September 29, 2017
The aerospace industry manufactures high-precision parts as well as repairing and maintaining complex engines and machinery. Production parts and parts from maintenance and repair operations are often contaminated by dirt, grease, oil or other lubricants deriving from normal operation or from production processes. Traditionally these parts have been cleaned manually by scrubbing or washing with aggressive solvents or other chemicals. Ultrasonic cleaning systems offer an alternative that saves time and money through an environmentally friendly process that cleans parts quickly and efficiently.
How Ultrasonic Cleaning Systems Work
Ultrasonic cleaning systems consist of ultrasonic generators, transducers and cleaning tanks. The ultrasonic generators produce the high frequency electrical signal that the transducers, located inside the cleaning tanks, convert to ultrasonic waves in the cleaning fluid. The ultrasonic waves create microscopic bubbles that scrub the parts immersed in the cleaning fluid and remove surface contaminants.
The process works quickly and cleans completely everywhere the cleaning fluid can penetrate, even in crevices, tubes, holes and other hard-to-reach places. The cleaning fluid can be plain water or mild detergents can be added for improved cleaning performance. When heavy grease or similar heat-sensitive materials have to be cleaned, the cleaning fluid can be heated to soften the contaminant and allow cleaning to be completed faster.
Transitioning to Ultrasonic Cleaning
The aerospace industry can change over to ultrasonic cleaning easily and smoothly because the cleaning tasks are often discrete and clearly defined. For example, machining metal parts or extruding tubes often involves coating the metal with lubricating oil. When the parts come off the line, they have to be cleaned. Traditional cleaning involves a cleaning station that spray washes or scrubs the parts. The station can be replaced with a turn-key ultrasonic cleaning system that works more quickly. Because cleaning now takes less time, the rest of the production process can remain unchanged although overall productivity may well increase.
For repairs and maintenance, parts may have to be cleaned before being re-installed. Such parts are often soaked in chemicals to remove contaminants. The same soaking tanks can be used for ultrasonic cleaning by installing transducers in the existing tanks. The production line remains unchanged but the cleaning is accomplished faster and without chemicals.
Advantages of Ultrasonic Cleaning
Using ultrasonic cleaning systems allows aerospace companies satisfy their cleaning requirements more quickly and at a lower cost than with traditional cleaning methods. Ultrasonic cleaning takes less time than mechanical or manual scrubbing and removes contaminants completely. A quick rinse and drying takes less time than a complete wash and possibly neutralization of cleaning chemicals used with other cleaning methods. Storage, handling and disposal costs for toxic chemicals are eliminated as are equipment costs for ventilation, fume hoods and employee safety. Ultrasonic cleaning uses only mild detergents and does not pose any hazards for workers.
In addition to faster cleaning and reduced costs, ultrasonic cleaning systems offer better cleaning performance. Lower frequencies deliver robust cleaning action with larger bubbles while higher frequencies generate smaller bubbles and more gentle cleaning. Customers can fine tune cleaning performance by selecting a frequency that cleans quickly to remove contaminants while leaving the underlying surface clean and smooth. Even delicate machined parts can be cleaned effectively at high frequencies while heavy dirt can be removed with low frequency systems.
Ultrasonic Cleaning Benefits
The lower costs, reduced cleaning time and safe cleaning method provided by ultrasonic cleaning systems can deliver substantial benefits to aerospace manufacturers. Production facilities become more efficient and improved cleaning performance results in higher customer satisfaction and fewer problems as a result of incomplete cleaning.
Ultrasonic cleaning technology leader Kaijo has supplied ultrasonic cleaners to the aerospace industry and has the experience and expertise to help aerospace manufacturers and sub-contractors transition to using ultrasonic cleaning. Kaijo can supply a complete line of ultrasonic cleaning systems, from turn-key installations to separate components and customized equipment. The company can advise customers how best to meet their ultrasonic cleaning needs, make specific recommendations and ensure that the anticipated benefits are realized. For a free quote or consultation to determine how ultrasonic cleaning can be used for your specific industry application contact Kaijo or email [email protected].Read More
September 21, 2017
Kaijo’s new Phenix Hyper ultrasonic cleaning generator along with the Hyper immersible transducer deliver improved cleaning performance using the latest ultrasonic technology. The generator can be used with the standard sweep frequency mode but also features the new Hyper mode that improves cleaning effectiveness with a uniform ultrasonic pattern that completely fills the process tank.
Typical ultrasonic controls are included in the generator’s standard functions and it can produce up to 1200 W output power. Its user-friendly operator interface makes process control transparent and an assortment of alarm, display and interlock functions ensure safe and reliable operation. Together with the Hyper immersible transducer, the new system helps avoid incomplete or non-uniform cleaning and reduces the possibility of surface damage to cleaned parts. Hyper mode allows finely tuned cleaning and removes small particles and deposits completely.
Phenix Hyper Ultrasonic Generator Features
Operating at 78 kHz and delivering adjustable output power up to 1200 watts, Kaijo’s Phenix Hyper ultrasonic cleaning generator incorporates advanced technology and a complete set of controls and alarms. Specific generator functions include:
- Auto tuning – the generator automatically adjusts to changing process environments
- Oscillation verification and alarm
- Choice of standard sweep mode or advanced Hyper mode
- Eight-level power adjustment through remote oscillation terminals
- Remote interlock terminals
The new vacuum fluorescent display (VFD) shows operators key process variables, alarms and settings and allows control of the cleaning process. Output power is displayed in teal time and alarms displayed include upper output limit, lower output limit, transducer error, abnormal inner temperature, interlock alarm and six different types of memory error.
The ultrasonic generator provides the following characteristics:
- Output 10 to 1200 Watts adjustable in 1 watt increments
- Dimensions 350 x 440 x 165 mm, W x D x H, weight 11 kg
- Power supply 200 to 240 V, single phase, 50/60 Hz, 12 A
- Ambient 1 to 40 degrees C, 0-80 percent humidity (no condensation)
Working with the new Hyper immersible ultrasonic transducer, the system represents an easy-to-use turn-key solution for applications with an existing cleaning tank. The Hyper ultrasonic transducer is matched to the Phenix Hyper generator with a 78 kHz operating frequency and a 1200 W maximum power capacity. The transducer is made of a high polish stainless steel, weighs 17 kg and measures 365 x 280 x 100 mm. It is suitable for immersion in cleaning solutions up to 80 degrees C.
Phenix Hyper Generator and Transducer Benefits
The new ultrasonic cleaning generator and transducer set combines improved cleaning with easier operation and more reliable performance. Parts made from metal, ceramics and glass can be cleaned effectively on all sides, even when they have complex shapes with hard-to-reach places. The Hyper ultrasonic cleaning technology works wherever the cleaning solution can penetrate, removing fine contaminants quickly and completely throughout the cleaning tank.
Benefits of the new technology include:
- The Hyper Mode achieves three-dimensional cleaning of complex shaped objects to insure all surfaces of irregular shaped objects are cleaned
- Solutions to problems of poor or incomplete cleaning or surface damage to cleaned parts
- Can be used with plain water or with mild detergents in cleaning solutions heated up to 80 degrees C
- User-friendly interface is easy to use
- The generator and transducer can be placed into service immediately in a turn-key configuration without a complicated installation and set-up
Kaijo can help customers with ultrasonic cleaning solutions and advise where the new Hyper technology would be appropriate. With extensive experience and unparalleled expertise in the ultrasonic field, Kaijo can evaluate a customer’s cleaning needs and make recommendations from its complete line of ultrasonic cleaning products, including those using the new Hyper technology.Read More