Ultrasonic cleaners utilize high-frequency sound frequencies of about 18 kHz in order to cause cavitation, or the formation and implosion of minuscule bubbles in a liquid cleaning medium. These bubbles, or implosions, serve as cleaning agents to rid parts of small dirt particles that reside in crevices and surface areas that would otherwise be impossible to reach. However, because ultrasonic cleaning is not intended for large particle cleaning, parts must first be cleaned by other methods before they are ready to undergo ultrasonic parts cleaning.
Offering precision and consistency, ultrasonic cleaning equipment removes soil and contamination from parts more rapidly than any conventional cleaning method. There are several types of application-specific ultrasonic cleaners. Ultrasonic blind cleaners are specifically designed to rid blinds such as mini blinds, verticals, duettes and pleated shades from nasty contaminates like dirt, grease, nicotine and fingerprints. Ultrasonic jewelry cleaners remove dirt and other contaminates from various jewelry such as rings, necklaces, bracelets and earrings. Golf club cleaners clean the golf clubs, including the grips, from dirt buildup that occurs on through use on the golf course. Ultrasonic degreasers are contaminate-specific, targeting grease in automotive equipment and parts processing. Ultrasonic cleaners typically are used to eliminate such contaminates as sludge, buffing and polishing compounds, mold release agents and oil.
Different types of ultrasonic washers have designs that are uniquely suited to their specific function. Ultrasonic jewelry cleaners, for instance, are much smaller than industrial ultrasonic cleaners since they are typically for commercial and personal use only. Ultrasonic jewelry cleaners are designed with a small tank containment basket and pressure controls located on the outside of the tank. Ultrasonic jewelry cleaners are typically powered by ultrasonic transducers, though some portable cleaners may be battery operated. Ultrasonic blind cleaners consist of a generator, transducer and a fairly large tank that can be made portable by attaching casters, depending on the size of the tank. The blinds are placed in the place the tank, which is filled with hot soapy water and injected with powerful sound waves that gently clean the various parts of the blind including slats, cords, and the head rail. Golf club cleaners differ from other ultrasonic cleaning equipment due to vertically-aligned tanks, which are necessitated by the length of the golf clubs that must fit in the tank to be cleaned. Ultrasonic golf club cleaners may also become portable through the addition of casters. Ultrasonic degreasers have a similar construction as ultrasonic blind cleaners, but they typically have an ultrasonic transducer mounted at the base of the tank that can reach sounds of up to 20 to 40 kHZ.
All ultrasonic cleaning equipment is at minimum equipped with a transducer, a generator and an immersion tank. The part requiring cleaning is placed into the tank, which contains an ultrasound conductive fluid. There are three different cleaning mediums commonly used: hot water cleaning, which uses a heated water stream; aqueous cleaning, which uses a water-based ultrasonic cleaning solution; and solvent or vapor cleaning, in which the solvent is evaporated then condensed onto the surface of the parts. The ultrasonic cleaning process begins when there is cavitation. Cavitation is caused by the transducer, which can be either attached to the tank or lowered into the fluid, when the transducer introduces ultrasonic sound waves into the tank. The agitation caused by the innumerable minute and intense imploding bubbles release both energy and heat that provides a highly efficient method of scrubbing both exposed and concealed surfaces of the immersed parts. There is a direct correlation between how high the frequency is and the number of implosions. However, the energy released by each implosion is also affected and decreases; this makes high frequencies ideal for minute particle removal with no harm to the part's surface. Materials commonly cleaned by the ultrasonic cleaning process include stainless steel, iron, aluminum, copper, brass, plastics, rubber, wood and cloth.
New developments for ultrasonic cleaning equipment include automated ultrasonic cleaning systems. These fully-automated systems incorporate a variety of cleaning actions such as power spraying, rinsing, precision flushing and drying parts. These processes are achieved at high rates of speed, which results in zero-residue cleaning when the ultrasonic cleaner is equipped or attached to deionized water. In addition, because rinsing is performed in the same tank as is the ultrasonic cleaning process, the rinse is already ultrasonic and there is no additional cost to add ultrasonic components to a rinse tank, as is the case with a multi-tank cleaning system. Fully-automated ultrasonic cleaners improve upon conventional models of ultrasonic cleaning equipment because they increase pre-assembly cleaning quality and cut solvent use by ninety percent. These improvements are the result of harnessing heat pump thermal transfer techniques which serve to minimize solvent evaporation that occurs overnight. Combined with diagnostic process control, full-automated ultrasonic cleaners offer a dedicated computerized work transporter that facilitates, establishes and maintains optimal performance levels.
