Ultrasonic Systems for Precise Cleaning Applications
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How an Ultrasonic Generator Works

August 17, 2017

How an Ultrasonic Generator WorksThe ultrasonic generator is at the heart of ultrasonic cleaning systems as it produces the high-frequency signal that the ultrasonic transducers convert to sound waves in the cleaning solution. In addition to generating the signal, the unit can control the frequency and the power, produce several or a range of frequencies and act as part of an integrated, turnkey solution or independently to power separate transducers. Ultrasonic generators need to be selected to match specific cleaning requirements in order for the system to work effectively. Key criteria for generator selection are the power and frequency of the generator and the matching transducers. In each case, the cleaning tank has to be large enough to hold the longest part to be cleaned, the power has to be high enough for the tank size and the frequency has to match the type of contaminant and the mechanical strength of the parts to be cleaned.

How It Works

An ultrasonic generator converts the 60 Hz facility power to high frequencies ranging from about 20 kHz to the 1 MHz range. Some models can generate only a single or a few frequencies while others can produce a wide range. Different levels of power are also available. For multiple-frequency models, operators can select the frequency that is most appropriate for their cleaning application.

In addition to producing the high-frequency signal, ultrasonic generators control the signal to maximize cleaning performance. Generators may automatically adjust the signal to compensate for heavy or light loading of the cleaning tank and they may “sweep” the signal, varying the frequency slightly to eliminate resonance or standing waves in the cleaning tank. For example, when a generator is operating at 38 kHz, varying the frequency randomly between 36 and 40 kHz eliminates hot spots and tank resonance that could damage the parts to be cleaned.

Selecting the Right Model

The right frequency is the key to effective ultrasonic cleaning. Low frequencies in the 26 to 38 kHz range produce large, energetic cavitation bubbles in the cleaning solution. The cleaning action is powerful but fragile components may be damaged and soft surfaces may suffer pitting. This range is suitable for items such as machined parts, glass and wires.

For the mid-frequency range of 78 to 160 kHz, the cavitation bubbles are smaller and the cleaning action is gentler. Hard disk drives, solar panels and ceramic parts can be cleaned at these frequencies. The most delicate components can be cleaned at the highest frequency ranges of 450 to 950 kHz. These frequencies are suitable for semiconductors, LEDs and fragile medical components.

If the ultrasonic generator is used with a single process and always has to clean the same kind of parts, selecting a single-frequency model makes sense. For general-purpose facilities, where the ultrasonic cleaning system may be used for many different cleaning applications, a generator that can produce many frequencies is a good choice.

Kaijo Ultrasonic Generators

Kaijo has a complete line of ultrasonic generators and offers free consulting to make sure customers select the type of system best suited to their cleaning applications. Generator models include the Quava high power, the Quava Mini and the Phenix Legend ultrasonic generators. Models are available as separate components or in turnkey packages.

The Quava high power models include generators that can operate at either multi-frequencies of 26/78/130 kHz or 38/100/160 kHz or ten different single frequency systems from 26 to 950 kHz. The Quava mini is a self-contained, compact tabletop system for small cleaning jobs. The Phenix Legend has 4 single frequency systems of 78kHz, 100kHz, 130kHz and 160kHz. Kaijo can help customers select the right ultrasonic components for a new process tank or help convert an existing tank.

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How to Design an Ultrasonic Cleaning System for Your Application

July 31, 2017

While ultrasonic cleaning systems are an ideal solution for many cleaning applications, they have to be designed with the particular tasks in mind. The operating frequencies of the system and tank size are key factors in selecting a system that will fulfill requirements. The rated power of the ultrasonic system, its flexibility to meet various cleaning needs and the type of transducers used also impact how well the system will perform. Only an ultrasonic cleaning system with the necessary design features will clean quickly and effectively.

Parts or Components to be Cleaned

The main influence on the design of an ultrasonic system is the nature of the parts or components that have to be cleaned. Key characteristics are a size of the parts, the material they are made of and the kind of dirt or contaminants to be removed.

