Ultrasonic Cleaners Technical Specification
An ultrasonic cleaner is a cleaner that uses ultrasonic sound waves to clean objects. Ultrasonic means having a high frequency. This frequency is too high for the human ear to detect. The ultrasonic sound waves excite the cleaning solution. When excited, the cleaning solution acts upon and removes the impurities such as grease, dust particles, molds, rust, fingerprints, fungus, soot, and bacteria on objects like glass, metals, ceramics, plastics, and rubber.
The Ultrasonic Clean-up Performance
An ultrasonic cleaning tank is basically a tank made of stainless steel, with ultrasonic transducers made of pizeo ceramic that are attached to the side or underside. When an electrical signal hits the transducers, they become instantly alert and change size. An alert transducer enlarges in size and this makes the tank underside or side move. Resultantly, a compression wave is generated in the tank liquid.
The transducer then provokes rarefaction and compression waves within the liquid, employing an electric generator which produces a high frequency signal ranging from 20 to 50 kHz. The liquid is split due to the intense refraction cycle. Next, a vacuum hollow crater is created inside the liquid. With continuous refraction and compression waves, the hollow cavities will become bigger and smaller in size. There comes a point when the cavity will attain a certain, non-maintainable range, due to the extreme frequency and wattage of signals. Consequently, the cavity collapses with a violent force, resulting in a temperature increase to 5000 degrees centigrade, contacting whatsoever is present in the tank with fierce power. Within an ultrasonic tank, millions of cavities the likes of such are generating and bursting every second.
Compression and rarefaction waves within an ultrasonic tank:
These violent and constant collapses clean up the tank. The jet like spray will eliminate any dirt off the surface of the part. To increase the effectiveness of the cleansing operation, it’s best to add soap or detergent to the liquid present inside the ultrasonic tank. Increased temperature of the water or liquid eradicates any vacuum pockets, making the cleaning chemical more effective. For optimum results, heating the liquid to 80% of its boiling temperature is recommended. Always keep the cleaning parts in a basket when cleaning the tank. Never place tools directly inside the ultrasonic tank.
Fundamental kinds of Ultrasonic Cleaning System
1. A solitary tank cleaning system: A single tank ultrasonic cleaner is used most when a less quantity of parts are to be cleaned. Always opt for a high standard, industrial grade ultrasonic cleaner instead of the regular, table top kind. The disadvantage of table top cleaners is that they encase the generator, heater and tank all in the same shell and are less robust in construction; their transducers are small in size. Systems such as these are employed for cleaning parts that are smaller in size, not more than twice a day. They are not meant to give top-quality results or return a high end cleanup process.
Industrial ultrasonic tanks that are table-top in nature always encase the generator separately; this decreases the chance of damage by heat produced inside the ultrasonic tank and provides more room for bigger sized transducers at the tank bottom.
The expenditure required to set up a single industrial table top tanks or multiple ultrasonic tanks is a much reduced amount. But that doesn’t mean it’s a free party. You need to manually clean the single ultrasonic tank system with complete operator assistance. The small size of the table top tank also means smaller loads; this applies most to multiple beaker cleaning setups which require around 4 beakers that are rested in holders and loaded with cleansing mixtures or solutions. The parts then need to be manually relocated from beaker to beaker.
For prototype, lab cleaning lines, single tanks are an excellent choice.
2. Commercial or industrial cleaning setups: A larger sized tank has a larger floor, which means while cleaning industrial applications or plating parts, there are no constraints on size.
3. Multiple tank cleaning setup: A multiple tank cleaning system is made of a minimum of three articles: an ultrasonic detergent tank, an ultrasonic rinse tank and a separate spray rinse tank. For better results, ultrasonic rinse tanks, multiple cleaning tanks and spray tanks can complement basic systems for enhanced output levels and better cleaning. With several tanks you can clean a number of parts together and still reap a high standard of cleaning. These systems come with convenience features such as automatic drainage, filling and filtration as well as DI liquid heaters. After a study of the cleaning requirements and an estimate of usage levels, system configurations can be worked out accordingly.
4. Automatic cleaning: To do away with inconsistency in the cleaning procedure, the automation feature is the best option. Automation of the cleaning procedure means that every lot will be cleaned under the same conditions and in the same way.
Why opt for Ultrasonic Cleaning ?