Multiple Transport Configuration Ultrasonic Cleaning System - Jayco Cleaning Technologies
Ultrasonic Vertical Agitation Parts Washer - JenFab
Bench Top Ultrasonic Cleaner - Ultrasonic Power Corporation
Ultrasonic Pre-Sterilization System - ESMA
Ultrasonic Pre-Sterilization System - ESMA
Automated Ultrasonic Cleaning System - JRI Industries
Ultrasonic cleaning equipment removes contaminants off the surface of metal pieces and electronics components, rapidly and effectively. It is considered the safest way to clean components, since ultrasonic parts cleaners use high frequency pulses to create bubbles in a tank of liquid, with the concept of cavitation, that create a scrubbing brush action.
Ultrasonic cleaners are a primary choice for a multitude of applications, as no other aqueous-based method is as efficient and fast at cleaning hardened contaminants around intricate metal parts as ultrasonic cleaning.
Benefits of ultrasonic cleaning equipment
Ultrasonic cleaning is the most feasible alternative to solvent-based cleaning, making it the most environment-friendly product on the market. They have virtually no undesirable characteristics. Be it reduced biodegradable waste, emissions, or a safer working environment, this equipment delivers in all of those areas. More companies are adopting the technology, since it is the only option that complies with the restrictions imposed on the use of solvents.
Since ultrasonic cleaning utilizes soap-based solvents in combination with sonic energy, the operating cost is minimal. The cost per operation can vary a little, depending on the type of cleansing agent used and the parts being cleaned. However, it is marginal in comparison to other options. You can save significant capital in the long-term, considering the cost of equipment, labor, and cleaning materials is relatively inexpensive.
The time required to clean metal parts using ultrasonic cleaning is relatively small, thus it creates great saving in terms of energy bill. Moreover, they consume less energy in comparison to mechanical washers, giving you all the efficiency you need with minimal energy expenditure.
All these benefits make the tech useful in a wide range of industries.
Ultrasonic bathing equipment provides impeccable cleaning and that is why they are used for a variety of healthcare requirements, such as optical and podiatry, dental, and general practice; ultrasonic cleaning solution achieves surgical standard hygiene with its cleaning action.
Ultrasonic cleaning machines can be readily found in research laboratories and centers. They are used in sonochemistry, cleaning scientific and medical research equipment and even in cell disruption and mixing technology
The manufacturing industry has a wide application for ultrasonic parts washers. They have been catering specific needs of automotive, aerospace, defense, pharmaceutical, filtration, molding and fabrication industry.
Ultrasonic cleaning equipment is a tool of choice for automotive servicing engineers, and jewelers and watchmakers. They are effectively applied for maintenance and cleaning of automotive parts, as well as the reconditioning of precision tools, heat exchangers, and weaponry. You can even buy specially designed ultrasonic jewelry cleaner and ultrasonic gun cleaners.
Ultrasonic cleaners deliver a superior level of cleaning that no conventional parts cleaning system can provide. Because of the long list of benefits, ultrasonic cleaning process equipment is used across industries and in a variety of production applications. Characteristically, ultrasonic washers are considered the best cleaning systems for small parts. With this advancement, you can use ultrasonic cleaners to perform cleaning in a more efficient way.
Following are some of the biggest advantages of ultrasonic parts cleaners.
Moderate Cleaning - With innovative ultrasonic cleaners, you can remove many types of contaminants from the surface of parts. To remove debris, ultrasonic cleaners do not reply on abrasion, scrubbing, spraying, vacuuming, etc.. You can even clean the delicate microchips of your phones and laptops that require gentle handling.
Offer Quick Cleaning -Ultrasonic parts washers leverage very high frequency sound wave to perform parts cleaning. The sound waves create vibrations that help take away the debris from the surface of the machinery in an instant.
Clean a Variety of Contaminants - Using ultrasonic industrial parts cleaners, you can remove almost every variety of pollutant and particulates. Oil, grease, metal chips, cutting fluids, dirt, dust, sand, metal melts, paint, shavings, carbon, sulfur, oxides, and many other elements are in the list of contaminants that these intelligent device can eradicate.
Clean the Smallest Parts - When you are working with ultrasonic cleaners, there is no need to worry about small machine parts. This cleaning system offers a ease in washing small parts that are typically tough to wash with conventional systems. In addition to this factor, you can perform cleaning even within open and deep sections of machine parts. Ultrasonic cleaning machines prove very effective for parts with passageways, small openings, cracks, and holes.
Energy Efficiency - In comparing the power consumption of ultrasonic devices with traditional industrial parts washers, ultrasonic cleaners are much more energy efficient. Other washing machines have scores of motors to perform different actions. However, ultrasonic washers have just one motor to carry out different exercises. Further, the motor in this device comes is usually designed to work efficiently without consuming too much electricity.
