Ultrasonic Systems for Precise Cleaning Applications
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How to Buy the Right Ultrasonic Cleaner for Your Application -Part 2

August 13, 2018

Ultrasonic cleaning systemsThe most important considerations in choosing an ultrasonic cleaning system are the size of the tank, the frequency of the system and the power it can handle. Accessories such as a cleaning tank temperature heater and a basket to hold the parts must also be considered. Once these basic characteristics are fixed and the type of system required for the cleaning application is clear, additional options are available that may improve cleaning performance and speed up the cleaning process, depending on the parts to be cleaned and the contaminants to be removed.

Cleaning Tank Heater

Ultrasonic cleaners work by generating microscopic bubbles that scrub surfaces clean and remove surface contamination. When contaminants are hard deposits, the bubbles work more slowly because the deposits either absorb some of their energy or are too hard to immediately be broken up and washed away. Typical deposits and contaminants of this type include grease, engine deposits and burnt oil or carbon.

Such contamination is difficult to remove by any cleaning method but heat usually helps soften the deposits or loosen them from the underlying surface. When the cleaning solution of an ultrasonic cleaning system tank is heated, the bubbles act much faster and the cleaning process is completed in less time.

Tank heaters are a useful option for ultrasonic cleaning systems but they have to be designed for the application. The cleaning solution may contain a mild solvent but it is mostly water that boils at 100 degrees centigrade. As a result, the heat settings should be controlled to make sure the cleaning solution does not start boiling.

The cleaning tank also contains ultrasonic transducers that work with electronic parts sensitive to high temperatures. If the cleaning solution is going to be heated to a point just under boiling temperatures, the transducers must be able to withstand 100 degree centigrade heat. For applications that require the tank heater option, making sure that the system is designed to support it is critical.

Using Sweep Frequencies

An ultrasonic cleaning system is designed to operate at a certain frequency at which optimum cleaning results are achieved due to the size of the microscopic bubbles and the cleaning action intensity. At a given frequency, a system may experience a number of unpredictable negative effects. There may be dead spots in the cleaning tank where ultrasonic waves cancel each other out and no cleaning occurs. Resonance vibrations may appear and threaten to damage equipment or the parts to be cleaned. Sweep frequency modes reduce these effects.

When using sweep frequencies, the ultrasonic cleaner frequency varies around a central value. If ultrasonic waves are cancelling out somewhere in the tank, changing the frequency slightly will stop this effect or displace it temporarily to another tank location. Overall, cleaning is more even. Changing the frequency also stops resonance vibrations because they occur at one particular frequency. Using sweep frequencies to continuously vary the operating frequency helps to achieve better cleaning performance.

Water Resonance System

A water resonance system treats water destined for the cleaning tank to promote the formation of cavitation bubbles and help ensure even cleaning action throughout the tank. The water treatment of a water resonance system provides an even distribution of nuclei essential to bubble formation. With the nuclei distributed evenly, bubbles form everywhere in the cleaning solution rather than mainly above the ultrasonic transducer. A water resonance system helps ensure even cleaning action on everything placed in the cleaning tank.

Kaijo Can Provide Ultrasonic Systems as well as Key Options

Kaijo works with many different manufacturers to supply of the right ultrasonic system to meet for their application requirements. The company can supply complete systems from its comprehensive line of ultrasonic products and it has optional features that include tank heaters, use of sweep frequency and water resonance. Specialists at Kaijo also help analyze a customer’s cleaning requirements and propose the most effective ultrasonic cleaning solution based on their specific cleaning requirements.

 

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How Ultrasonic Cleaning Systems Promote Profitability

January 19, 2018

Conventional degreasing and other cleaning processes involving the use of pressure cleaning, solvent and abrasives are on their way out in many industries. The change has come about for a number of reasons. The movement of industry towards green processes is one reason — solvents are often toxic to the environment. New environmental regulations being put in place by various state and local governments make it very hard for industries to get around, as well.

Cost- and efficiency-related concerns, however, have been the primary reason for the move away from conventional cleaning techniques. The chemicals needed in these approaches can be expensive, and can require further expense in the protection of the workers who use them. Safe disposal of toxic residue and the requisite inspections can take considerable investment, as well.

Yet, effective cleaning is essential to a great many industrial processes. From the immaculate surfaces needed prior to the application of powder coating processes, to the cleaning of high-tech filters and bearings at NASA, and from the jewelry industry to the automotive industry, safe, cost-effective and superior cleaning technology is a great need.

