultrasonic Cleaners Are Used to Provide Effective Infection Control.” You may contact Kaijo Shibuya if you would like to set up a free consultation by calling them at 408-676-5575 or sending an email to info@kaijo-shibuya.com.

ROI on Using Sonic Cleaners

Every business manager that buys equipment needs to consider the return on investment (ROI) as part of the decision process. In the case of ultrasonic cleaners, the manager compares the cost of purchasing equipment with the anticipated savings. If the savings over two to three years are equal or greater than the ultrasonic cleaner's cost, the business manager will likely proceed with the equipment purchase. In this case, it means that the cost of purchasing the ultrasonic cleaner is returned after two or three years.

For many ultrasonic cleaner applications, the ROI is expected in much less than two or three years due to the substantial savings on labor and supplies it can provide. The analysis has become more favorable for the cleaners' purchase when the expected lifespan of the equipment is taken into account. After the two or three years are up, and the business has paid back the cost of the purchase from its savings, the ultrasonic cleaners will continue to generate these savings, increasing business profitability.

Apart from financial considerations, the ultrasonic cleaning systems’ performance is superior to most traditional cleaning methods, which also require a lot of work such as scrubbing and soaking of the parts in harsh chemicals. The work is difficult and time-consuming, especially if the parts being cleaned have complex shapes and difficult-to-access areas.

With ultrasonic cleaners, labor costs, and the cost and use of chemicals are significantly reduced. The parts are placed in the cleaning tank, and then the timer is set. After the timer period is up, the parts are now cleaned, with all the contamination completely removed. Supervision is not needed for the cleaning process, allowing the operators to complete other tasks as the ultrasonic cleaner works.

Plus, ultrasonic cleaners deliver rapid and thorough cleaning of parts, which results in increased throughput and improved quality. This means that apart from saving money and improving product quality and customer satisfaction, the use of ultrasonic cleaning is the right one for most businesses.

For more details read the complete article “ROI on Using Sonic Cleaners”. If you have questions or would like to set up a free consultation to discuss your specific cleaning requirements, contact Kaijo at 408-675-5575 or email info@kaijo-shibuya.com.

Why the Medical Industry Has Increased Their Use of Ultrasonic Cleaning

Safe medical practices require a high degree of cleanliness. That's why medical instruments, implants, and other medical devices have to be cleaned thoroughly before use.

Medical instruments and devices may have been contaminated with bodily fluids, while implants may have manufacturing residues that have to be removed. Ultrasonic cleaning uses microscopic cavitation bubbles to break up and dislodge surface contamination quickly and thoroughly.

Medical ultrasonic cleaners work by generating microscopic cavitation bubbles throughout the cleaning bath. When these bubbles collapse, they emit a tiny but powerful jet that dislodges dirt and contamination from the devices' surface to be cleaned. The millions of the tiny cavitation bubbles produce an intense scrubbing action that leaves device surfaces completely clean.

Traditional cleaning methods such as manual cleaning and soaking the parts in chemicals can be time-consuming, costly, unsafe, and, most of all, won't produce the same complete cleaning results as an ultrasonic cleaner does. The traditional cleaning process may also require constant monitoring. Manual cleaning and scrubbing of sharp objects can cause puncturing wounds or cuts, and the process can take a lot of time and effort. Not to mention that manual cleaning can be difficult, especially if the device has complex shapes or hard-to-clean openings and crevices.

On the other hand, soaking the parts requires chemicals that have to be purchased, stored, delivered, and (when they're no longer needed) disposed of properly. These harsh cleaning chemicals can pose a significant environmental hazard if not handled properly.

Many of these medical tools and devices are delicate that they cannot withstand high temperatures. For instance, cleaning them with hot water may cause damage and, in turn, compromise their efficiency. Optical devices such as parts of fiber optics may have delicate surfaces that manual scrubbing can damage them. Medical ultrasonic cleaners can be designed to deal with these issues and thoroughly clean fragile electronic and optical devices

Ultrasonic cleaning, therefore, may help address these issues. The parts are placed in a basket immersed in the cleaning bath that can be plain water or solution with only mild detergent or disinfectant. After a timed period of ten to twenty minutes, the clean parts can be removed from the bath. No manual cleaning or scrubbing, use of chemicals, and supervision of the cleaning process are needed. The result is clean objects that can be sterilized without fear that hidden contamination may protect microbes and pathogens against sterilization.

