June 27, 2018
Ultrasonic generators produce the high-frequency electric signal that is required for an ultrasonic cleaning system to operate effectively. The devices are powered by normal 60 KHz electric circuits and use electronics to generate ultrasonic frequencies between about 20 kHz and 1 MHz. Piezoelectric or magnetorestrictive transducers convert the electric signal to ultrasonic waves in the cleaning solution. Ultrasonic generators are an important part of the ultrasonic cleaning system as they control the frequency, and also insure that the selected frequency and power output are maintained.
The Role of Ultrasonic Generators in an Ultrasonic Cleaning System
Ultrasonic cleaning systems work by using high-frequency sound waves in a cleaning solution to remove dirt and surface contaminants from a variety of parts and products. When the systems are selected with the right characteristics for an application, they work quickly and efficiently to completely clean items submerged in the cleaning tank. Even irregular parts and components with holes or crevices are cleaned wherever the cleaning solution can penetrate. The systems remove the need for corrosive chemicals, soaking and mechanical scrubbing.
The cleaning performance of ultrasonic cleaning systems depends on the action of cavitation bubbles created by the ultrasonic waves in the cleaning solution. These bubbles form in sound wave pressure troughs and collapse in the pressure peaks, delivering intense scrubbing action on the surfaces of the immersed parts. The transducers placed in the cleaning liquid create the sound waves by vibrating at the selected ultrasonic frequency produced by the ultrasonic generators. The whole system has to have matching characteristics with the frequencies, power, tank size and controls forming an integrated system that works together in a specific cleaning application.
In such a system, the ultrasonic generator plays a key role. Depending on the size of the parts to be cleaned, the nature of the parts, the type of contaminant and the projected use of the system, the generator voltage, power, frequency and other characteristics can be determined. Choosing the right generator affects the performance of the entire system.
How to Choose the Ultrasonic Generator
The ultrasonic frequency generator has to fit into the production environment while at the same time match the cleaning application requirements. Factors making it suitable for a facility include the operating voltage, the size and the type of use. For a particular cleaning application, the selected frequency, power and controls are important. Once the specific cleaning application requirements are defined, selecting the right frequency and corresponding transducers and cleaning tanks is clear.
If a cleaning system is always used the same way, to clean one kind of part made of the same material, a single-frequency generator is the most cost effective option. In manufacturing operations machined parts made from softer metals (i.e. aluminum) will require gentler cleaning from using a higher frequency generator at 78 kHz, while the same part made from a harder metal (i.e. steel) can be cleaned best using of a low frequency generator at 26 kHz. Generally, low frequencies produce intense cleaning action for parts or components made from harder materials while high frequencies provide gentle cleaning of parts or components made from softer materials. In all cases, the ultrasonic generator power must be high enough to fill the cleaning tank with ultrasonic waves, and the system design must ensure that the wave pattern is uniform for the most effective cleaning action.
Kaijo can Help Select the Best Generator
Kaijo’s generators are available as part of a complete ultrasonic cleaning system or as individual components. The complete line of generators ranges from small, desktop units to 1200 W industrial cleaners. Their advanced control systems ensure consistent and quick cleaning action even for difficult cleaning tasks. Kaijo can advise what generators and systems are best suited for a customer’s specific cleaning application and can recommend the corresponding equipment. For a free consultation or quote on using any of Kaijo’s products call 408 675-5575 or email [email protected].