If you wish to get your Casted Aluminum components thoroughly cleaned, then ultrasonic cleaning is the best choice. The procedure is eco-friendly and green, plus it has the right combination to replace old-fashioned vapor degassing procedures. Secondly, ultrasonic cleaning is improves aqueous cleansing procedure in numerous appliances. The jet action can penetrate the trickiest crevices, getting to surfaces that are normally out of reach for other cleaning techniques. The cleaning process uses effective tools such as automatic handling systems, jet sprays and oil skimmers.
Functions and usage of Ultrasonic Cleaners
1. Publishing and printing business
There is no doubt about the excellence of cleaning records of the ultrasonic cleaning systems in the printing trade. Be it complicated multistage setups employed in engineering, or special machinery used in the printing industry, ultrasonic tank systems are the ideal technology, created to suit not only standard systems but also to cater to any specific requirements. The system can accommodate cleaning for a maximum of 6 rolls at 1040 face breadth or 12 at 450 face breadth and easily rotate them (the numbers are subject to certain roll specifications).
Conventional methods of cleaning are unsuccessful at cleaning Ceramic Anilox rolls. Ceramic cell cavities are miniscule and hard to cleanse with even the finest techniques. With the ultrasonic method’s ability to clean up to 12 rolls at one time, it’s unmatched in cleaning methods for Ceramin Anilex rolls. All machinery manufactured by Beijing Ultrasonic is sturdy and durable, with outstanding quality and design.
When ultrasound oscillates about a represent frequency, it is called Frequency sweep. This rotating frequency is vital to cleaning of Anilox Rolls and even Gravure cylinders, even more so with escalating screen counts and roll rotation, which is the chief defense of the roll during the cleaning process. Including a healthy frequency sweep makes sure that there is an equal division of the signals and waves produced by the ultrasound upon the total roll surface; this eradicates all ‘hot-spots’ of sound which are the major reason why rolls are injured.
‘Super sweep’, a special feature of our ultrasonic signal generator can provide a sweep speed of up to 4 kHz, which is considerably more than any other generators in the market. Another advantage is that due to super sweep, our frequencies are much more elevated as compared to competing machinery, leaving us with the best speed and safety, and a more effective yet tender cleaning operation. The special structure and making of our equipment is what makes us the most advanced ultrasonic cleaning system manufacturers worldwide, not to mention, most reliable and safe.
2. Medicinal and clinical industry
Ultrasonic cleaning systems are widely employed in the medical industry for many purposes. It is widely applied for cleaning of:
- Surgical equipment
- Endoscopy tubes
- Orthopedic implants
- Hypodermic needles and surgical blades and knives
For sterilization to be successful, effective cleaning is a must and if decontaminating of equipment is considered, then our machinery and tools will meet the most challenging criteria. Our commercial ultrasonic equipment can never be cleaned to perfection by manual methods, even biopsy forceps and other spiral shaped tools. Ultrasonic vibrations are, however, incapable of killing micro-organisms and germs or bacteria; this means infective aerosols can be produced. To keep related dangers at bay, the lid needs to be tightly during cleaning use.
As explained, ultrasonic cleaning systems cleanse tools and products by high frequency sound signals that are high on energy. This means dirt from tools and equipment that is being cleaned will be extricated and will make its way to the bottom surface of the tank, or might even just be loosened so that removal is easy during rinsing. Discuss with the tank consultant which type of detergent will work best for your specific cleaning requirements. For best performance, usually a neutral, low-lathering detergent will be employed since they yield better results; enzymatic detergents also produce the best cleaning outcomes.
The occurrence of organic residue, e.g. blood bits and other secretions can mean the equipment has not been disinfected. This is due to the fact that Microorganisms are defended by organic substances from contact with the biocide or maybe because the biocide was inactive when it met the organic residue. Resultantly, violent cleaning of bendable endoscopy equipment is needed to make sure the medical tools are completely clean prior to sterilization. Disinfection should take place as soon as the equipment has been cleaned so that the secretions do not dry out.
PREWASHING by means of Surface sweep or Turbo Filter — The primary step is to get rid of most of the buffing elements when using turbo setups that have a hug filtration system. The most effectual turbo systems need gross soil (mentioned below) before targeted cleansing. Oil removal system is designed to eradicate organic residue that settles in from binders of compounds.
