How Four Power Factors Affect Ultrasonic Cleaning

Effect of Power on Ultrasonic Cleaning.

Hello again..

Well, since I have been talking about the various things we are learning in finishing industry,it might be apt that we also speak the factors that affect the performance in ultrasonic cleaning.

Ultrasonic Power is a critical factor in deciding the effectiveness of a cleaning System.

It’s generally accepted that 50 W per litre is acceptable level to induce cavitation in a cleaning bath of the system. However there are factors that must be considered.

What’s loaded in the tank?

The washing component could be made from  plastic or cast iron . Will the power requirement capacities change? An honest answer is yes, In order to maximise the cavitation efficiency the power will have to be altered. The ability of component to absorb the energy and vibrations are extremely important. 

The relative density of the medium?

The medium in the tank could be could be water or a solvent ( specific gravity < .099 or > 1.44) Will the power rating differ? Yes, it will.

Changes in the media , when bath temperatures of 66-75 degree celsius is achieved?

There are materials whose properties change dramatically with temperatures. Thereby the ultrasonic power would need to be adjusted accordingly. Certain fluids drop in Viscosity at elevated temperatures.

What about using different viscosities of fluids to clean?

The relation between the power and the viscosities of the fluid is directly proportional. The thicker the fluid, the more power would be required, The thinner the fluid, the lesser the need of power.

People always want to know what is the ideal cleaning power of a tank. The answer to this varies from person to person due to different perspectives. They have their own standard or interpretation to such a question.

The cleaning ability depends on a few set factors, such as:

1.    Actual electrical power input

2.    Cleaning solution used

3.    Transducer matching

4.    Physical construction of the tank

As the manufacturers of these systems, we use universal electrical power expressed in RMS Volts or Watts to evaluate cleaners. The tanks are then properly sized according to the industrial standards of power levels for cleaning levels, as is, so many watts/gallon. Like I mentioned above, 50 Watts/litre is typically and widely used and is categorised as a high power cleaner. In a few cases, 35 Watts/litre is used and is categorised under lower power industrial cleaner.

Industrial Ultrasonic Cleaning - Advantages and Limitations

Ultrasonic Cleaning: Handicaps and Limitations

Hi…

Thanks for dropping by!

This is Chandrakant from ESP Ultrasonic .

Last week, while I was visiting an Auto Component manufacturer, I was asked by their production manager Mr. Thirumuragan, what was exposure that i considered most valuable , as a Sales Professional.

Without hesitation I blurted out, “We don’t have a solution for every need.”

It’s true, we don’t!

We deal with various Industry verticals and each one of which are so well tuned with their expectations of process fit, budget considerations, Safety standards and Production . No two experiences are the same.

More often than not, we have to devise solutions. By networking with like minded professionals, process experts and by reviewing resources online , we work out a fitting solution. The internet has changed the outlook to successful marketing personnel to that of a marketing consultant. We source popular solutions and work with industry defined norms of acceptance and economy.

Our ability to offer solutions is important because we can offer technical options, which generally are not available to an outsider or on the internet. 

The Limitations of Ultrasonic Cleaning

Industrial Cleaning is evolving and so is technology, process and metallurgy . 

As salesmen, we have the most exciting occupation . Each client has a different challenge.

After about six months of follow up, I met the Senior Vice President of a company and he put forth his requirements .

“Can you dry clean a component”, he asked me.

In my head, I was thinking, ‘Obviously, NOT!

Since I could not offer them any of the wet cleaning options, I took time off to check alternatives. Finally,we arrived at a solution that could give them the ‘dry cleaning’ that they required.  

Ultrasonics do have their limitations. There are two obvious challenges: 

a) The Montreal protocol has prohibited the use of various solvents by restricting the use of the most compatible ones.

This was a body blow to the industry. After working on development of alternatives, the result was the emergence of water soluble solvents and aqueous based systems. The trends are emerging that this seems to be the best way out for most component cleaning challenges.

b) The other limitations of Ultrasonic Cleaning is that it doesn’t work in moving (flowing) media (be it water or solvents).

Yet considering the general methods of cleaning, Static media can’t flush out contaminants in deep recess parts or inside the intricate designed component.

In order to bridge the gap between these two challenges, Ultrasonic technology emerged by using slow flowing media or intermittent pressure jets or rotating component basket. Equipment designs have arisen where media is subjected to sudden turbulence created by blade propelled movement.

Another technique is to gently rock the component back n forth to dislodge deep set contaminant.

Hybrid technologies have also developed.

The good news is that cleanliness levels of 0.04 mg have been achieved using aqueous equipment.

The application of creativity and plethora of chemicals has ensured that almost every requirement for cleaning systems are addressed using Ultrasonic in total or in conjugation with other technologies. This has prompted most professions to adopt a solution based approach rather than a technology based approach.

Strengths of Ultrasonic Cleaning

Well, I think we should also look at the bright side of using Ultrasonic in cleaning.

The ideal system is built on using the combination of the technologies that mask the handicaps and limitations of the other.

Let’s take  another example - Cleaning Materials Exposed to Radioactive Particles.

This has traditionally been a stronghold of Vapour degreaser and High Pressure jets. However the flushing of beta and gamma radiations have been a very closely guarded technology as exposure is fatal and the contaminant cannot be disposed off.

With the challenge for recycling the irreplaceable resource, it was decided to develop a nano-filtration system that works to collect the particulate matter and remove the metal or non-radioactive substances.

Now 99.999% of the required can be achieved with beta filtration using multiple Ultrasonic tanks and jet spray arrangement.  This system is well set to increase the profitability of the cleaning process.

Also, new designs have emerged in the stainless steel tank construction, micro polishing of inner surfaces and use of acoustic technology like resonance, etc.

Ultrasonic Cleaning has emerged as a modern, flexible and dynamic cleaning technology. The technology can be tuned to adapt strengths from water blasting, to that of vapor based cleaning.

In washing, ultrasonic has ceased to exist as a technology.  Its now a solution based to a specific challenge.