Ultrasonic Systems for Precise Cleaning Applications
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Why Industrial Ultrasonic Cleaners Are Used by Plastic Manufacturers

August 28, 2018

Why Industrial Ultrasonic Cleaners are used by plastic manufacturersManufacturers of plastic products have to clean their equipment between production runs and often have to clean the plastic products they manufacture as well. Also depending on the end use of the products, different standards of cleanliness for the equipment as well as the materials used may apply. Products provided for food or medicine will require high levels of cleanliness while other, less critical applications may not have the same stringent requirements.

Traditional cleaning methods use mechanical scrubbing for rough cleaning, harsh chemicals for dissolving stubborn dirt and other chemicals for sanitary cleaning. These cleaning methods are expensive, not environmentally friendly and may require additional handling and labor. High performance industrial ultrasonic cleaners can deliver different levels of cleaning action by varying the frequencies and the power. They work without harsh chemicals and clean quickly and effectively. Ultrasonic cleaning bubbles responsible for the cleaning action penetrate wherever there is cleaning liquid and cleaning completely removes contaminants down to the plastic base or tool material.

Advantages of Ultrasonic Systems for Cleaning Plastic Products and Manufacturing Equipment

Industrial ultrasonic cleaners consist of a high power ultrasonic generator, a cleaning tank filled with water and an ultrasonic transducer mounted in the tank. A mild solvent may be added to the water to help dissolve some contaminants and the cleaning solution may be heated to soften grease and rubbery deposits. No strong chemicals are used and there is no requirement for mechanical scrubbing. The benefits of using such a system include the following:

  • Reduced costs due to absence of chemicals. No costs for purchase of expensive chemicals or their storage, handling and disposal.
  • Reduced labor costs because no manual scrubbing, scraping or pressure washing is required.
  • Increased worker safety because the ultrasonic cleaning process is completely safe and does not need supervision or monitoring.
  • Less time spent on cleaning because the one-step ultrasonic process is quick.
  • Better cleaning performance because ultrasonic cleaning penetrates into holes and crevices and cleans everywhere, completely.
  • Longer tool and mold life because ultrasonic cleaning does not scratch or otherwise damage the surfaces of tools and molds.
  • Better output quality because the ultrasonic cleaning parameters can be chosen to match specific cleaning requirements by using proper frequencies and power levels.

Once an industrial ultrasonic system has been matched to the requirements of an application by a competent ultrasonic equipment manufacturer, the above benefits automatically flow from the use of the new system. If cleaning applications are varied, such as having to clean a wide variety of products or working with a number of different plastic materials, ultrasonic systems with different power levels and multiple frequencies are available.

Ultrasonic Cleaning Benefits

Plastic manufacturing plants that switch from traditional cleaning methods using chemical baths and mechanical dirt removal to ultrasonic cleaning achieve better facility performance and acquire several competitive advantages. The cost savings from labor and chemicals are substantial but there are additional savings from reduced cleaning times. When the ultrasonic system is adjusted to give the desired cleaning intensity, cleaning performance is better and therefore output quality is improved in general.

Additional improvements are achieved from the ability of ultrasonic systems to clean interior surfaces and hard-to-access areas. With traditional cleaning, such areas were either not cleaned or were cleaned with special tools and measures. Such efforts are no longer required with the new systems.

The key to effectively using an ultrasonic cleaner is to use a system that matches the requirements of the cleaning application. Kaijo has the experience and the complete line of ultrasonic cleaning products to deliver the system that is needed. Using the new system will deliver benefits that come from the advantages of the ultrasonic cleaning technology.

 

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How to Buy the Right Ultrasonic Cleaner for Your Application – Part I

July 30, 2018

 

Ultrasonic Cleaner SystemsIndustrial ultrasonic cleaners can clean parts quickly and completely if they have the right characteristics for the application. Ultrasonic cleaning systems are made up of a generator, one or more transducers, and a cleaning tank. Each component has to be selected correctly and they have to work together for the system to live up to its cleaning potential. Systems can be designed to clean one kind of part or they can be flexible and clean many different kinds. The key to selecting the right system is to be clear about what cleaning has to be done and what the required result should be.