For more details read the article, “Why the Medical Industry Has Increased Its Use of Ultrasonic Cleaning”. As a leader among ultrasonic cleaner manufacturers, Kaijo Shibuya provides extensive experience with a broad product line and outstanding customer support to address your industrial cleaning requirements. Contact them at info@kaijo-shibuya.com or call 408-675-5575.

What Medical Applications Require High Frequency Ultrasonic Cleaning?

Ultrasonic cleaning is the ideal solution for many medical applications because medical ultrasonic cleaners deliver rapid and complete cleaning without using hazardous chemicals. They can even clean parts with complex shapes, interior cavities, or cracks and ridges wherever the cleaning solution can penetrate. Medical applications, such as implants, surgical instruments, and other medical devices, must be clean and sterile in ultrasonic bath with a disinfecting solution.

Choosing the right type of frequency in an ultrasonic cleaner will result in optimum cleaning performance. For medical devices with soft or delicate parts, or those that may have parts with delicate structures, the best cleaning performance is achieved by gentle cleaning at high frequencies. Low frequencies produce a powerful cleaning action that can dislodge contaminants effectively, causing pitting of soft surfaces or damage to fragile components.

Ultrasonic systems generate microscopic bubbles in the cleaning solution. When the bubbles burst, they produce energetic jets that dislodge contaminants from the medical devices' surfaces. Higher frequencies produce smaller bubbles and less energetic jets, which are ideal for cleaning fragile and delicate parts such as parts of medical devices. Such components could be damaged very easily by powerful mechanical cleaning. High-frequency medical ultrasonic cleaners deliver thorough but gentle cleaning action, which is suitable for medical devices.

Specific medical instruments – such as those that take readings of a patient's condition – can't be sterilized with heat because their circuitry and material are heat-sensitive. In this case high-frequency ultrasonic cleaning technology can clean such instruments in a solution of disinfectant, which will sterilize and clean them at the same time.

For more details, read the complete article “What Medical Applications Require High Frequency Ultrasonic Cleaning.” If you have questions, or would like to set up a free consultation to discuss how an ultrasonic cleaner can be used to meet your cleaning needs, contact Kaijo Shibuya at 408-675-5575 or email to info@kaijo-shibuya.com.

Which Ultrasonic Frequencies Are Used in Automotive Parts Cleaning?

Automotive parts typically have hard surfaces and are comparatively rugged, allowing ultrasonic cleaning to take place at the low-frequency spectrum in an ultrasonic cleaner. Within that lower range, there is still room for optimizing the cleaning performance by matching the automotive ultrasonic cleaner frequency exactly to the automotive parts to be cleaned.

Low frequencies can clean solid, rugged steel parts rapidly and thoroughly. Higher frequencies can clean more delicate parts or parts with special coatings.

Ultrasonic cleaners work by using ultrasonic generators to produce microscopic cavitation bubbles as the ultrasonic sound waves pass through the cleaning solution. The bubbles form in the low-pressure troughs and collapse in high-pressure peaks. As the cavitation bubbles bust, they produce tiny, high-energy jet that impacts the surface of the part being cleaned which dislodges and removes contaminants.

The size of the bubble and the energy of their jets depends on the ultrasonic frequency. Lower frequencies produce larger bubbles and more powerful jets. High frequencies produce smaller bubbles and less energetic jets. The ideal match between the frequency and the parts to be cleaned uses a frequency powerful enough to dislodge dirt, but not too powerful to cause pitting or damage part surfaces, coatings, plating, or small structures.

Typical parts cleaned with automotive ultrasonic cleaners include brake parts, injector nozzles, cylinder heads, carburetor and differential components. In each case the frequency selected depends on the part material and surfaces, the amount of contaminating material and the contaminants' composition.

Kaijo helps customers select the right ultrasonic cleaners from their extensive line of ultrasonic cleaning equipment to achieve effective automotive part cleaning results.

Read the complete article, “Which Ultrasonic Frequencies Are Used in Automotive Parts Cleaning?” for further details on using ultrasonic cleaners for automotive parts cleaning. If you would like to get a free consultation on your cleaning requirements, contact Kaijo Shibuya at 408-675-5575 or email info@kaijo-shibuya.com.