The Continuous Ultrasonic Cleaning Line

The Continuous Ultrasonic Cleaning Line

A continuous ultrasonic cleaning line is used in manufacturing plants for a variety of industrial tasks including drawing wire and cladding it before further processing, producing parts for aerospace and medical equipment, and more. Ultrasonic cleaners use high-frequency sound waves transmitted through liquid to scrub surfaces and remove adhering contaminants from the items placed in the tank. This occurs through the creation and implosion of microscopic bubbles which are attracted to contaminants on surfaces and dislodge them from the surface of the parts. This results in an amazingly rapid and effective cleaning process. While the same basic technology is employed for all types of items – from delicate medical instruments to grungy engine components - tuning the process to produce high quality results can require careful attention to the specific factors involved.

Ultrasonic generators produce high-frequency acoustic energy for the ultrasonic cleaning process. The frequency is given in Hz (hertz) or kHz (kilohertz – thousands of waves per second). The higher the frequency, the more vigorous the cavitation action. Industrial ultrasonic cleaners typically use modules or arrays of transducers that can be fixed to the inside walls of a large tank.

Various power levels are available for the continuous ultrasonic cleaning line, with higher powers providing more vigorous action and a shorter duration of time required to achieve the desired level of cleanliness. Higher frequencies are usually used on rugged and heavily soiled parts while lower frequencies may be better for delicate or intricately shaped parts.

A filtration system is often included in the continuous ultrasonic cleaning line to remove contaminants from the liquid and protect the acoustic transducers from damage. This can also help reduce the amount of time and energy needed to refill the cleaning solution. Some tanks also include a pump to circulate the liquid and prevent contaminants from settling at the bottom of the tank.

An ultrasonic cleaner requires a large volume of cleaning solution for proper operation. This is often stored in a container called an ultrasonic cleaning tank that is made of stainless steel for durability and corrosion resistance. They range in size from tabletop models for small items to industrial-sized tanks that can hold very large objects. Tanks feature sloped bottoms that allow for easy draining and a filtration system to remove particles and residue from the cleaning solution as it is drawn through and back out of the tank.

A continuous ultrasonic cleaning line requires an efficient generator to deliver the correct amount of power for the process. Low-quality electrical components that do not last can result in erratic performance and drastic variations in ultrasonic cleaning power that reduce the effectiveness of the process. This can lead to scrapped and reworked parts, and failure to meet required validation protocols and specifications in medical and aerospace applications.

Some ultrasonic cleaning lines use a pulse or dynamic mode to provide intermittent bursts of extra ultrasonic energy to break up and remove tenacious contamination, or to degas fresh cleaning solutions. Others use a Sweep mode to continuously vary the frequency of the ultrasonic cleaning line, and some even have two modes to optimize the power for a particular application.

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