August 29, 2016
Industrial cleaning of machine parts, tools and components has traditionally meant cleaning with strong chemicals, blasting with streams of water and mechanical scrubbing. These techniques all have their drawbacks with regard to effective cleaning and they harm the environment by using large amounts of water with chemical runoff. Ultrasonic waves clean faster, better and need only plain water. There is a compelling case to be made for replacing traditional cleaning methods with industrial ultrasonic cleaners.
How Ultrasonic Cleaning Works
Industrial ultrasonic cleaning systems use an ultrasonic generator to produce high frequency electric signals with a frequency range of about 20 kHz up to 200 kHz. These signals are fed to a transducer that is immersed in a water bath. The transducer vibrates to convert the electrical signal to sound waves in the water.
The sound waves produce tiny cavitation bubbles that continuously appear and collapse as each sound wave passes. As they collapse, the bubbles scrub the surface they are cleaning and remove contaminants and foreign material. The cleaning action is more intense with larger bubbles at low frequencies and gentler with smaller bubbles at higher frequencies. The cleaning effect is quick, thorough and mechanical, using no solvents or other chemicals.
For managers at manufacturing facilities faced with the high cost of cleaning chemicals and the costs of complying with environmental regulations, ultrasonic cleaners represent an attractive alternative to traditional cleaning methods. But even beyond the question of cost savings is the fact that ultrasonic waves clean more effectively than chemicals and solvents.
The three additional advantages of ultrasonic cleaning are that these systems clean small holes and crevices, cleaning takes less time and they don’t damage the parts being cleaned. Ultrasonic waves bend around corners and the cleaning water enters small holes and cracks that chemicals can only diffuse into slowly and mechanical brushes can’t penetrate. The intense mechanical bubble cleaning action works more quickly than waiting for chemicals to dissolve or soften grime. While the bubbles are quick and intense, once the correct frequency is applied they don’t damage the underlying material to be cleaned as scrubbing, corrosive chemicals or water blasting might do.
Kaijo’s Ultrasonic Technology
Kaijo Corporation has been a global leader in ultrasonic technology since 1948 and developed its first ultrasonic cleaner in 1957. Since then, the company has continuously improved the effectiveness of the cleaning technology, added to their product line of industrial ultrasonic cleaners and reduced the costs of the ultrasonic cleaning equipment. Today Kaijo’s ultrasonic cleaning systems offer state-of-the-art technology with excellent cleaning performance at a price that is highly competitive with that of traditional cleaning systems.
Kaijo’s Industrial Ultrasonic Cleaners
Kaijo’s product line includes the Phenix III Turn Key Ultrasonic Cleaning System for general industrial use and specialized systems such as the Quava Mini table top ultrasonic system for smaller more delicate parts. Individual components include ultrasonic generators for a wide range of frequencies, transducers for producing the sound waves in water and tanks for the cleaning water and the parts to be cleaned.
Customers who want to change from traditional cleaning methods can purchase the latest technology in a turnkey ultrasonic cleaning system or buy an ultrasonic generator and transducers to use with existing tanks. Kaijo’s experienced support team can help customers with their choices and ensure that they get the best system suited for their particular applications. Call Kaijo at 408 675-5575 or email [email protected] for a free consultation or quote on using ultrasonic technology for your application.Read More
August 16, 2016
Industrial manufacturing facility managers and business owners are finding that ultrasonic cleaning systems offer significant advantages over traditional chemical-based cleaning methods. Ultrasonic systems provide significant operational cost savings because they don’t require the use of chemicals and the costs of compliance with environmental regulations. Ultrasonic systems clean faster and more effectively and can clean the surface of oddly shaped devices or parts. The main question that remains before making a purchasing decision is regarding the frequency that will be best for the particular cleaning application.
Ultrasonic cleaning systems operate at frequencies between about 20 kHz and 200 kHz. The cleaning system includes a generator, transducer and a cleaning tank. The transducer creates ultrasonic waves that produce bubbles in the water of the cleaning tank. Low frequencies generate larger bubbles and more intensive cleaning while the small bubbles of high frequencies will clean more gently. A 40 kHz ultrasonic transducer generates mid-range to large bubbles that clean a wide range of manufactured parts well but are not as aggressive as the large bubbles generated at the 20 kHz range.
Ultrasonic Cleaning System Components
In an ultrasonic cleaning system, a generator produces the high-frequency electric signal and the transducer converts the signal to sound waves in water. One or more transducers are located inside the tank that holds the cleaning solution and the parts to be cleaned. Transducers can be designed to handle different frequencies but they have to match the frequencies produced by the ultrasonic generator. The tanks are the same no matter what frequency is used.
For a 40 kHz generator, corresponding 40 kHz ultrasonic transducers can be immersible, bolt-on or tank mounted. Immersible transducers are supplied as separate units with an electrical cable connection and can be moved and placed anywhere in the cleaning tank. Bolt-on transducers are bolted onto the bottom or sides of a tank while mounted transducers are already installed.
Turnkey systems may come with a tank that has the transducers already mounted or has bolt-on transducers that can be changed for different frequencies. For customers purchasing just the transducers or wanting to retrofit an existing tank, the immersible or bolt-on transducers may be more appropriate because they offer more installation flexibility.
Parts to be Cleaned
The parts or components to be cleaned and the nature of contamination or dirt determine which frequency is the most appropriate for ultrasonic cleaning. Heavy deposits to be removed from robust parts require a low frequency with intensive cleaning. Delicate parts with only a dirty film or microscopic particles require high frequencies. The mid-range frequency of 40 kHz combines the most desirable features of both extremes.
For example, at 40 kHz, a cleaning system can effectively clean machined parts, industrial devices, ceramics, jewelry, electronics such as hard disk drive parts, wires and glass parts such as lenses. Both heavy contamination and light films are removed effectively without damaging the surface of the parts to be cleaned.
Kaijo can supply 40 kHz nominal (38 kHz actual) transducers in immersible, bolt-on and tank-mounted configurations. The transducers are available in 600 W and 1200 W models and can withstand cleaning solution temperatures of up to 100 degrees Celsius. Kaijo has the ultrasonic cleaning technology and experience to help customers choose the transducers or ultrasonic cleaning solutions most appropriate for their applications. For a free consultation or quote on selecting the right ultrasonic cleaning system and transducer for your specific cleaning application call Kaijo at 408 675-5575 or email [email protected].Read More