ULTRASONIC WASH with Surface Sweep and Turbo Filter — The secondary stage is intended to accurate and targeted cleansing of the orthopedic implants. The precision wash makes use of ultrasonic waves plus the turbo filter. The dominant purifying blend of the ultrasonics partnered with the turbo filter (read above) largely heightens the clean-up practice and gives better-quality outcomes.
CASCADING RINSES — Two high temperature rinses are employed with platform rotation and oscillation for the rinsing process. The elevator transfers the parts in to the cleaning mixture and oscillates in strokes, set at either long or short. You can choose between a 5–9 inch stroke and 2–4 inch stroke. The longer rubbing stroke does improved washing out since hydraulic solution penetrates through the working zone, especially for nested pieces or complicated shapes with shortened paths whereas the shorter stride provides faster oscillation rates and faster procedure for little components. Flexible strokes are better for cleaning.
KNIFE DRYING (with Hot Air )- The concluding phase of the procedure is the drying stage. ACT Hot Air Knife Blow-Off Dryers are particularly apt at quickly airing components with no extra heat. The answer to the method is the process elevator. This process elevator changes flow patterns and the outcome is a dynamic drying procedure, which means that platform oscillation and hot air flow are the ideal combination. This successful ‘dynamic flow combo’ is best for reaching all surfaces of every part, meaning utmost evaporation and faster processing rates.
As mentioned before, presence of blood residue or other secretions can mean disinfection can be rendered useless.
The occurrence of organic residue, e.g. blood bits and other secretions can mean the equipment has not been disinfected. This is due to the fact that Microorganisms are defended by organic substances from contact with the biocide or maybe because the biocide was inactive when it met the organic residue.
Resultantly, violent cleaning of bendable endoscopy equipment is needed to make sure the medical tools are completely clean prior to sterilization. Disinfection should take place as soon as the equipment has been cleaned so that the secretions do not dry out.
3. Dental and Orthopedic Insertion and Implant Cleaning
We can give you the most comprehensive variety for systems to clean your orthopedic tools and equipment, and free them from dust, oil, compounds.
As per your cleaning requirements, we can devise a multi stage cleaning setup with automated features and semi automated attributes. For specifying your requirements and demands, email us at email@example.com.
Using precision cleaning for cleansing orthopedic implants:
This function is a Target clean Rinse Dry scheme for crucial clean-up of medical machinery. It carefully cleans a comprehensive group of orthopedic implants (precision machined) and refined with buffing compound. The method attains very high hygiene conditions in agreement with the manufacturers demands. The line is assembled from two metal modular A2PR Console Systems, running from one side to the other. These console systems are manufactured upon a sturdy I beam — built foundation for precision and stability; the scheme also provides convenient installation.
- PREWASHING by means of Turbo-Filter and Surface Sweep: This is the first stage that includes cleaning away buffing compounds with a turbo system. The best turbo system needs gross oil before precision cleaning. Oil removing is schemed to remove organic leftovers that settle from binders.
- ULTRASONIC WASH with Surface Sweep and Turbo Filter — Next, precision cleaning is the aim, for orthopedic equipment. The targeted waves make use of the turbo filter. The major purifying mixture is the combination of filter and ultrasonic waves which gives unbelievable results.
- CASCADING RINSES — Twin heated rinses are used with rotation and oscillation for rinsing the required parts. The crane transfers the parts in to the cleaning mixture and oscillates in strokes, set at either long or short. You can choose between a 5–9 inch stroke and 2–4 inch stroke. The longer rubbing stroke does improved washing out since hydraulic solution penetrates through the working zone, especially for nested pieces or complicated shapes with shortened paths whereas the shorter stride provides faster oscillation rates and faster procedure for little components. Flexible strokes are better for cleaning.
- KNIFE DRYING with Hot Air — The concluding phase of the procedure is the drying stage. ACT Hot Air Knife Blow-Off Dryers are particularly apt at quickly airing components with no extra heat. The answer to the method is the process elevator. This process elevator changes flow patterns and the outcome is a dynamic drying procedure, which means that platform oscillation and hot air flow are the ideal combination. This successful ‘dynamic flow combo’ is best for reaching all surfaces of every part, meaning utmost evaporation and faster processing rates.
4. Armor and artillery Industry
Firearms regularly require intense cleaning and lubrication to function at an optimum level. The elements that need to be removed by the cleaning process include carbon, oils, by-products of combusted black gun powder, lead and copper fouling that can mount up over time and cause faults. Firearms are best cleaned with ultrasonic methods for both exterior and interior surfaces.
