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Industrial Automated Ultrasonic Cleaning Line
Industrial Automated Ultrasonic Cleaning Line
An industrial automated ultrasonic cleaning line removes residue, dirt, oil and grime from precision parts and components.industrial automated ultrasonic cleaning line Manufacturers in aerospace, medical manufacturing, drug and food production, automotive and machining have discovered that ultrasonic cleaners offer premium results over traditional manual scrubbing with toxic solvents.
An ultrasonic cleaning system typically consists of a washing, rinse and drying tank with an ultrasonic generator and a series of transducers.industrial automated ultrasonic cleaning line The sonic generator converts electricity into mechanical/sound energy to create an ultrasonic field in the liquid solution, which in turn, causes cavitation of the solution molecules. These microscopic bubbles agitate the liquid, which scrubs the surface of immersed items to release adhered contaminants such as dirt, oils, and fingerprints.
Many sonic systems have multiple modes to optimize performance and save power. Sweep mode provides a +/- variation in frequency to ensure consistent, even cleaning action and reduce the risk of damage caused by high or low cavitation activity. Pulse mode boosts power for a brief period to provide more focused action on stubborn deposits, while Dynamic mode simultaneously utilizes sweep and pulse to achieve optimal results. A temperature control sets the desired water or solvent temperature and a timer controls the duration of each cycle. Many units also have a degassing function to speed up the removal of trapped air in fresh cleaning solutions.
Most industrial-grade sonic cleaning machines use either water or solvent cleaning solutions, depending on the materials to be cleaned. Aqueous solutions contain wetting agents to reduce surface tension and increase cleaning efficiency, while a solvent-based solution offers greater cleaning power than an aqueous one but requires special handling and disposal procedures. The type of cleaning solution used in an industrial sonic system impacts the overall cost of operation since spray solvents can be costly, especially for large volumes of fluid.
The most commonly used industrial ultrasonic cleaning frequencies are 40 kHz and 70 kHz. Lower frequencies produce fewer but larger bubbles and are best for heavily soiled items, while higher frequencies generate smaller but more numerous bubbles. This allows for more precise cleaning of tightly-adhered deposits from intricate items with blind holes, cracks and crevices.
Depending on the size of an item and the level of contamination, the cleaning cycle may last between two and 10 minutes. To maximize efficiencies and reduce downtime, an industrial automated ultrasonic cleaning system can be configured to automatically cycle through each step of the cleaning process with minimal operator intervention.
A properly maintained ultrasonic system will deliver the highest quality of cleaning results. Inspecting the condition of the sonic generator, monitoring the level of cleaning solution and training staff on proper loading techniques for the sonic bath are best practices that will ensure consistent and repeatable cleaning results.
Unlike conventional scrubbing with toxic solvents, ultrasonic cleaning systems are environmentally friendly and can be used without the need for specialized waste disposal containers. In addition, the use of ultrasonic technology replaces a number of expensive and labor-intensive operations including degreasing, etching, and deburring. In some cases, an automated ultrasonic cleaning system can cut the total cost of ownership by up to 50 percent compared to traditional methods.
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