Provide Reliable Cleaning - Ultrasonic technology centers on effective and reliable parts washing. There is no moving or rotatory part in this application. To put it simply, ultrasonic cleaning devices do not work on a rotating mechanism. For that reason, ultrasonic washers keep working reliably and constantly.
Effective and Thorough Cleaning - The high-frequency sound waves that ultrasonic cleaners array make sure that all the debris and pollutants are removed from their very base. Ultrasonic waves hit the (layer of) contaminants from various angles, which removes them from the surface, and provides simple cleaning, making ultrasonic washers undeniably a great tool for manufacturing industries.
Ultrasonic cleaners are tremendous equipment for detailed and thorough cleaning of complex and intricate metal parts. They become important when all other available options fail to give optimum results, or fail to clean delicate and expensive parts with efficiency and without any damage. These are their unique selling points. Moreover, the thorough and efficient cleaning ability of ultrasonic cleaners has made them the preferred tool for cleaning of medical equipment and apparatus.
How do they work?
As the name suggests, an ultrasonic cleaner uses ultrasonic sound waves, basically, to rub off the buildup or dirt from the surface of metal parts. Ultrasonic Parts Cleaners are filled with a solvent bath and the part to be cleaned is immersed in the bath. The walls are installed with transducers that emit the pulses of high frequency sound waves, causing cavitation, a fluid process that produces small bubbles that repeatedly attack the solid surface of the parts to be cleaned. The bubbles act as scrubbers that remove the flux or build up from the surface of the parts.
Ultrasonic cleaning solution has a range of applications; however, it is commonly used for jewelry, delicate parts for electronics, industrial manufacturing, as well as medical and dental instruments.
Tips to buy an ultrasonic cleaner
The first step is to determine what is to be cleaned. Ultrasonic cleaning equipment comes with a multitude of tub sizes, therefore, the shape and size of the parts to be cleaned should be considered first. The quantity of parts that will be cleaned in a batch should be taken in to account too.
Selecting a general or common cleaner
Choosing a high-capacity ultrasonic cleaner
Special type cleaners
You can buy ultrasonic cleaners through various vendors; however, they are readily available online through various manufacturers. You can have save money by buying through the Internet, but ensure that the after sales services and maintenance assistance is available in your region.
Ultrasonic parts washers are available in a wide variety, ranging from small, home or office purpose devices to large-scale industrial appliances. Industrial ultrasonic cleaners work by creating high-frequency sound waves to lift debris and pollutants on the surface of an object that is intended to be cleaned. In addition to employing an ultrasound wave, the device also makes use of a customized solution to clean dirt from the industrial parts.
Additionally, this device also has a robust heater that warms the cleaning solution in the tank. Sometimes, ultrasonic washers can also have more than one sink and an automation feature to ease and automate the entire operation. At times, with industrial ultrasonic parts washers, ultrasonic transducers are also used to improve efficiency. That is how custom ultrasonic are designed. Immersible ultrasonic cleaners are also available, which offer many advantages including high flexibility and ease of operation, installation, and endurance.
During most of the cleaning processes, clearing all the pollutants, cavities, debris, etc. is a desirable outcome. The mechanical effects of ultrasonic sound waves can be used to achieve this objective. These powerful sound waves vibrate, dissipate and displace waste products and impurities. Moreover, toxic chemicals and gaseous elements can also be removed through this cleaning process.
Many times, the physical structure or molecular bonding of contaminants can be complex. Such complex combinations may contain soils composed of soluble and insoluble constituents. By making adjustments to the control panel of ultrasonic cleaner, these components can also be removed during the cleaning process. However, this typically requires a stronger sound wave.
Further, to achieve a more efficient cleaning, ultrasonic transducers can be introduced in conventional cleaning systems. This way, such cleaning devices will perform cleaning using the rigor of ultrasonic energy. The transducer converts the energy driven by the electric current into high-frequency mechanical vibrations.
These transducers are technically called ultrasonic generators, as they create the power of ultrasound waves. To be specific, these generators can translate 50 to 60 Hz of electric current into mechanical force or ultrasonic energy. Modern-day transducers come with an innovative feature that allows you to set the output parameters or customize the energy output according to your application requirements.
Typically, there are two types of ultrasonic transducers-magnetostrictive and piezoelectric- used by today's manufacturers. Both the mechanisms have the same use-to convert electrical energy into ultrasonic energy.
By pairing an ultrasonic cleaner with a square wave signal, you can turn your normal cleaning system into a multi-frequency cleaning system with which you can work on a variety of contaminants using a diversity of vibrations and frequencies.
The amount of time for which the ultrasonic wave remains engaged can be changed to meet desired cleaning outcomes. The frequency output of your ultrasonic generator can be moderated using a central frequency.