We are one of the pioneers to use ultrasonic cleaning for weapon washing in China. Ultrasonic cleaning has set up a high standard of cleaning armor and weaponry since it is unmatched, compared to manual cleaning. Large numbers of the best agencies and companies all over Chian, especially law-enforcement agencies, trust our products for the cleaning of their firearms and weaponry.
Why is ultrasonic cleaning the best choice for artillery?
Firearms need to be well cleaned and oiled to make sure they continue to function in a proper manner. The need to clean them arises from the presence of carbons, oils and gunpowder residue that settles in over time, and stays with the weapon to ultimately result in faulty functioning. Cleaning with ultrasonic waves will leave your armor completely cleansed, in and out.
Our hydraulic repellent removes all residues within minutes and each weapon is left looking and feeling as good as new. We have a special solution that eradicates oils, dirt and any greasy leftovers from all metallic and plastic surfaces that is called the weapon cleaning solution concentrate that is designed in a non-ammoniated fashion.
Main characteristics of the Ultrasonic Cleaning System :
- Eradicates grime, rust, loosened lead powder and copper residue
- Eco-friendly, meaning good for the environment
- Cleans within minutes, economizing on precious time
- Cleans areas that can never be cleaned manually
- Works on all styles and sizes of guns be it long arms, rifles, hand guns, tactical weapons, and machine guns
- Greases and conditions to make sure the gun functions in a proper manner
- Sports a complete line up of systems, sizes and side tools to fit your precise wants
- is acknowledged by leading gun manufacturers as the best cleaning system for artillery
Range of firearm departments that can be cleaned with ultrasonic waves system:
- Police Divisions
- Munitions stores
- Firing assortments
- Armed forces
- Federal and state defense agencies
- Gun retailers
- Gun manufacturers
- Gun devotees
- Sport Stores
- Weapon enthusiasts and collectors
- Gun companies
How to clean your guns?
Semi-Automatic hand-held firearms:
- Begin with making sure the weapon is not loaded
- Adjust the field strip in concurrence with company directions.
- Take out grips where suitable.
- Fasten the hammer in reverse and depress the de-chocking handle to unlock device where appropriate.
Shotguns plus rifles:
- Disconnect the stock and forearm from the barreled act.
- Take away the magazine spring.
- Eliminate the container from the action.
- Remember that shotgun triggers are groped as smaller machines
Cleaning of Revolvers:
- Be sure that there are no bullets in the weapon
- Do away with grips that are easy to take off
- Leave hammer in chocked situation.
- Get rid of yoke and cylinder from the frame.
- Disconnect the yoke and from the cylinder.
- Remove side section plates for primary ultrasonic cleaning.
- For cylinders, raise star and position a small spacing bar connecting the star with the cylinder to improve cleaning routine.
Our Ultrasonic Systems are obtainable in a range of models to suit your cleaning needs relating to firearms. Be it handguns, shotguns, rifles or any other arms, our setup can leave your weaponry looking as good as new. It is the best lubrication and automatic cleaning for the service of your firearms.
5. Car and Automotive Industry
The aspects where we can use ultrasonic cleaning in the automobile industry is to clean pistons, crank shafts, bearings, gears and even fuel injectors; the treatment is best applied to air conditioning parts as well.
The design of the all-efficient Ultrasonic cleaning system:
While building a cleaning system you need to think about the substances that need to be cleaned off, the cleanliness level that needs to be achieved, the amount of parts to be treated, the shape and material of the component and the last design and mapping. The structure and shape, as well as the production rate and the cleaning time period will give a correct estimate for the size of the cleaning system.
Conventional tank sizes are 20 to 400 L capacity, and many even huger. Other aspects that need to be kept in mind are temperatures and rinsing, drying and loading necessities. Our engineers will help you out in important decisions that need to be taken when you require technical advice.
Check list for cleanliness:
The conventional water-involving ultrasonic cleaning system has a few standard phases: the cleaning stage will dislodge all contaminants. The next phase is rinsing which will remove and eradicate any loose dirt or residue, and then the last stage is called drying, where any remaining moisture is evaporated. The overall procedure is concluded based on testing and experimentation. We have a testing laboratory, where after a long trial and error process we come up with the best methods to meet your cleaning standards.
There are plenty of ways to test cleanliness levels. Some are uncomplicated water break tests to check for oil removal. Others are more detailed and check for surface quality with the help of electron emission to gauge thin films of impurities down to the level of Angstrom.
