Ultrasonic Systems for Precise Cleaning Applications
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How Industrial Ultrasonic Cleaners Are Used in Industry

April 28, 2016

How Industrial Ultrasonic Cleaners Are Used in IndustryMany industries produce parts and components with surface contamination that must be removed. Other products may require cleaning before being used. Industrial ultrasonic cleaners offer precise cleaning solutions without using harsh chemicals. Properly designed and adequately powered ultrasonic cleaning systems can quickly and completely remove dirt and contaminants from the surfaces of a wide variety of materials. Kaijo offers turnkey ultrasonic cleaners such as the Phenix III as a way to improve industrial cleaning processes.

Powerful Adjustable Cleaning Action

Materials such as glass, metal and ceramics; components such as hard drive disks and machined parts; and products such as jewellery and medical devices require different levels of cleaning intensity. The industrial ultrasonic cleaners have to be able to deliver enough power for rough cleaning jobs as well as gentler cleaning action for delicate parts requiring precise cleaning. Ultrasonic systems such as the Kaijo Phenix III turnkey solution provide cleaning at 26 kHz and 38 kHz with power adjustable in ten steps up to 1200 W. The higher frequency produces smaller cavitation bubbles for gentler cleaning while adjusting the power determines how many bubbles are produced. Operators can adjust the cleaning action to provide exactly the intensity required for adequate cleaning of a particular part without eroding its surface.

Cleaning Without Chemicals

Industrial ultrasonic cleaners can work in a pure water environment, but for some cleaning solutions, solvents may be added to improve cleaning performance. In either case, harsh chemicals to dissolve persistent contaminants are not required. For non-ultrasonic cleaning, the chemicals used are often restricted, hazardous and subject to special handling regulations. They may have to be neutralized before disposal and both the chemicals and the neutralization process can be costly.

Ultrasonic cleaning is based on using water and the cleaning performance of Kaijo systems can be increased with the Kaijo Water Resonance System. If further cleaning improvement is needed, wetting agents to reduce water surface tension and detergents to help dissolve grease can increase the effectiveness of the ultrasonic cleaner. Such ingredients help the ultrasonic cleaning process and usually do not require special handling.

Flexible Turn Key Solutions

Ultrasonic cleaning solutions such as the Kaijo Phenix III turn key system have to be easy to install but need flexible features to adapt the solution to the requirements of the application and the installation site. The Phenix III is available for operation at a maximum of 600 W or 1200 W. Stainless steel tank sizes range from about 10.5 inches by 15 inches to 20 inches by 22 inches. Tank depth is either 10 inches or 12 inches. The power supply is single-phase 50/60Hz and can be 200 V, 208 V, 230 V or 240 V. These characteristics mean that these systems can satisfy a wide range of customer requirements.

Benefits of Kaijo Industrial Ultrasonic Cleaners

Kaijo’s product line of industrial ultrasonic cleaners is designed to deliver the cleaning power required at the appropriate frequency and in systems that can meet any industrial ultrasonic cleaning requirements. These systems can clean parts quickly and effectively with an environmentally-friendly process that is inexpensive to operate and does not require corrosive chemicals. Flexible features ensure that even turnkey systems can meet the needs of many applications. For custom solutions, Kaijo will provide advice and suggestions based on the size and nature of the parts to be cleaned and the possible contaminants.

The latest ultrasonic cleaning technology used in Kaijo systems ensures that they deliver unparalleled cleaning performance and exceptional value. Whether it is a turnkey solution, ultrasonic cleaning components or a custom-designed system, industrial ultrasonic cleaners from Kaijo can help improve cleaning performance and reduce costs.

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How High Power Ultrasonic Generators Provide Precise Cleaning for Industry Applications

April 20, 2016

How High Power Ultrasonic Generators Provide Precise Cleaning for Industry ApplicationsHigh power ultrasonic generators are especially versatile because they can clean a wide variety of materials, covering a range from high-frequency gentle cleaning action to more robust cleaning at lower frequencies. At the same time cleaning intensity can be controlled up to high levels. This means that a high power ultrasonic generator such as the Kaijo Quava can be used in manufacturing operations that require precision cleaning of many different parts and components. These units deliver cost-effective and easy-to-use cleaning performance with the capacity for adjustment to particular and varied cleaning requirements.

Providing Appropriate Cleaning Functionality

Parts such as medical tools, circuit boards and ceramic components can withstand robust cleaning and may have tough contaminants adhering to their surfaces. Low frequency cleaning at 26 kHz or 38 kHz generates comparatively large cavitation bubbles that release high energy when they collapse. Cleaning systems operating at these frequencies remove stubborn impurities from the surface of the parts to be cleaned but the parts themselves must be adequately rigid and stable.

Higher frequencies, in the 100 kHz range, create smaller bubbles and the energy applied to component surfaces is lower. This means that the cleaning action is suitable for more vulnerable surfaces. Hard disk drive components, optical parts and delicate electronics may need such a gentler approach to cleaning.

The highest cleaning frequencies, 750 kHz and 950 kHz, are reserved for extremely delicate parts, such a finely machined components or semiconductors. Cleaning is precise but less energetic than at lower frequencies. Parts may take longer to clean but the ultrasonic action is very gentle to protect the integrity of the delicate part.

In addition to varying the frequency, an effective high power ultrasonic generator can vary the power delivered to the cleaning solution. While changing the frequency changes the size of the cavitation bubbles that deliver the cleaning action, increasing the power increases the number of bubbles and therefore the intensity of the cleaning process. High power ultrasonic generators such as the Quava can deliver power up to 1200 W. High power capacity gives operators the flexibility to adjust both cleaning bubble energy and delivered power to match the requirements of the particular application.

Benefits of the Kaijo Quava High Power Ultrasonic Generator

A high power unit able to generate a wide range of frequencies delivers the precision and flexibility essential in a manufacturing operation that has varied cleaning requirements. The ultrasonic generator has to be able to adapt to all kinds of cleaning applications without requiring major modifications in the unit or changes in the set-up. The unit must deliver the selected power and the set frequency reliably and accurately to ensure uniform and effective cleaning performance.

The Quava generator satisfies these requirements by being able to produce ten distinct frequencies from 26 kHz to 950 kHz at up to 1200 W. The same generator may be used for all ten frequencies and no field calibration is required when a transducer is changed. The delivered power and frequency are monitored and may be controlled remotely. The Quava high power ultrasonic generator is ideal for a manufacturing environment requiring a versatile ultrasonic cleaning unit.

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