The Cleaning Application

Cleaning parts effectively depends on the kind of part that has to be cleaned and the type of contaminants that are on the parts. When the right industrial ultrasonic cleaner is used, the surfaces of the parts to be cleaned are unaffected while the substances that have to be removed are washed away quickly. Ultrasonic cleaners remove light contamination such as dust, films and residue quickly and completely, even when the parts are odd shapes or have holes, cracks and crevices. The ultrasonic cleaners act wherever the cleaning solution can penetrate so interior cavities are also cleaned as long as the cleaning solution can enter.

When contamination is heavy, additional measures may be appropriate. For thick deposits of oil or grease, heating the cleaning solution helps speed cleaning because the oil and grease become softer and easier to remove. For some difficult deposits, mild solvents that act on the contaminant may also help clean the parts. If a cleaning application falls into these categories, the ultrasonic cleaning system should be able to handle solvents and heat the cleaning solution.

Size and Power

The size of the parts to be cleaned determines the cleaning tank size and influences the power required for the industrial ultrasonic cleaner. For unusually shaped parts, such as long thin parts or large flat ones, a custom tank may be appropriate to avoid having to power a large amount of cleaning solution, most of which is empty. In any case, the tank has to be slightly larger than the longest dimension of the parts to be cleaned.

Larger tanks will need more power but the most important factor is that the ultrasonic waves have to be evenly distributed and reach all sections of the cleaning tank. Too much power may cause pitting on the surfaces of the parts so buying a system with the right power is important. A competent manufacturer can help select the required power levels or recommend a system for which the power level is adjustable, depending on the cleaning application.

How to Immerse the Parts to be Cleaned

Since ultrasonic cleaning is carried out by means of high-frequency sound waves in the cleaning solution, both the tank walls and the parts to be cleaned may vibrate slightly as cleaning takes place. This means parts must be suspended in the cleaning solution to avoid contact between the parts and the tank walls or bottom because the vibrations can cause damage.

A basket that fits inside the tank can hold the parts safely suspended in the cleaning solution but the cleaning tank will have to be slightly larger to accommodate the basket. Baskets are usually stainless steel but they can be coated to hold delicate parts without scratching.

Kaijo’s Experts can Provide Help

With extensive experience in industrial ultrasonic cleaning systems, Kaijo can help customers select the ultrasonic cleaner best suited to their needs. Kaijo will provide free consultation on size, power, baskets as well as the appropriate frequency to use for a given cleaning application. They offer an extensive product line of ultrasonic cleaning equipment to address the needs of many different kinds of industrial cleaning applications.

 

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Should De-Ionized Water Be Used with an Ultrasonic Cleaning System?

October 16, 2017

Should De-Ionized Water Be Used with an Ultrasonic Cleaning System?De-ionized (DI) water is plain water that has been purified to remove contaminants such as metals and salts (ions). When DI water is used in ultrasonic cleaning systems it can improve cleaning performance, depending on the parts to be cleaned and the nature of the contaminants to be removed. Such increased cleaning performance is especially important for delicate parts that can’t tolerate detergents. For these cleaning applications, using slightly heated DI water makes the ultrasonic cleaning process more effective than when using plain water.

When to Use DI Water

While ultrasonic cleaning systems will work with plain water, adding a mild detergent can often speed up the cleaning action. Delicate parts such as semiconductor wafers, printed circuit boards and some medical devices might be damaged by using detergents, so in these applications cleaning with DI water is recommended. The DI water helps the ultrasonic bubbles clean rapidly, even in the absence of detergents.

For stubborn grease and oil contamination, DI water is not effective in speeding up the cleaning process. Instead, a mild detergent or solvent specific to the particular contaminant is needed. Sometimes using a solvent that attacks the dirt but doesn’t harm the part to be cleaned can be found. For other types of cleaning, the use of DI water throughout the cleaning process is beneficial.