How to handle components:
The shape of parts needs to be thoroughly studies before it is decided how it will be placed inside a tank. Oversized components e.g. engine blocks can be dangled in from a lift whereas smaller components can simply be placed in a basket and lowered into the tank. The major determinant in part placement is to make sure that no air is entrapped within the part. If carelessness is rendered in this mater, cleaning solutions will not be able to reach into the air pockets of the parts, and cleaning will not be as thorough as desired. If you still wish that the pat be cleansed completely, you will have to turn the part around while it is in the tank to turn the air hole upwards. Manage this manually or by an automated lifting machine, whichever is convenient.
For ideal results keep small parts away from each other when placed in a basket. The best solution is to keep dividers or locators between them e.g. if you have machinery valve parts, keep them away from one another. Most times, in high outcome pipes, it’s impossible to physically keep parts away from each other, such as the cleaning of electronic connector pins where hundreds and thousands of parts have to cleaned up at the same time due to high production levels and small geometry of parts. Ultrasonic sound waves will be able to reach between these parts and allow the solution to scrub well between all crevices, even if parts are piled up in a stack. It’s difficult, sometimes, for the rinsing process to remove all detergent residues, and for the dryer to dry all moisture from parts that are embedded. The only way to solve this problem is to use an automatic hoist with a steady rotating arm that lets the basket tumble at a fixed rotation per minute. This rotation and movement will allow the parts to rinse and dry to the innermost corner and crevice.
6. Ornaments, jewelry and artifacts Industry
Ultrasonic Jewelry and Eyeglass Cleaner :
Ultrasonic Jewelry and Eyeglass Cleaner is so strong that it can complete the cleaning process with just water. This cleaner can be employed to cleanse necklaces, rings bracelets and the like. Even glasses, spectacles and lens can be purified. We also supply a machine that cleans carats.
- Separate Circuit plan to provide extra safety by keeping water away for enhanced safety
- For precise cleaning time periods there is a large digital time display
- Spill proof tub with cover to keep cleansing solution
- Transducer with a wider diameter
- Holder for watches and jewelery
For enhanced cleaning: simply include more water with the cleaning mixture as it makes millions of bubbles that go into places where hand or brush cannot reach.
7. Hardware and Brassware Industrial Cleaning
Ultrasonic treatment can be applied in the metal finishing process and utensil cleaning. The utensils are cleaned after polishing e.g:
- Cooking vessels and pans
- Chandeliers and light bulb holders
- Grips and knobs, etc
- Brass instruments
In the procedure of hand polishing or automated polishing off animal and vegetable fat, we use different substances such as aluminum or Tripoli powders etc. We can make various types of these solutions, depending on the cleaning stage. Some special features of this solvent are:
- Slow & roundabout heat so that the solvent does not disintegrate.
- High number of cooling coils.
- Built-in cooling unit
- Proprietary planned Water divider.
- Fully automated security features.
- completely encapsulated with automatic treatment method.
We also manufacture single tank cleaning systems to remove compounds prior to electroplating.
8. Ultrasonic treatment to clean Ballpoint Pen Tip
Turned products are impossible to clean without ultrasonics. But in the process it’s important that they sensitive parts not be damaged. One major problem is the small parts and especially the holes, that cannot be penetrated without rotation and ultrasonic action both.
A typical system built for treating metal finding that are actually ball pen tips is as follows: It is vital to understand that tips of ballpens are no more than 9mm long, which means they have a dead pole. They are coated in oil and coil shavings are placed inside. Once cleaned, the tips are filled with the ink refill component. If by mistake, any component is still stuck inside then the pen would not write smoothly and wouldn’t pass the test or check of being a good pen.
It is only the ultrasonic treatment that has always returned 100% results. In the start, we employed organic solutions, but recently we have begun using environment-friendly water based detergents which are completely eco-friendly and bio-degradable. The successful action of the ultrasonic is actually eensured by the rotation process in the basket.
This is the final work sequence:
- Ultrasonic cleansing in heated detergent
- Rinsing in cold aqua that is moving rapidly
- Demineralized water to rinse again, this time warm water
- Drying in warm pressure-moving air
You can opt for the system to be completely automatic with the presence of a supervisor every 20 minutes or so. Energy is consumed at 12 or 14 kW, and detergent cost is negligent.
Originally published at www.bjultrasonic.com.