The size of the parts determines the size of the cleaning tanks and the type of basket needed. The basket keeps the parts suspended in the cleaning solution so they don’t rest on the bottom or against the sides of the tank where vibrations might damage them. The basket has to fit inside the tank, and its mesh has to be fine enough to support the parts. Large numbers of small parts or single large pieces might need a large tank while a smaller tank might be suitable for fewer or smaller parts. Large tanks need more power and may require several ultrasonic transducers to cover the whole tank.

The part material and the nature of the contaminant determine what frequencies are best. Low frequencies of 20 kHz to 40 kHz deliver robust cleaning action to remove heavy dirt from rugged parts such as metal components and glass. Higher frequencies in the 100 kHz range clean more fragile items such as delicate machined parts and solar cells. Higher frequencies in the 1 MHz range deliver gentle cleaning for items such as semiconductor components. Choosing the wrong frequency can result in either slow cleaning or damage to the parts to be cleaned.

Selecting the Right Type of Ultrasonic Cleaning System

Ultrasonic cleaning systems are made up of an ultrasonic generator that produces the ultrasonic signal, transducers that convert the signal to sound waves in the cleaning solution and the cleaning solution tank. The components can be purchased separately or as a turnkey ultrasonic system that incorporates three components in one integrated package. Transducers can be independent, immersible units or they may be mounted or bolted onto the tank. Selecting the right type of system for an application helps ensure effective and rapid cleaning as well as reliable performance.

For some applications, it may make sense to purchase immersible transducers to place in an existing cleaning tank. Cleaning requirements may be for cleaning a specific part or component and a single-frequency system optimized for the use might be the most appropriate. Another production line might need multiple cleaning tasks to be performed at different times. Small turnkey systems are often cost effective, or a customer might need a large, custom tank with multiple transducers.

Kaijo can help customers select the best system for their needs and make sure that it performs as expected. Kaijo’s team of ultrasonic system experts have the experience to analyze a customer’s requirements and suggest the most effective solution. They can make recommendations on key system characteristics such as frequency, power and system configuration to ensure that the resulting cleaning performance matches the customer’s requirements to improve efficiency.

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How Ultrasonic Cleaning Tanks Work

July 19, 2017

How Ultrasonic Cleaning Tanks WorkUltrasonic cleaning tanks hold the solution that cleans parts and components through the action of cavitation bubbles generated by the ultrasonic sound waves. An ultrasonic generator produces the electric signal and transducers mounted on the tanks convert the signal into waves in the cleaning liquid. The cavitation bubbles deliver a strong scrubbing action throughout the liquid and can clean fully in hard-to-reach places.

Ultrasonic cleaning tanks have to withstand the cleaning action and vibrations created by the transducers and they have to be constructed to satisfy many different cleaning requirements. Kaijo ultrasonic cleaning tanks feature high-quality construction and provide reliable cleaning performance. The tanks are designed for use in industrial cleaning applications and clean parts and components quickly and completely. A wide range of sizes designed for use at 600 W or 1200 W cleaning power is available.

Tank Construction

Kaijo’s ultrasonic cleaning tanks are made of thick gloss polished stainless steel to provide a stable structure for the mounted transducers and as an inert container for the cleaning liquid. Kaijo can supply specific tanks designed to work with Kaijo ultrasonic generators and custom-designed tanks are also available.

Ultrasonic cleaning tanks have to be sized to hold the parts to be cleaned. Parts are usually suspended in a basket to avoid contact with the sides or bottom of the tank where they could suffer damage due to vibrations. The basket has to be large enough to hold the parts to be cleaned and has to fit inside the tank

Kaijo has an extensive range of standard tank sizes and can supply custom tanks sized to customer applications. The tank length determines the size of the largest piece a tank can hold and standard tanks are available in lengths from 370 mm (14.6 in.) to 550 mm (21.7 in.) while custom tanks can be larger if required.