When an ultrasonic cleaning system has removed dirt from the parts to be cleaned, the cleaning solution is drained away but the parts often still have to be rinsed to finish the cleaning process. Normal water has dissolved minerals and other impurities so that rinsing can leave a deposit. After the parts are dry, they may have spots or films left over from the evaporated water. If this is not acceptable, DI water can be used for rinsing. Since it contains no impurities, dried parts and components will be completely clean and free of spots.

How DI Water Helps Clean

DI water helps ultrasonic systems clean parts and components in two ways. DI water without any additives has no impurities and therefore acts like a sponge. Once the microscopic bubbles generated by the ultrasonic cleaning system have dislodged tiny particles, the DI water quickly absorbs any dissolved substances. Normal water already contains impurities and therefore doesn’t absorb contaminants to the same extent.

A second way in which DI water helps ultrasonic systems clean quickly applies when mild detergents are added to the system. When normal water is used, the detergent first absorbs the impurities in the water before going on to help clean away dirt. With DI water, there are no impurities to reduce the effectiveness of the detergent and all of the cleaning power goes to absorb contaminants removed from the parts to be cleaned.

As a result, the use of DI water can improve the effectiveness of ultrasonic cleaning systems in general. It speeds up cleaning for applications that can’t use detergents and helps systems clean when detergents are required. In both cases, rinsing with DI water will remove any remaining impurities.

How Kaijo Can Help

Kaijo has over 65 years of experience with ultrasonic technology and can help with specific customer applications. The company will provide free consultation and advice on using ultrasonic cleaning systems and can help determine whether the use of DI water is effective in each customer’s application. As well as giving expert advice, Kaijo can follow up with concrete proposals drawn from its extensive line of ultrasonic cleaning systems and components. In addition to guidance on DI water, customers can get advice on which systems will work best for them, what ultrasonic frequencies to use for their cleaning applications and how to best configure their systems.

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How the Immersible Ultrasonic Transducer is Used in Industrial Cleaning Applications

September 19, 2016

Immersible Ultrasonic Transducers Used in Industrial Cleaning ApplicationsManagers and process engineers at industrial facilities can use ultrasonic cleaning solutions to reduce the use of chemicals and improve cleaning performance. While turnkey solutions that include ultrasonic generators, transducer and tanks are available, specific industrial cleaning applications often require a more flexible solution.  A portable immersible ultrasonic transducer is ideal for meeting these kinds of cleaning requirements.

Drop-In Immersible Ultrasonic Transducer

Kaijo offers several models of immersible ultrasonic transducers. These units can be dropped into existing tanks and they work with any Kaijo ultrasonic generator. They are available in 600 Watt and 1200 Watt versions and operate at frequencies from 26 kHz to 160 kHz. The transducers are hermetically sealed and welded and the enclosure is polished 316L stainless steel. The stainless steel enclosure does not suffer from cavitation erosion and the transducers maintain their performance characteristics over time without degradation.

Typical applications include cleaning parts and components in existing tanks or cleaning items too large to fit in the standard tanks of turnkey systems. Additional requirements involve ultrasonic cleaning at several different frequencies and with different transducer configurations. Kaijo’s immersible ultrasonic transducers can be placed in any tank in single or multiple configurations. They can be mounted horizontally or vertically and transducers can easily be changed to handle different cleaning problems.

Using Immersible Ultrasonic Transducers

Facility managers and process engineers faced with industrial cleaning tasks can save time and money by replacing chemical-based cleaning and mechanical scrubbing with ultrasonic cleaning. Immersible transducers can often be placed into the tanks already used for cleaning. Instead of using harsh chemicals, the tanks can be filled with water only or water with a mild solvent. The transducers generate tiny bubbles that clean rapidly and thoroughly.