In Search of a More Affordable, and Cost-effective Cleaning Approach

In many industries that require the cleaning of industrial parts or other articles of various sizes, ultrasonic cleaning systems have proven to be the method of choice for a number of important reasons.

The action of ultrasonic energy on certain surfaces is observed in a number of scenarios. Anyone who is familiar with boats, for instance, has usually seen some damage to propellers — ultrasonic energy generated in the churn of propellers can be uncontrolled in its power; it often excavates tiny pits in the metal. When this energy is applied in a well-controlled manner, however, it can be used as a powerful cleaning agent.

Ultrasonic energy works in a very simple way — when dense, elastic media such as water is subjected to high-frequency energy, it expands and contracts so rapidly as to cause millions of microscopic fractures or tears. The small bubbles that are created collapse quickly after they are formed, often with great force. When such vacuum bubbles collapse close to the surface of an object, the force can knock surface contaminants off. Ultrasonic cleaning systems successfully apply ultrasonic energy to perform a great deal of useful work.

How do Ultrasonic Cleaners achieve their Effect?

Ultrasonic cleaning units consist of a tank usually filled with water, coupled to a powerful ultrasonic transducer capable of generating high-energy ultrasonic frequencies between 20 to 200 kHz. When objects to be cleaned — anything from industrial parts to dental equipment and jewelry — are placed in the bath, the ultrasonic waves generated create millions of cavitation bubbles. Localized areas can experience pressures over 10,000 psi, and temperatures over 10,000°F; dirt is effectively knocked off. Since these pressures and temperatures are created over microscopic areas, however, there is never any harm done to the work to be cleaned.

How are Ultrasonic Cleaners Superior to Conventional Cleaning Solutions?

Every nook is reached: With conventional cleaning — the pressure sprayers, solvents and abrasives — the cleaning action can often only reach areas clearly exposed. Ultrasonic energy, however, is able to get to hidden, unexposed areas.

The cleaning tends to be thorough: With cavitation bubbles forming and imploding in their millions, there is cleaning action in a way no water jet or abrasive can ever achieve. Even more importantly, the cleaning is achieved with little surface damage done, something that can be very important in the high-tech industry, the jewelry industry, or even the automotive industry, where delicate engine seals and finishes may need attention.

Insoluble contaminants are cleaned: Solvents are able to clean soluble contaminants; many contaminants, however, are simply resistant to the effects of solvents. Ultrasonic energy simply displaces such contaminants without the need for abrasive action.

Ultrasonic cleaners Help the Bottom Line

With such powerful and safe cleaning ability, the toughest cleaning jobs are usually completed in under an hour, with little need for supervisory personnel, or the need for the toxic waste disposal. With practically no moving parts, these appliances tend to require minimal maintenance, as well.

Ultrasonic cleaning systems are not all made the same. Kaijo, an industry leader in ultrasonic cleaning, has been at the cutting edge of the technology for over 65 years, developing purpose-built ultrasonic cleaning solutions for every industrial application. With the latest in ultrasonic cleaning deployed in practically every industry around the world, Kaijo has more experience with this technology than nearly any other name in the business.

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Using Ultrasonic Cleaning Technology for Food Plants

January 30, 2017

Using Ultrasonic Cleaning Technology for Food PlantsCompanies that prepare or process food have extensive cleaning requirements that can be addressed with ultrasonic cleaning systems such as those offered by Kaijo. Machines, tools and even the food itself can be cleaned quickly and completely using ultrasonic cleaning baths. While machines and most tools can be cleaned with intense ultrasonic cleaning delivered at low ultrasonic frequencies, delicate food items can be cleaned at higher frequencies with less robust cleaning action. In each case, the ultrasonic system frequencies, power, bath size and transducer configuration can be matched to specific requirements for delivering effective cleaning performance.

How Ultrasonic Cleaning Works

Ultrasonic cleaning systems consist of an ultrasonic generator, transducers and a tank for the cleaning solution and the parts to be cleaned. The generator produces the ultrasonic frequencies and is wired to the transducer, which converts the electric frequency signal to ultrasonic pressure waves in the cleaning solution. Transducers can be placed in a tank as independent units, integrated in the tank bottom or wall or bolted onto a tank. The cleaning solution can be plain water or a mild detergent can be added to help with the speedy removal of specific contaminants.

When the ultrasonic waves from the transducers travel through the cleaning solution, millions of microscopic cavitation bubbles form in the low pressure areas between the waves and collapse in the high pressure at the peaks of the waves. This collapsing of bubbles creates a strong scrubbing action that removes impurities and contaminants from the surfaces to be cleaned. The higher the frequency, the smaller are the bubbles and the gentler is the cleaning action. For companies in the food industry, metallic tools and machine parts can be cleaned of oil, grease and food residue with low frequency ultrasonic cleaners while delicate plastic parts and food can be cleaned with the gentler action of higher frequencies.