Ultrasonic Cleaning Tank Operation

Kaijo tanks are available with mounted transducers and generators operating at 26 kHz, 38 kHz or 78kHz. These ultrasonic cleaning tanks are complete systems that deliver robust cleaning action, typically cleaning most parts in about 10 minutes.

For example, the highly reliable Phenix III generator can be combined with Kaijo’s ultrasonic cleaning tanks and mounted transducers to form a cost-effective turnkey system. Such a combination can clean glass, ceramics, machined parts and food as well as jewelry, cosmetics, and medical devices.  The transducers are heat resistant up to 100 degrees Centigrade and Kaijo’s Water Resonance System is available to substantially increase cleaning effectiveness.

The tanks can operate with a water bath but adding a mild detergent and heating the cleaning solution can speed up cleaning performance for some contaminants. This is especially true of greasy or waxy dirt that softens at higher temperatures and is dissolved by detergents. The ultrasonic system can clean complicated shapes and crevices as well as dead-end holes and areas inaccessible for mechanical cleaning methods.

Kaijo Can Help

Kaijo has over 60 years of experience in ultrasonic cleaning technology and can help customers select the best system and configuration for their cleaning application. Selecting the appropriate tank, frequency, power and system features ensures that the ultrasonic cleaning system performs up to its capability. When the selected system can either carry out a single cleaning task effectively or has the flexibility to clean multiple different parts well, it maximizes the return on investment and improves production line efficiency.

Kaijo’s specialists can help analyze a customer’s cleaning requirements and propose effective ultrasonic cleaning solutions. Consultations with ultrasonic cleaning experts are free and Kaijo’s team can recommend specific ultrasonic cleaning tanks and systems that match a customer’s needs. A well-designed and properly configured ultrasonic system can reduce costs, improve output quality and increase productivity.

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Can My Parts Be Cleaned Using Ultrasonics?

June 29, 2017

Industrial operations often require the cleaning of parts during or at the end of the manufacturing process. Traditionally such cleaning methods use harsh chemicals to dissolve contaminants and mechanical scrubbing to remove tough residue. Cleaning parts in this way is time-consuming and expensive. Even the best traditional cleaning methods are not completely effective and leave contaminants in hard-to-reach places. Ultrasonics can address these problems and provide quick and completely effective cleaning solution for all kinds of parts, tools and equipment.

How an Ultrasonic Cleaning System Works

Ultrasonic cleaning systems remove surface dirt and contaminants through the action of microscopic bubbles in a cleaning bath filled with water (which may also include a mild detergent). As the ultrasonic sound waves travel through the cleaning solution, the waves produce crests of high and low pressure. Cavitation bubbles form in the low-pressure areas and collapse under high pressure, creating an intensive scrubbing action. The effect of bubble formation and collapse is strong enough to deliver a substantial improvement in cleaning performance over traditional methods.

How to Choose an Ultrasonic System

Ultrasonic cleaning systems can increase production facility efficiency by reducing cleaning times, but they must have the right characteristics for a particular cleaning application. Choosing the right frequency and power are critical for optimal performance and choosing the right system ensures that all required cleaning needs can be met.

Low-frequency systems operating at around 26 kHz or 38 kHz create comparatively large bubbles with a robust cleaning action. Such systems are ideal for heavy residues on hard surfaces such as steel, copper and glass. Systems with higher frequencies operating at 100 kHz or more generate smaller bubbles that create a gentle cleaning action for delicate parts such as solar cells, medical devices and semiconductors.

No matter what the frequency, the system has to be able to generate enough power to fill the cleaning tank with bubbles. Finally, if an industrial process involves a single, specific cleaning action, a single-frequency system is an appropriate choice. If many different cleaning applications may be needed, a multiple-frequency system is better.

Additional Features of Ultrasonic Cleaning Systems

Other features used with an ultrasonic cleaning system include baskets to hold the parts to be cleaned, the possibility of heating the cleaning solution, different sizes of cleaning tanks and the ability to operate with different cleaning solutions. Making sure that your cleaning system includes the features you need is critical for effective ultrasonic cleaning performance.