A key factor in ensuring effective cleaning with ultrasonic transducers is to select the correct power and frequency. Low frequencies such as 26 kHz and 38 kHz generate comparatively large cavitation bubbles that may damage delicate parts when the bubbles collapse during the cleaning action. High frequencies such as 130 kHz and 160 kHz produce smaller bubbles that collapse with less energy and result in finer, gentler cleaning. The power of the transducer affects the number of bubbles the transducer generates. A larger tank will require higher power transducers or several transducers to handle the required cleaning.

For typical industrial cleaning applications a plant may have to clean many types of components and remove various materials. Immersible ultrasonic transducers can provide the flexible cleaning solution required for such situations. For small, delicate parts, a single high frequency transducer might be placed into a small tank. For robust parts with heavy contamination, a low frequency transducer can be placed into the same tank. For large items, several transducers of an appropriate frequency can be placed into a large tank. When a company keeps several transducers of different frequencies and powers on hand, it can respond to various cleaning requirements easily and efficiently.

Immersible Ultrasonic Transducer Benefits

Companies that replace their chemical and mechanical cleaning systems with ultrasonic cleaning can reduce chemical costs, environmental contamination and improve facility productivity. The immersible transducers are easy to install and move and provide reliable service and trouble-free operation. The flexibility of immersible ultrasonic transducers means companies can start with one or a few transducer for a specific cleaning application and add additional models when they become convinced of the effectiveness of ultrasonic cleaning. Call Kaijo at 408 675-5575 or email [email protected] for a free consultation or quote on using their ultrasonic technology for your application.

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No Need for Chemicals – Ultrasonic Waves Clean in Water

August 29, 2016

No Need for Chemicals - Ultrasonic Waves Clean in WaterIndustrial 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.

Advantages

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.

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Why 40kHz Ultrasonic Transducers Are Used by Manufacturers in Cleaning Applications

August 16, 2016

Why 40kHz Ultrasonic Transducers Are Used by Manufacturers in Cleaning ApplicationsIndustrial 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’s 40 kHz Transducers

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].

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Why a Mini Ultrasonic Generator System May Be the Best Choice for Your Device Cleaning Requirements

July 28, 2016

Why a Mini Ultrasonic Generator System May Be the Best Choice for Your Device Cleaning RequirementsUltrasonic cleaning is an effective alternative to cleaning parts and components using chemicals, agitation and scrubbing. The bubbles produced by an ultrasonic generator can clean stains and contaminants with robust cleaning action at low ultrasonic frequencies while high frequency cleaning can remove microscopic particles with gentle cleaning action. Ultrasonic cleaning is fast, cost effective and environmentally friendly, delivering complete cleaning solutions for all shapes and materials.

Kaijo’s Quava Mini ultrasonic generator can clean small parts at a wide range of frequencies. The generator and its associated tank/transducer combination are versatile tabletop units designed for all-purpose ultrasonic cleaning. Manufacturing and laboratory facilities that have either specific cleaning requirements or often need to clean a variety of manufactured components may find that the Quava Mini system represents the ideal solution for their needs.

Quava Mini Characteristics

Kaijo’s Quava Mini ultrasonic generator is available in two models. The low frequency model delivers either 26/78/130 kHz or 38/100/160 kHz at up to 50 W. The high frequency model produces 200/430/950 kHz or 1.6 MHz at up to 100 W. Both models are powered by 100 to 240 V AC and weigh 4.6 kg while fitting easily on a desk.

The transducers to make up a turnkey ultrasonic cleaning system are available in multiple frequencies at the low end and single high frequencies. The low frequency models work with either 26/78/130 kHz or 38/100/160 kHz while the high frequency models are available for either 200 kHz, 430 kHz, 950 kHz or 1.6 MHz. For a complete range of low or high frequencies an installation needs either the low range generator with the two multi-frequency transducers or the high range generator with the four single-frequency transducers.

The cleaning tank units that form a single assembly with the transducers complete the turnkey installation. They are large enough to clean parts about 140 mm long and are available in PVC or quartz glass. The same tank model is used for all frequencies and transducers.