Advantages for the Food Industry

The machines and tools used by the food industry in the processing and preparation of food products require very frequent cleaning. Companies using ultrasonic cleaners obtain a competitive advantage because their cleaning is more efficient. As a result, they can reduce their maintenance costs and increase their productivity.

Ultrasonic cleaning is not only faster than traditional cleaning methods it’s also much less labor-intensive. Using ultrasonic cleaning systems, food plants can clean their equipment and resume production much faster than with mechanical scrubbing and strong solvent baths.

Secondly, ultrasonic cleaning is more effective. The bubble action of ultrasonic cleaning systems removes contaminants and foreign matter along oddly shaped pieces, within cracks and crevices and through holes. Areas that are hard to access with scrubbing pads and manual cleaning methods are no challenge for ultrasonic cleaners. The bubbles are created everywhere the cleaning solution penetrates and cleaning is even and complete.

Finally ultrasonic cleaning methods reduce chemical and solvent use. The systems clean with only plain water or with mild solvents or detergents. There is no need for soaking in strong detergents or scrubbing with abrasives. Ultrasonic cleaning can save substantial sums when these chemicals are no longer needed and the ultrasonic process is more environmentally friendly as well.

Kaijo’s Advanced Ultrasonic Cleaning Systems

Kaijo has been supplying ultrasonic cleaning systems to customers in the food industry which is helping them improve their bottom line. The company has a complete range of ultrasonic cleaning systems and can offer active support to clients in food processing plants. Customers who have specific needs can receive components, such as ultrasonic generators and transducers, that can work with the existing tanks of their traditional cleaning systems. Kaijo is helping such customers find new applications for ultrasonic cleaning in their plants and customizing equipment to fit their processes while improving performance.

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Advantages Kaijo Provides Over Other Ultrasonic Cleaner Manufacturers

September 29, 2016

Advantages Kaijo Provides Over Other Ultrasonic Cleaner ManufacturersThe development of ultrasonic cleaning systems has been driven by the need to reduce the use of harsh cleaning chemicals for environmental reasons and the desire for rapid cleaning action tailored to the cleaning application. As leader among Ultrasonic cleaner manufacturers, Kaijo provides innovative, easy to use systems that clean a wide variety of manufactured parts. These include ceramics, circuit boards, semiconductor wafers, medical tools and optical components including LCDs and solar panels.

Kaijo has been in the forefront of ultrasonic technology innovation and delivers ultrasonic cleaning systems that clean as well as or better than Freon-based cleaning systems. Continuing to invest in ultrasonic research and development, Kaijo emphasizes finding cleaning solutions for its customers worldwide. Its systems deliver powerful cleaning action and precise control within flexible cleaning solutions.

Characteristics of Kaijo’s Ultrasonic Cleaning Systems

Kaijo can provide complete turnkey ultrasonic cleaning systems as well as ultrasonic generators, tank-mounted or immersible transducers and cleaning tanks. The operating frequencies of Kaijo systems range from 19.5 kHz for strong cleaning action of rugged parts to 1.6 MHz for the gentle cleaning of delicate components. Powerful ultrasonic generators can deliver up to 1200 W and feature advanced controls for accurate cleaning action.

Cleaning system controls on the ultrasonic generators are precise and can control several or a range of frequencies. Remote control and automation by computer commands is available on some models. Kaijo can help customers select the system or the components they need for effective and rapid cleaning without chemicals or scrubbing.

Benefits of Using Kaijo’s Ultrasonic Cleaners

Kaijo’s ultrasonic cleaning systems and components offer a number of benefits over the equipment supplied by other ultrasonic cleaner manufacturers:

  • Products designed and built to the highest standards using high quality components. Kaijo has been a leader in the field of ultrasonic cleaning for over 65 years and has the knowledge, experience and technology to build the best ultrasonic cleaning systems possible.
  • Ultrasonic cleaning systems that are easy to use, quick to install and reliable to operate. The ultrasonic generators deliver constant rated power precisely at the specified frequencies. Transducer performance does not degrade over time and transducer and tank surfaces are resistant to pitting caused by cavitation bubbles. The systems provide powerful cleaning with minimal down time.
  • State-of-the-art systems featuring the latest technology. The company’s research and development puts it at the leading edge of ultrasonic cleaning performance. Customers can be sure of receiving ultrasonic cleaning systems that work well, and they can ask Kaijo for help in selecting the best system for their cleaning applications.