For baskets and size of the tank, the basic requirement is that tank size has to be large enough for the parts you want to clean. Baskets hold the parts to be cleaned and keep them from touching the walls and floor of the tank. Baskets are not necessary for cleaning, but the floor or walls of the tank may vibrate with the ultrasonic waves and contact with the parts could cause damage. If a basket is used, the basket has to be sized according to the parts it will hold, and the tank has to be large enough to hold the basket.

Heating the cleaning solution is an advantage for contaminants that soften with increased temperature. Grease and oil are easier to remove when warm and heating can speed up the cleaning process. The same is true for cleaning solutions. While ultrasonics will work with plain water, adding a mild solvent designed to remove a specific contaminant improves cleaning performance.

Kaijo Ultrasonic Cleaners

An excellent way of ensuring that an ultrasonic cleaning system can fulfill the requirements of a specific application is to consult a company specializing in ultrasonic cleaning solutions. Kaijo has over 65 years of experience in this field and can help choose the ideal system. The Phenix turnkey ultrasonic cleaning system is an example of a versatile system that can meet a variety of requirements. Kaijo’s staff of experts can explain how the Phenix system operates and the features it offers while examining the needs of customers and proposing specialized solutions where required.

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Kaijo Shibuya America Inc. Exhibiting at SEMICON West 2017

June 21, 2017

Kaijo Shibuya America Inc. will be exhibiting at SEMICON West 2017, at Booth 5518 North Hall, from July 11-13 at the Moscone Center in San Francisco. Come by our booth to talk with us and learn how our new Phenix Hyper wave can enhance the uniformity of your ultrasonic cleaning process. Kaijo is an industry leader in megasonic and ultrasonic cleaning technology and offers a wide selection of state-of-the-art products and innovations not found with other ultrasonic cleaning manufacturers. (more…)

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Ultrasonic Cleaning 101: What Are Ultrasonic Waves and How Do They Clean?

June 19, 2017

Ultrasonic cleaning systems use ultrasonic waves to clean parts, tools and equipment quickly and effectively. A typical system is made up of an ultrasonic generator, a transducer and a cleaning tank. The generator produces an electrical signal at the required ultrasonic frequency. Ultrasonic frequencies used range from about 26 kHz to 200 kHz, and a generator may be designed for a single frequency or a frequency range.

The transducers convert the electric signal to physical vibrations that can create ultrasonic waves in a liquid. The transducer is submerged in the cleaning solution and includes a heavy metal plate. When the transducer receives the electric signal from the generator, the metal plate vibrates at the ultrasonic frequency and fills the liquid in the cleaning tank with ultrasonic waves.

The cleaning tank holds the parts to be cleaned, the cleaning solution and the transducer. It may include a basket to keep the parts from touching the tank walls and bottom, and it may include a heater to warm the liquid. High performance industrial ultrasonic cleaners work with plain cold water but adding a mild detergent and heating the solution can improve cleaning performance for some contaminants.

How Ultrasonic Waves Clean

The ultrasonic waves in the cleaning liquid remove contaminants and dirt from the surfaces of the parts to be cleaned through the action of cavitation bubbles. Just like waves on the surface of a body of water, ultrasonic sound waves have peaks and troughs. When the sound waves travel within a cleaning solution, the peaks and troughs become areas of high and low pressure.

In the low-pressure areas, cavitation bubbles form and the bubbles collapse under high pressure. As an ultrasonic sound wave trough passes the surface of a part to be cleaned, the cavitation bubbles form along the surface. When the high-pressure peak of an ultrasonic wave passes by, the bubbles collapse and release energy which produce a scrubbing action on the surface. This process repeats at the frequency of the ultrasonic wave. As a result, millions of microscopic bubbles form and collapse many thousands of times per second delivering intensive cleaning action by loosening dirt and contaminants and scrubbing the surfaces to be cleaned.