Quava Mini Features

The Quava Mini turn-key ultrasonic cleaning system is designed to provide an easy-to-use low-cost solution to the cleaning of small manufactured parts. Installation and assembly are trivial, consisting of placing the ultrasonic generator on a table or desk, mounting the tank unit on the transducer with the appropriate frequency and plugging in the units. Once the tank is filled with the cleaning solution and the item to be cleaned is placed in the tank, ultrasonic cleaning can often be completed in a few minutes.

The Quava Mini ultrasonic generator has an LED display for precise control of the power delivered to the transducer. Power can be varied in steps of 0.1 W for precise control of cleaning power. For the low frequency model, different cleaning frequencies can be selected without changing the system configuration while for the high frequency model changing the transducer to match the selected frequency is easy and fast. Low frequencies create larger bubbles and a more robust cleaning action while the high frequency bubbles are smaller and less energetic. Increasing the power delivered to the transducer results in more bubbles at a given frequency.

When evaluating different cleaning methods for small parts, the low cost of both acquisition and operation together with its high cleaning performance and flexibility makes the Kaijo Mini ultrasonic cleaning system an effective choice. Call 408 675-5575 or email [email protected] for a free quote or consultation on using Kaijo’s mini ultrasonic system for your application.

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Selecting Ultrasonic Parts Cleaners for Your Industrial Cleaning Application

June 29, 2016

Selecting Ultrasonic Parts Cleaners for Your Industrial Cleaning ApplicationUltrasonic cleaners work by generating ultrasonic acoustic waves into a cleaning solution. During the expansion phase of the wave, the low pressure results in cavitation bubbles in the liquid while the subsequent compression phase collapses the bubbles suddenly. This bubble action removes impurities and contamination from surfaces to be cleaned. Ultrasonic parts cleaners are fast and cost-effective, eliminating the use of harsh chemicals and the mechanical scrubbing required for traditional cleaning solutions.

Low frequency cleaners using ultrasonic frequencies of 26 kHz or 38 kHz use a much longer wavelength than high frequency cleaning systems operating above 200 kHz or in the MHz range. With a lower frequency and longer wavelength, there is more time for the bubbles to grow and the energy with which they collapse is higher. At the highest frequencies the bubbles are very small and the cleaning action from the collapse of the bubbles is very gentle. While cleaning intensity is controlled by the frequency, the number of bubbles depends on the power of the ultrasonic parts cleaner. High power units work faster and can handle larger parts while low power cleaners are for small systems.

Low Frequency Ultrasonic Parts Cleaners for Robust Cleaning

Kaijo ultrasonic cleaning systems such as those using the Phenix III ultrasonic generator operate at 26 kHz or 38 kHz and are suited for the cleaning of robust parts with stable surfaces. If an ultrasonic parts cleaner is used for parts that are not suitable, surface pitting can result and the parts may be damaged. Systems based on the Phenix III are suitable for cleaning machined parts, ceramics, glass, medical devices and jewelry. The generator is available with outputs of 600 W and 1200 W for cleaning parts of different sizes and the corresponding tanks can hold small or large parts.

Systems such as those based on the Phenix III generator are suitable for general purpose cleaning in a manufacturing environment that does not deal with delicate parts. An ultrasonic parts cleaner suitable for a wide variety of applications, the flexible Phenix III is a cost effective and reliable solution. It can be purchased as an immersible set for an existing tank or in a turnkey configuration with Kaijo transducers and tanks designed specifically to work with the ultrasonic generator.

High Frequency Cleaning for Delicate Parts

High frequency ultrasonic cleaners are used for parts that could be damaged by the robust bubble action present at 26 kHz and 38 kHz and for light surface contamination. Frequencies up to the MHz range can clean parts such as printed circuits, semiconductor components, optical components and precision-machined parts. The cleaning action is powerful enough to remove surface films and particles down to sub-micron sizes but gentle enough so that relatively soft surfaces and microscopic details are not affected.

