4 Simple Tricks To Enhance Ultrasonic Cleaning

Arranging parts in an ultrasonic cleaner

It is always advisable not to place the components on the lowermost part of an ultrasonic tank. It would be similar to placing a thumb on a speaker diaphragm. Not only does it prevents the proper movement of the diaphragm but also tends to interfere with the ultrasonic energy that is generated. There are some basic issues that need to be taken care of while designing tanks for optimum ultrasonic cleaning efficiency.

The various components should be placed properly in a basket or work holder in an Ultrasonic Parts Washer that is specifically designed for each individual component. It is of special significance in high end cleaning systems where it is essential to achieve good cleaning of various components. Make use of a stainless steel basket because soft components tend to absorb the ultrasonic energy. Do not use plastic or other lighter materials. If the component is of a kind that is damaged easily, racks composed of stainless steel that come with Nylobond or Teflon coatings can be used in tanks for optimum ultrasonic cleaning efficiency.

How many parts can be cleaned in a tank?

The total space of components that are to be cleaned during ultrasonic cleaning should be less than the tank volume as measured in cubic inches which translates into about 50 square inches of cleaning area per liter of tank capacity. The volume of the tank should be such that when the object is placed into the basket there should be a minimum of 1.5 inches on each side and top and at least 2 inches of liquid on the bottom parts. The design of work fixtures and corresponding baskets is significant to a good cleaning process.

Should we filter the cleaning solution in the ultrasonic tank during ultrasonic cleaning?

It varies depending on the size of the tank in an Ultrasonic Parts Washer.  In case of a small tank, you may change the solution for a fresh one rapidly but a larger tank can require up to 2-3 hours for changing the solution and then reheating to the proper temperature. It would also be dependent on how much cleaning the components require. If high volume of cleaning is required, then a frequent changing of cleaning solution becomes necessary.

The solution to these issues is a filtration system that will help in re-circulating the cleaning fluid through a filter of the appropriate type which keeps re-circulating the solution and then returns it to the tank. Keep in mind the following things while using a filter system:

1. It is recommended that you make use of the filter at not more than 5-10 liters per minute (assuming a tank capacity of 100 liters) if you are using the ultrasonic simultaneously. Air will be introduced by the pump in a filter system and it can lower the ultrasonic activity if it is allowed to run at higher rates. It is always advisable to make use of filter between cleaning cycles.

2. Even if you make use of a filter, it is always suggested that the tank be emptied and cleaned as soon as the soap or other cleaning agent is exhausted.

3. Filters should be regularly changed.

Rinsing parts after cleaning in an ultrasonic tank

As a rule washing will enhance the end result but keep in mind that when you utilize a cleaner of any sort you will also be leaving a deposit of that cleaner on a component. The most ideal approach to expel this buildup is to flush in DI water spray as well as another Ultrasonic tank loaded with a nonstop over stream of Hot DI water. This will expel any hints of the cleaning substance.

Spray Rinse Tanks are intended to be somewhat bigger than the ultrasonic tank that is utilized. The splash is conveyed from 2 or more spray bars on the topsides of the tank. The channel is typically double the extent of the bay. As a rule a state of utilization DI water radiator is utilized to convey a hot spray wash. The tanks may be composed of Polypropylene or stainless steel.

At a point of use DI water warmer uses ceramic heaters to quickly raise the temperature of the DI water as it streams into the tank. A switch that is sensitive enough to the stream of water into the radiator activates the system as per demand. A definitive temperature will then be attained that is determined by the stream rate of the water and the force of the warmer. It must be estimated to the interest of the system.

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.