How System Frequency Affects Cleaning Performance

While all industrial ultrasonic cleaners operate the same way, the operating frequency influences what kinds of parts can be cleaned most effectively. In general, low frequencies can better deal with heavy dirt and contamination on hard surfaces while higher frequencies are used for delicate cleaning applications.

The sound wave pressure peaks of low frequencies such as 26 kHz to 38 kHz are relatively far apart, leaving more time for the cavitation bubbles to grow. The comparatively large bubbles give off a lot of energy when they collapse, and the resulting cleaning action is especially intense. Frequencies such as 100 kHz or higher leave less time for the bubbles to grow and the smaller bubbles give off less energy when they collapse. The cleaning action at the higher frequencies is gentler, becoming less aggressive as the frequency rises.

The low frequencies are suitable for items such as metal tools, glass or hard disk drive components. High frequencies are used for more fragile items such as delicate machined parts, semiconductor components or solar cells. Choosing the correct frequency and other ultrasonic system features is critical for optimal cleaning performance.

How Kaijo can Help You Choose the Right System

Global ultrasonic cleaning system manufacturer Kaijo offers a wide range of standard and turnkey solutions and can customize systems to match special cleaning needs. The company has the expertise to evaluate cleaning applications and suggest the ideal system to match specific requirements. Kaijo’s ultrasonic cleaners can clean quickly and completely to help increase manufacturing productivity, reduce the use of harsh cleaning chemicals and improve output quality with better cleaning performance.

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Why You Need an Ultrasonic Cleaning System for 3D Printed Parts

May 30, 2017

Advances in 3D printing have made this new technology widely accessible with broad manufacturing capabilities. The 3D printers work by depositing tiny drops of material in thin layers according to a digital design. The material of the 3D part is usually a type of resin or plastic that is in liquid or paste form when it is deposited and then hardens into a solid. The printers make it possible to create items with complex shapes as prototypes or samples and they can be used to make test pieces before starting production.

Complex items may require several types of material and there may be overhangs, gaps or complicated structures. The 3D printer makes sure that overhangs and structures don’t collapse by depositing supporting material underneath. Some parts of the item may have to slide or rotate over, around or through other parts. For such parts, the printer deposits thin layers of separating material to make sure the sliding or rotating parts don’t stick together. When the item is finished, it may have several areas where such supporting or separating material is present. Before the 3D printed item can be used, the extra material must be removed.

Ultrasonic Cleaning Systems Can Clean 3D Printed Parts

Removing extra supporting and separating material from a 3D printed part quickly and effectively can be difficult. The layers to be removed are often thin and not easily accessible. Scrubbing or mechanical removal is time-consuming and can leave an unwanted residue. Using a specially formulated solvent to dissolve the material can require lengthy soaking times and result in incomplete removal. An ultrasonic cleaner is often an excellent solution for the cleaning of these parts and the removal of the unwanted material. Ultrasonic cleaners clean quickly and clean thoroughly, even around complex shapes and in hard-to-reach places.

An ultrasonic cleaning system works by using ultrasonic waves to generate cavitation bubbles in a cleaning liquid. The bubbles form and collapse in time with the frequency of the sound waves. This bubble action results in an intense scrubbing effect wherever the cleaning liquid touches the surface of the 3D printed item. If the cleaning liquid contains a solvent for the unwanted material or if the material is soft compared to the rest of the item, only the unwanted material will be removed.

Kaijo Ultrasonic Cleaners for Optimum Results

Kaijo’s ultrasonic cleaning systems can clean 3D printed parts and remove unwanted filler material quickly and effectively. The Phenix III turnkey system is ready to clean with a minimum of installation and set up work and is sized to handle most typical 3D printed items. The system operates at 26 kHz or 38 kHz and delivers 600 W or 1200 W of cleaning power.