Other than the conventional parts washers, these days, many industries, where quality matters, are using ultrasonic cleaning equipment. They are used in a variety of manufacturing and maintenance processes, improving quality of products.
Ultrasonic cleaners generate millions of microscopic bubbles per second through cavitation, which removes debris or dirt from hard metallic surfaces. The process efficiently cleans the complex shapes and design, reaching intricate spaces easily and effortlessly.
Here, we will discuss some practices that will help you to run ultrasonic cleaning equipment optimally:
To clean different types of contaminants, you need specific types of ultrasonic cleaning solution.
Cleaning contaminants, like oil, light grease, dirt, soil, or carbon, require an alkaline soap, with high pH. Alkaline solutions can clean almost anything; however, it can damage softer metals, like aluminum. It is suited for hard metals, such as stainless steel and titanium. Stain prone steel and other ferrous metals should not be washed with water-based solution; they need a built-in rust inhibitor and rinsed in a rust inhibitor to be washed effectively, without any harm to the metal.
To clean water-damaged metals, contaminated with calcium deposits or rust, an acidic cleansing agent is better suited. It not only removes the top layer of metal surfaces, but also shines the metal surface.
Delicate parts, such as electronics parts, need neutral pH soap; a neutral pH cleaning solution does not damage copper filaments or thin layers of metal. Mainly it is used in ultrasonic jewelry cleaners. Neutral pH cleaning solutions are fine for parts with light surface contamination such as dust or light dirt particles.
Industrial ultrasonic parts washers work optimally in 135 degrees F to 150 degrees F range. The temperature range softens and loosens contaminants and is important to achieve effective microscopic level cleaning. However, temperature above the range can accelerate evaporation, which can damage softer metals.
For removing burned-on carbon from metal surfaces, temperatures as high as 180 degrees F is required, whereas for delicate parts, including electronics, temperatures below 150 degrees F is appropriate.
For some critical applications, lower temperatures are deemed more appropriate. However, in such cases the washing period is elongated to compensate for lower temperature.
Ultrasonic watt density, a measure of how much ultrasonic power is available in a tank against liquid volume, is an important factor in ultrasonic cleaning.
Generally, lighter metal parts with lower degree of contamination require less power, while larger parts require more power. However, in general, 25 watts per gallon is right for cleaning tanks with capacity of 40 gallons.
Interestingly, ultrasonic parts washers with smaller tanks require higher watt density.
Standard ultrasonic washers work at 40 kHz, or 40,000 cycles per second. In such washers, each transducer creates 40,000 microscopic bubbles per second. The 40-kHz rate is considered effective at cleaning; it also maximizes equipment life expectancy.
Washers that have application in heavy industry work at a frequency of 20 kHz to 25 kHz, creating fewer bubbles but stronger, and stronger bubbles are more effective for cleaning bigger parts.
For cleaning sub-micron contaminants, like those on medical or electronic parts, frequencies as high as 68 kHz or 170 kHz is used, creating bubbles at a greater rate, which helps to clean smaller debris.
New ultrasonic cleaning equipment, mainly industrial-sized, is expensive, so it makes sense to purchase a used unit.
Here we discuss the factors that you should consider while acquiring a second-hand ultrasonic cleaning system.
Ultrasonic cleaning units are basically made up of a tank, an ultrasonic generator, and ultrasonic transducers, which are fixed to the bottom of the tank. Any mechanical force acted upon it can damage the unit irreversibly; therefore, the first thing that you have to care about is if the unit has been dropped. To tell if a unit has been dropped check for dents, if you find any, look for other options.
The most common defect with used ultrasonic parts cleaners is heat damage. Ultrasonic transducers release quite a bit of heat, which is dispersed by the liquid or solution in the tank, and running a unit with a low-level of solvent can effectively damage the bonding between the transducers and the tank, preventing cavitation. To check for heat damage, see there is any discoloration on the housing. Excessive discoloration signals bad handling of the machine. Do not buy it.
A bad practice among operators is to put parts directly at the bottom of equipment's tank, which damages the transducers. The right practice is to use a basket instead. If an ultrasonic cleaner is offered without a basket, enquire about the basket. If it is missing, it is an indicator that machine has been used badly, which cuts the life of a machine significantly. It is better not to invest money in such ultrasonic cleaning unit.
Ask for all the documentation, this will give you all the important information you need, from functional properties, to model, to competencies, to date of purchase. All this information will you help to determine if the ultrasonic washing machine will serve your requirements.
All these factors are accumulated with the help of an expert, if a machine passes all these considerations, buy it.
Cleaning Solution - Water-based detergent or organic solvents that provide an intense amount of cavitation energy.- A water break testing process used to determine if the components are free of oil and other contaminants. A surface quality monitor takes measurement for thin films of contaminants.
- Determines if oil is no longer present on the cleaned part.