March 16, 2018
Industrial ultrasonic cleaners deliver more effective and efficient cleaning performance without the use of harsh chemicals typically used in traditional cleaning methods. A variety of parts, from robust metal and ceramic components to delicate semiconductors can be cleaned quickly and completely via the cavitation bubbles from ultrasonic waves generated from an ultrasonic system. Parts of all shapes are immersed in cleaning tanks with the bubbles cleaning even hard-to-access holes and crevices. The systems are available in varying frequencies to satisfy the requirements of any industrial cleaning application.
Ultrasonic Cleaning System Components
Industrial ultrasonic cleaning systems are made up of ultrasonic generators, transducers and the cleaning tank. They can be purchased as separate units or as turnkey systems that can be plugged in and are ready to start cleaning. When existing cleaning tanks can be used, it is often cost-effective to buy generators and portable immersible transducers while tabletop turnkey solutions are ideal for cleaning small parts. Choosing a supplier that has a full range of industrial ultrasonic cleaners will help in getting the system that best suits a particular application.
The ultrasonic generator produces the electric signal that forms the basis for the ultrasonic waves. Signals can range from about 20 kHz to 200 kHz (for ultrasonic frequencies) and 200 Khz to 1.6 MHz (for megasonic frequencies), and the generators can deliver up to 1200 W of power. For specific applications, a single frequency generator is sufficient, but for cleaning applications that handle many different kinds of parts, multi-frequency generators are available.
The electric ultrasonic signal generates ultrasonic waves via an ultrasonic cleaning transducer. The transducer has to be able to handle the frequency and power produced by the generator and it can be mounted at the bottom or on the sides of the tank as well as being an independent unit placed in the tank. Large tanks may need more than one transducer to effectively fill the volume of the tank with ultrasonic waves.
The cleaning tank has to be made of material heavy enough to withstand the cleaning action of the ultrasonic waves and it has to be big enough to handle the largest parts to be cleaned. Baskets for the parts are often used to keep easily damaged components from vibrating against the sides or bottom of the tank, and in that case, the tank has to be big enough to hold the basket as well.
How Ultrasonic Cleaners Work
The ultrasonic transducer takes the electric signal from the generator and uses either piezoelectric or magnetic effects to create ultrasonic waves in the cleaning solution. When an electric charge is applied to piezoelectric crystals, they change size. As a result, a high-frequency electric signal produces a vibration in the crystals and, via a heavy metal plate, the crystals can produce ultrasonic waves in the cleaning liquid. The same effect can be achieved with materials that change size in magnetic fields. The ultrasonic waves fill the cleaning tank and start the cleaning action.
When an ultrasonic wave travels through water, it creates compression peaks and troughs. Microscopic bubbles form in the troughs where the pressure is low and collapse in the peaks due to the high pressure. When a bubble collapses, a small but powerful jet of liquid rushes into the space where the collapsed bubble was. These jets produce an intense cleaning action on the surfaces of the parts to be cleaned. Cleaning takes place wherever the bubbles are present, throughout the tank, inside cavities and all around complex structures. Cleaning is fast and removes all contaminants.
Kaijo can Help
Kaijo has a complete line of industrial ultrasonic cleaning equipment, including separate components and turnkey systems. The company uses transducers based on the piezoelectric effect and can deliver powerful low-frequency systems for robust cleaning action as well as systems using high frequencies for gentle cleaning of delicate components. Kaijo’s unparalleled experience in developing ultrasonic technology for various industrial cleaning applications ensures that the company’s equipment delivers the expected performance.
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
July 28, 2016
Ultrasonic 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.Read More
May 26, 2016
Ultrasonic 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.Read More