For bigger 3D printed items, Kaijo ultrasonic generators, transducers and tanks can be used to set up special solutions aimed at a customer’s specific cleaning needs. The components can operate with the solvents needed for 3D printed parts cleaning and the transducers mounted in the tanks are rated for up to 100 degrees centigrade. When a customer has existing cleaning tanks to be re-used, Kaijo can help design custom configurations with multiple transducers to deliver excellent cleaning action in large tanks. Kaijo’s extensive experience with ultrasonic cleaning systems helps customers get the 3D cleaning performance they need. If you want a quote or free consultation on which ultrasonic cleaning systems should be used for your application call Kaijo or email info@kaijo-shibuya.com.

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How Ultrasonic Cleaners Utilize Cavitation

May 17, 2017

Ultrasonic cleaning systems use cavitation in cleaning liquids to remove contaminants and surface dirt from a wide variety of parts that need cleaning. Cavitation bubbles are created by the action of sound waves in a cleaning solution. As the ultrasonic sound waves travel through the liquid, bubbles appear in the low-pressure troughs of the waves and collapse in the high-pressure peaks. The creation and collapse of the bubbles results in a powerful scrubbing action that operates throughout the liquid.

Manufacturing plants that have equipment cleaning needs can benefit from the fast, thorough cleaning provided by industrial ultrasonic cleaners. Parts such as nozzles, containers, valves and tools can often be cleaned completely in as little as ten minutes.  Manufacturers of parts or finished products can use ultrasonic cleaners to remove process material before shipping or clean products such as medical devices, solar cells, jewelry and ceramics. Ultrasonic cleaners work quickly and effectively without harsh chemicals.

How to Get the Cleaning Action You Need

The action of the cavitation bubbles can be adjusted by varying the ultrasonic frequency and the cleaning power. At low frequencies such as 26 kHz to 38 kHz, the ultrasonic wave peaks and troughs are comparatively far apart, resulting in larger bubbles. When large bubbles are created and collapsed, the scrubbing action is comparatively intense. Such low frequencies can clean rugged parts with stubborn dirt rapidly but they are not suitable for more delicate parts or parts with soft surfaces where the large bubbles may cause pitting or other damage.

Intermediate frequencies such as 78 kHz to 160 kHz result in smaller bubbles and less aggressive cleaning. Systems operating at these intermediate frequencies can clean fragile machined parts and soft materials. Even higher frequencies such as 1 MHz and above deliver very gentle cleaning action and are suitable for cleaning delicate semiconductor devices and microscopic structures. Customers can select either a single-frequency cleaner suitable for a clearly defined cleaning task or cleaning systems that can operate at several frequencies to deliver the level of cleaning action required for different cleaning applications.

Depending on the size of the parts to be cleaned, the power of the ultrasonic cleaning system must be high enough to generate bubbles throughout the cleaning tank. A single ultrasonic transducer array can deliver power of up to 1200 W and clean parts up to about 500 mm (20 inches) long. For larger parts needing bigger tanks, several ultrasonic transducers can be mounted along the bottom or on the sides. A custom design for such applications can use existing or new tanks to match customer needs.

Benefits of Kaijo’s Ultrasonic Cleaning Systems

Kaijo offers a complete line of industrial ultrasonic cleaners. Turn-key systems such as the Phenix III include an ultrasonic generator and a tank with the transducers already mounted. These systems are ready to start cleaning with a minimum of installation and setting up.

Alternatively customers can opt to buy ultrasonic generators such as the Quava or Phenix Series and buy transducers and tanks separately. These are excellent options for applications where existing cleaning tanks are to be re-used and Kaijo can help with such customizations.

Benefits of using these systems for industrial cleaning applications include the following:

  • Quick and complete cleaning of all types of parts to remove a variety of contaminants
  • Effective cleaning of complex shapes and parts with holes and crevices
  • Cleaning without harsh chemicals or mechanical scrubbing
  • The safe, efficient cleaning process results in improved facility performance and better quality output

Kaijo can advise customers on how to best satisfy their cleaning requirements and help them select the system they need. The company’s experience and expertise help ensure that the ultrasonic cleaners meet and exceed expectations. If you would like a quote or free consultation on how industrial ultrasonic cleaners can be used for your cleaning application call Kaijo or email info@kaijo-shibuya.com.

