Ultrasonic Systems for Precise Cleaning Applications
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How Kaijo’s Ultrasonic Cleaning Generator Improves the Manufacturing Process

May 26, 2016

How Kaijo's Ultrasonic Cleaning Generator Improves the Manufacturing ProcessUltrasonic cleaning generators produce an electrical signal that transducers change into ultrasonic waves in the cleaning liquid. The waves produce cavitation bubbles that appear and collapse in time with the frequency of the ultrasonic generator. The collapse of the bubbles results in a powerful scrubbing action that removes surface contaminants from the parts to be cleaned. Ultrasonic technology is clean, environmentally friendly and often works more quickly and more effectively than other cleaning technologies. Small and mid-sized manufacturing plants and shops can improve their manufacturing process by converting to ultrasonic cleaning, achieving improved cleaning performance at reduced cost.

Cleaning Without Chemicals

Where other technologies produce effective cleaning with harsh chemicals, ultrasonic technology cleans with bubble action using no chemicals or only a benign detergent solution. The liquid baths can go to boiling temperatures so chemical additives are often not needed. Ultrasonic cleaning generators such as the Kaijo Phenix Legend Series can produce a wide range of frequencies to match any cleaning application.

Robust items such as machined parts, glass and ceramics can be cleaned at lower frequencies that deliver large bubbles with high cleaning energies and intensive cleaning action. Kaijo Phenix Legend models producing 38 kHz and 78 kHz fall into this category. Frequencies such as the 100 kHz, 130 kHz or 160 kHz produced by the higher frequency Phenix Legend models produce smaller bubbles with less energy and can be used for more delicate cleaning tasks. Fragile electronic components are often cleaned at these frequencies.

Cleaning with ultrasonic generators can improve the manufacturing process itself and reduce costs. Cleaning with the appropriate frequency delivers exactly the type of cleaning action required for a particular application and makes cleaning more effective. The reduction or elimination of chemical use is itself a substantial cost saving, but additional savings result from the elimination of costs associated with the storage, handling, neutralization and disposal of such chemicals.

Cleaning Irregular Parts

Cleaning parts with cavities or irregular surfaces is sometimes challenging. Chemicals often diffuse slowly into holes and mechanical cleaning can’t easily reach into deep crevices. Ultrasonic cleaning generators produce sound waves that are distributed throughout the cleaning tank. In this way bubbles and cleaning action are created even in hard to reach places. Parts are cleaned evenly and thoroughly, leaving no residues and giving an improved cleaning result.

Using Kaijo’s Water Resonance System with an ultrasonic cleaning generator will significantly enhance the clean power by conditioning the water. The system promotes a more even distribution of bubbles for an effective cleaning power that can approach five times that of cleaning systems without water resonance.

Cleaning Quickly at the Right Power

Unlike other cleaning technologies, ultrasonic cleaning generators can accurately control the cleaning power they deliver. The correct frequency gives the appropriate cleaning intensity but the generator power gives the cleaning power delivered to the cleaning solution. When operated at the right frequency and power for the particular cleaning job, ultrasonic cleaning generators often deliver excellent cleaning in a short time. Even tough jobs can take about 20 minutes and light cleaning can be carried out very quickly.

Kaijo’s Phenix Legend Ultrasonic cleaning generator can reduce cleaning time, clean more effectively and reduce costs when compared to other cleaning solutions. Small and mid-size manufacturing operations can get better process results and save money at the same time.

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How an Ultrasonic Cleaning System Works and the Benefits It Provides to Manufacturers

May 19, 2016

How an Ultrasonic Cleaning System Works and the Benefits It Provides to ManufacturersSmall and mid-size businesses and manufacturers can use an ultrasonic cleaning system to help improve their productivity. Such systems can remove contaminants and surface matter from components and can clean products before they are offered for sale. They will clean items such as machined parts, glass, ceramics and medical devices quickly and completely without using harsh chemicals. Businesses that have to clean products and manufacturers that require cleaning as part of their production can benefit from the gentle but effective cleaning action provided by ultrasonic cleaners such as Kaijo’s Phenix III TurnKey Ultrasonic Cleaning System.

How Ultrasonic Cleaning Systems Work

A turnkey ultrasonic cleaning system is made up of a generator, one or more transducers and a tank. The ultrasonic generator produces an electric signal at different frequencies and powers to actuate the transducers. The ultrasonic transducers convert the electrical signal into ultrasonic waves in the water within the tank. The water may have cleaning solutions added to improve the effectiveness of the ultrasonic cleaning process, depending on the nature of the contaminant to be removed.

When the ultrasonic transducers produce compression waves in the water, cavitation bubbles form in the liquid between the compression peaks. When a compression peak passes over the bubbles, they collapse and then form again after the peak travels on. This formation and collapsing of bubbles in the liquid in contact with the item to be cleaned results in a strong scrubbing action. The collapse of the bubbles is especially energetic and the bubbles remove any foreign material adhering to the surface to be cleaned.

Kaijo’s Turn Key System

Kaijo’s Phenix III Ultrasonic Cleaning System operates at 26 kHz or 38 kHz and delivers up to 1200 W of cleaning power. The two frequencies are ideal for general purpose cleaning, with the lower frequency providing robust cleaning with larger bubbles generated by the system and the higher frequency delivering gentler cleaning with smaller bubbles. The system comes as the Phenix III ultrasonic generator and a stainless steel tank with the transducers already installed. The system is easy to connect and can go into service right away.

The cost-effective Phenix ultrasonic generator is available in four models with outputs at the two frequencies and at 600 W or 1200 W. The output is adjustable in ten steps and the unit can be connected to 200 V to 240 V, 50/60 Hz (selectable). The compact unit weighs only 22 lbs. and can be operated from and external controller using the remote terminal.

The cleaning tank is available in sizes from about one cubic foot to the largest tank measuring about 4.5 cubit feet. The tank is made from one-eight inch thick gloss polished stainless steel for excellent ultrasonic cleaning performance. A Kaijo Water Resonance System to condition the water for superior ultrasonic cleaning can be added. The water resonance system increases the sound pressure and improves the cleaning action of the bubbles.

Kaijo ultrasonic cleaning systems are designed for low noise and no erosion of the parts and components to be cleaned. The tanks and transducer can withstand up to 100 degrees C for hot bath cleaning. For specific cleaning solutions, lower and higher frequency systems are also available.

Ultrasonic Cleaning System Benefits

Ultrasonic cleaning is often the lowest cost, quickest and most effective solution available to small and mid-sized businesses and manufacturing plants. Avoiding the cost of aggressive chemicals and of their neutralization and disposal can be a major cost factor. The systems can work very quickly, depending on the material to be removed. Light cleaning can be completed in a few minutes and the removal of heavier deposits often takes less than 15 or 20 minutes. The cleaning action of the tiny bubbles penetrates cavities and cleans irregular surfaces completely.

Ultrasonic technology is applicable to a wide variety of materials and can help make plant and business operations more productive while saving money. They represent an excellent investment for small and mid-sized operations seeking to improve their bottom line.

 

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