Managers of industrial facilities that have cleaning requirements and process engineers whose process includes cleaning applications can switch from using Freon and chemical cleaning methods to ultrasonic cleaning systems supplied by Kaijo. In addition to eliminating environmental issues and the cost of chemicals, Kaijo ultrasonic cleaners clean rapidly and effectively, especially for applications cleaning oddly shaped parts with holes and crevices.

Kaijo advanced ultrasonic system technology reduces the use of water and operates efficiently, lowering energy use. The engineers at Kaijo can design cleaning systems for customers taking into account chemical compatibility, size, power, frequency and flow. Being an ultrasonic technology leader allows Kaijo to work with customers to either choose the best standard system or to have their engineering team help analyze the customer’s cleaning process and make the appropriate choices. Either way, customers will benefit from the advantages Kaijo provides. For a free consultation or quote on selecting the right ultrasonic cleaning system for your specific cleaning application call Kaijo at 408 675-5575 or email [email protected].

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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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What Ultrasonic Transducers Do in an Ultrasonic Cleaning System

July 19, 2016

What Ultrasonic Transducers Do in an Ultrasonic Cleaning SystemUltrasonic cleaning systems are made up of ultrasonic transducers, generators, and cleaning tanks. The transducers are submerged in the cleaning solution and take the electric signal from the generator to produce the cleaning action. As the electric ultrasonic frequency signal rises and falls, the transducer vibrates and generates compression waves in the cleaning solution. These compression waves produce the cavitation bubbles responsible for ultrasonic cleaning.

The immersion of the ultrasonic transducers in the cleaning solution can be carried out in two ways. The immersible transducers are self-contained, sealed units connected to the ultrasonic generators with a cable. They are placed in the tank containing the cleaning solution together with the object to be cleaned.

The bolt-on or mounted transducers are mounted at the bottom or on the sides of the cleaning tank. Systems with bolt-on or mounted transducers produce consistent cleaning results but changing a bolt-on or mounted transducer for one of with a different frequency takes more time than changing an immersible transducer.

Transducer Characteristics

Ultrasonic transducers must be resistant to erosion from the effects of the cavitation bubbles and must be able to operate submerged in cleaning solutions at high temperatures. Kaijo ultrasonic transducers are hermetically sealed in 316L stainless steel housing with a thick metal plate to transmit the sound waves to the cleaning liquid and avoid damage from cavitation over extended periods. The transducers can be used at temperatures of up to 100 degrees Centigrade for most transducers and up to 80 degrees Centigrade for the transducers operating at 1 MHz.

Immersible Transducers

Immersible ultrasonic transducers are available at ratings of up to 1200 W and at frequencies of 26kHz, 38kHz, 78kHz, 100kHz, 130kHz and 160kHz. They can be connected to any Kaijo ultrasonic generator and can be placed in existing tanks. Their ease of use and flexibility makes them ideal for facilities that have a wide variety of ultrasonic cleaning requirements.

Operators can place the object to be cleaned in a tank with an appropriate cleaning solution and insert one or several transducers with the desired frequency. The transducers can be placed in the tank either horizontally or vertically and cleaning can be varied to ensure optimum performance for a particular object and for the contamination to be removed or the type of cleaning required.

Bolt-on or Mounted Transducers

Bolt-on or Mounted ultrasonic transducers are available at ratings of up to 1200 W and at frequencies of 26kHz, 38kHz, 78kHz, 100kHz, 130kHz, 160kHz, 200kHz, 430kHz, 750kHz, and 950kHz. They are mounted at the bottom or on the sides of cleaning tanks or can be bolted onto the desired location on existing tanks. Kaijo ultrasonic transducers are compatible with the Kaijo Quava, Phenix Legend and Phenix III generators and they are available installed on Kaijo ultrasonic baths and tanks.

Bolt-on or mounted transducers are especially suited for manufacturing and laboratory facilities that have clearly defined ultrasonic cleaning needs. Kaijo can recommend a configuration that delivers top cleaning performance for a particular application. Frequency, tank size and number of transducers can be optimized for the specific cleaning requirements and the fixed transducer installation can deliver consistent cleaning results.

Whether the immersible or the fixed bolt-on or mounted transducers are the best solution for a particular application, Kaijo can propose a custom solution that delivers the optimum level cleaning without the degradation over time that can occur with other piezoelectric systems. Call 408 675-5575 or email [email protected] for a free consultation or quote on using an ultrasonic cleaning 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 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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