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Ultrasonic Cleaners for Pharmaceutical Equipment

April 28, 2017

Pharmaceutics manufacturers have challenging cleaning requirements when equipment such as pill punches and filling machine valves are used with different materials or when they become contaminated with mold or bacteria. Traditional cleaning methods with toxic chemicals bring their own contamination issues, and cleaning by shaking and agitation may not penetrate into inaccessible spaces or hard-to-reach crevices. Industrial ultrasonic cleaners offer an environmentally friendly cleaning solution that removes contaminants thoroughly and quickly at a low operational cost.

Issues With Traditional Cleaning

Exposed pharmaceutical parts such as pill punch dies or containers are usually cleaned with small bristle or wire brushes and solvents. While such cleaning can be effective, it is labor-intensive and slow. When the shapes to be cleaned are more complex and include internal surfaces, such cleaning is often not complete.

For cleaning inaccessible internal surfaces such as the inside of valves or nozzles, strong chemicals acting together with agitation or shaking as well as high impact spray cleaning may be used. The use of these aggressive cleaners required to sterilize the equipment often means technicians have to wear extensive protective gear and even then contaminants may remain in small crevices.

The main issues with this type of traditional cleaning are that it is time-consuming, potentially hazardous, expensive and not completely effective. As a result, costs are high and product quality can suffer. Ultrasonic cleaning can address both these issues.

How Ultrasonic Cleaning Works

Pharmaceutical devices and parts to be cleaned have to be detached and placed in the ultrasonic bath. Pill dies, valves, nozzles and hoses are placed in a stainless steel basket and immersed in a tank containing a water-based solution of a mild detergent. When the ultrasonic cleaning system is switched on, there can be a buzzing depending on the frequency used and a slight agitation of the tank liquid can often be observed.

In the liquid bath, the ultrasonic transducer is converting an electrical signal of perhaps 40 kHz into ultrasonic waves that travel through the liquid. Higher frequencies are used for delicate components while lower frequencies, down to about 20 kHz, are used for the powerful cleaning of rugged parts.

As the sound waves travel through the liquid, they produce microscopic cavitation bubbles whose formation and collapse produce the cleaning action. The bubbles loosen any material, down to the original machined or manufactured surface. The loose material floats away and is filtered out.

The sound waves travel through the parts and create bubbles wherever there is liquid. As a result, even threads, cracks and crevices and internal surfaces are cleaned thoroughly via the bubble action. Depending on the frequency and the power of the ultrasonic system, cleaning can take as little time as ten minutes and for even for challenging applications, the ultrasonic cleaning method works more quickly than traditional cleaning.

Kaijo Industrial Ultrasonic Cleaners

Industrial ultrasonic cleaners from Kaijo can clean pharmaceutical equipment quickly and completely with a low total cost of ownership. Managers and decision makers at pharmaceutical manufacturing facilities can choose turnkey solutions such as the Phenix III system or individual components such as the Quava ultrasonic generator, ultrasonic transducers and cleaning solution tanks.

Buying ultrasonic generators and transducers separately is especially useful when customers want to use existing cleaning tanks in the manufacturing facility. Immersible or bolt-on transducers can be placed in the tanks or bolted on to the sides or bottom. Large tanks can have multiple transducers installed and Kaijo can help configure the appropriate generator and transducer installation.

Whether customers can satisfy their requirements with standard equipment or whether they have custom applications, Kaijo can supply an ultrasonic cleaning solution. The company has over 65 years experience in the field of ultrasonics and supplies pharmaceutical companies with cost effective ultrasonic cleaners to address their specific requirements.

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Using Ultrasonic Cleaners to Clean Carburetors and Engine Parts of Motorcycles and Autos

April 21, 2017

The carburetors and other related engine parts on older or vintage motorcycles and autos are mostly mechanical devices designed to achieve precise fuel-air mixtures for their internal combustion engines. They are built of valves, chambers, floats, jets and other intricately designed components placed together in fine balance.