Ultrasonic cleaners such as the Kaijo Quava models can generate a wide variety of frequencies and powers to deliver the specific cleaning intensity and power required for a particular application. Decision makers and production managers in manufacturing plants that have part cleaning requirements have to decide whether to purchase a low-frequency all-purpose ultrasonic parts cleaner for robust cleaning, a high-frequency model if only delicate parts are to be cleaned, or a general purpose parts cleaner able to generate both low and high frequencies. Kaijo’s ultrasonic parts cleaners are available to cover all these needs. If you need more information on any of Kaijo’s products and want a quote call 408-675-5575 or email [email protected].

 

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How Ultrasonic Tanks Are Used in Industrial Cleaning Applications

June 21, 2016

How Ultrasonic Tanks Are Used in Industrial Cleaning ApplicationsIndustrial cleaning systems that utilize ultrasonic technology can clean a variety of objects and parts without aggressive chemicals or rough scrubbing. Ultrasonic tanks hold the cleaning solution and the part to be cleaned. The tank mounted transducers generate the ultrasonic signal. Ultrasonic cleaning is especially suitable for objects such as ceramics, glass, optical devices, medical devices and machined parts.

When the ultrasonic transducers are used in a water-based cleaning solution, the ultrasonic energy creates cavitation bubbles that form and collapse at the ultrasonic frequency. The part to be cleaned is suspended in the tank and immersed in the cleaning solution; the bubble action removes surface contamination. A typical cleaning cycle might take 10 minutes and even parts with complex shapes can be cleaned effectively.

Kaijo’s ultrasonic tanks and baths are specifically designed for ultrasonic cleaning applications. The tanks have to be built to withstand ultrasonic sound waves and to support the transducers in their cleaning action. Systems are available with transducers and generators in turnkey configurations and custom systems can be designed to meet specific needs.

Tank Characteristics

The ultrasonic tanks are made of gloss polished, thick stainless steel for excellent durability. Standard sizes range from 270 mm x 370 mm (10.6 in. x 14.6 in.) with a height of 250 mm (9.8 in.) to 520 mm x 550 mm (20.5 in. x 21.7 in.) with a height of 300 mm (11.8 in.). Kaijo can also provide custom sizes.

Tanks with transducers and generators are available in a choice of ten different frequencies. Lower frequencies deliver larger bubbles and more robust cleaning while the higher frequencies are used for more delicate cleaning action. Systems and tanks are available with power outputs of 600 W and 1200 W per generator. The higher the power the more bubbles are generated and the more powerful the cleaning action.

System Options

In addition to providing turnkey systems, Kaijo offers matched sets of generators and transducers for installation into existing tanks. A user can install the transducers in the tanks and connect the ultrasonic generators to construct complete ultrasonic cleaning systems.

Transducers types are immersible, bolt-on or tank mounted. Immersible transducers are independent units that can be placed in tanks horizontally or vertically while bolt-on and mounted transducers can be placed at the bottom or on the sides of the tank. The transducers have heavy metal plates to transmit the ultrasonic energy to the liquid and they are designed to withstand a hot, ultrasonic cleaning environment.

Kaijo’s ultrasonic generators are matched to their transducers and to produce high performance cleaning action. Generators such as the Phenix III are cost effective, flexible solutions that work well with the Kaijo ultrasonic tanks and transducers operating at 26 kHz or 38 kHz. These and the Kaijo turnkey ultrasonic cleaning systems offer unparalleled savings in cost and time compared to other types of cleaning systems. The ultrasonic bubbles remove all kinds of foreign matter from part surfaces and can clean inside holes and crevices where other cleaning methods fail. In addition, ultrasonic cleaning is environmentally friendly by eliminating harsh cleaning chemicals and cleans effectively without mechanical damage to the items to be cleaned.

Ultrasonic tanks and baths together with Kaijo’s transducers and generators or the Phenix III turnkey ultrasonic cleaning systems represent a cost-effective and reliable cleaning solution to a wide variety of industrial and research lab cleaning needs. If you have any questions about using ultrasonic technology for your application or need a quote on any of Kaijo’s ultrasonic baths and tanks call 408-675-5575 or email [email protected].

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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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