When a carburetor and other engine parts become greasy and coated with soot from extended use, it can result in difficult starts, poor power delivery and fuel inefficiency, soot-filled exhaust, timing sneezes and overheating. Visible fuel leaks from the carburetor are not uncommon, either. Cleaning carburetors and other engine parts requires the ability to thoroughly clean all surfaces of the component. This can be a tough challenging endeavor.

The conventional way to clean carburetors is to painstakingly disassemble the component to separate every intricate part, and to manually scrub every nook with powerful, hazardous chemicals. The entire process can be very time-consuming. Not only is it very hard taking these intricate components apart, it can be challenging putting them back together, as well. This is where the use of ultrasonic cleaning technology enters the picture.

What is ultrasonic cleaning?

Ultrasonic cleaning technology was first developed by RCA way back in the 30s. In 1957, Kaijo Corporation developed their first ultrasonic cleaner that was the beginning of their product line of industrial ultrasonic cleaners. The use of the Ultrasonics has continually evolved over the years. Many advances in the past decade alone have made the technology particularly accessible and affordable to businesses that would have previously deemed it out of reach.

Ultrasonic cleaning is a powerful, but gentle cleaning method that makes practical use of a natural phenomenon called cavitation. The term refers to the behavior of bubbles in liquid, when they are subjected to intense levels of pressure variation.

When rapid changes of pressure pass through a liquid, the condition creates tiny bubbles that periodically implode to intense shockwaves. The forces generated by such implosions can be great enough to dislodge grease, rust or other stubborn deposits.

While the cavitation phenomenon is one that designers strive to prevent in certain applications such as marine propeller design, it is a useful one when correctly applied to various industrial processes that involve tough cleaning applications.

How does ultrasonic cleaning technology help clean motorcycle and auto carburetors?

Motorcycle and auto carburetors use complex, intricate constructions, and cleaning layers of heavy, burned-on grease can present a challenge to mechanics. It requires the use of ultrasonic cleaning technology to address the cleaning action needed.

Industrial ultrasonic cleaners come with a cleaning tank or bath that includes either a built-in or removable ultrasonic cleaning transducer. The cleaning tank is filled with ordinary water or a mild cleaning solvent, and the carburetor and other engine parts to be cleaned are placed in the tank. The unit generates sound waves of ultrahigh-frequency to rapidly cycle pressure waves in the tank which create a powerful cavitation effect. Millions of tiny, microscopic bubbles form over the surface of the carburetor and other parts implode with strong force, each implosion generating enough power to dislodge the grease, rust or baked-on dirt on the surface.

Since the liquid of the tank and the sound waves passing through it reach every crevice on the surface of and inside the carburetor, there is no area left untouched. In no more than a few minutes, the carburetor and other engine parts emerge clean, completely stripped of grease, rust and other contaminants that were on the surface.

No part is too complex for ultrasonic cleaning. The process can save hours upon hours of human labor.

The benefits of Industrial ultrasonic cleaners

One might imagine that forces of cavitation strong enough to eat grease and rust away would be powerful enough to cause damage to metal, as well. While such an effect is technically possible, it is prevented in practice, by using the right ultrasonic equipment to apply the appropriate frequency and power for the specific cleaning application needed.

Megasonic (frequencies of 200kHz-1.2 MHz) and Ultrasonic (frequencies of 20khz-200kHz) cleaning is one of the most advanced cleaning approaches in existence; such technology is used to clean everything from semiconductor wafers to computer parts, to large rugged industrial parts safely and effectively.

Kaijo’s Industrial ultrasonic cleaners can be used to address a wide variety of motorcycle and automotive cleaning applications. The environmental and monetary benefits of ultrasonic cleaners are also quite significant. The method requires no use of harsh chemicals or solvents, and is therefore healthy both for the environment and for workers. Contact Kaijo for a free consultation or quote on using the right ultrasonic cleaning equipment for your cleaning application.

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