Industrial application of ultrasonics

Answer 1

Printing Industry

Ultrasonic used as a method of cleaning intricate and difficult to clean parts has been available for many years within a wide range of industries. The main advantages being that components of the most complicated shapes can be cleaned efficiently, speedily and comprehensively. Ultrasonic achieves this deep and complete cleaning via the build up and collapse of millions of tiny bubbles within the fluid which act on the surface of the component, behaving in many ways as a brush. The scrubbing action of this brush can be made as vigorous or gentle as is required.

We have developed several systems to suit a number of applications. From the very specialized machines utilized within the printing industry, through to the sophisticated multistage systems used in the engineering, electronics and other sectors, we have the technology to design and construct not only standard systems but also equipment to suit any specific requirement. The system shown will accept and rotate up to 6 rolls at 1040 face width, or 12 off rolls up to 450 face width (depending on particular rolls).

The units have the all new TSS generator with "Super sweep" and are packed with many features. Ultrasonic is far and away the best possible way to clean anilox rolls and now with the ability to clean up to 12 rolls at a time, there can be no comparison with other cleaning Methods. All of the equipment manufactured by TRANSONIC is built to last, with inherent quality of engineering design and manufacture.

This term is used to describe the oscillating of ultrasound about a mean frequency. The use of this oscillating frequency is vital when using ultrasonic to clean ANILOX ROLLS or GRAVURE CYLINDERS, especially with today's ever increasing screen counts and along with Roll Rotation is the primary protection for the roll during cleaning. The inclusion of a generous Frequency Sweep ensures an even distribution of the ultrasound over the complete surface of the roll, thus eliminating "hot spots" of sound, a known cause of roll damage.

Our SPL generator with "Super sweep" can deliver up to 4 kHz of sweep, which is considerably more than any other known generator. There is also another advantage. Because of "Super sweep" we are able to work at higher frequencies than our competitors, thus further enhancing the safety aspect of our systems, as a higher frequency offers a more gentle cleaning action.

The unique design and construction of the heart of our machines is what enables us to boast not only completely safe equipment, but also the most technically advanced ultrasonic roll cleaning systems in the world.

Medical Industry

There exists a wide application of ultrasonic cleaning in the medical industry. It is extensively used for :

• Surgical tools cleaning.
• Endoscope tube cleaning.
• Orthopedic implants cleaning.
• Surgical blades & hypodermic needles cleaning.
• Lens cleaning.

Effective sterilization requires effective cleaning, and when it comes to cleaning reusable instruments and equipment, our equipment & detergents meets the most demanding criteria.

Our industrial ultrasonic cleaners are used to assist with the cleaning of instruments that cannot be adequately cleaned manually such as spiral wound instruments like biopsy forceps etc. The ultrasonic vibration at the frequency used for cleaning does not kill microorganisms and infective aerosols may be produced. It is for this reason that the lid of the tank must be tightly closed during operation.

Ultrasonic cleaners work by subjecting instruments to high frequency, high-energy sound waves. This causes the soil to be dislodged from instruments and drop to the bottom of the tank, or be sufficiently loosened that it will be removed during the rinsing process.

The detergent used in the ultrasonic tank must be carefully selected in accordance with advice from the tank's manufacturer. Optimally it will be a neutral, low-foaming product and enzymatic cleaners will have enhanced benefits in this process.

The ultrasonic Environmental friendly cleaning detergents & Solvents that we offer are :

• S.K.4053-N : A neutral liquid detergent for long instrument life.
• SK 4053-A : Is a low foaming cleaner for aluminum-safe washing.
• Leksol solvent : Precision cleaner for research instrument maintenance.

The presence of organic material such as blood faces and respiratory secretions can result in the failure of disinfection. This may be because either the organic material protects the microorganisms from exposure to the biocide or because the biocide may be inactivated by contact with organic material.

Consequently, rigorous cleaning of flexible endoscopes is required to remove such material before disinfection or sterilization. This should occur immediately after use to prevent the drying of secretions.

Orthopedic Implants Cleaning

TRANSONIC can provide different types of cleaning systems suitable for the cleaning of orthopedic implants for removing dust, oil, buffing compounds etc during manufacturing process.

Depending upon the cleaning requirement we can design multi stage cleaning system with automatic/ semi automatic cleaning machines. You may contact us with your requirements at ultrasonic@transsonicindia.com

Precision cleaning system for implants :

This application is a Precision Wash Rinse Dry System for critical cleaning of medical components. It thoroughly processes a complete family of orthopedic implants that have been precision machined and polished with buffing compound. The system achieves very high cleanliness specifications in accordance with the manufacturers requirements. The line is constructed from two stainless steel modular A2PR Console Systems and runs left to right. The consoles are built upon a heavy duty I beam fabricated base for accuracy, stability and ease of shipping and installation.

Process :

PREWASH with Turbo/Filter and Surface Sweep - The first stage is designed to remove the bulk of the buffing compounds using a turbo system with large capacity filtration system. The highly effective turbo action reduces the gross soils (see below) prior to precision cleaning. An oil removal system with Surface Sweep is used to remove residual organic based deposits from the compound binders.

ULTRASONIC WASH with Turbo/Filter and Surface Sweep - The second stage is designed to precision cleaning of the orthopedic implants. The precision wash uses ultrasonics combined with turbo filter. The powerful cleaning combination of the ultrasonics alternating with the turbo (see above) greatly accelerates the cleaning process and yields superior results.

CASCADING RINSES - Two heated rinses uses with platform oscillation for the rinsing. The elevator moves the parts into solution and oscillates with either a short or long stroke. A two position switched is used to select either long 5 to 9 inch or short 2 to 4 inch strokes. The long stroke is used to provide better flushing (hydraulically forcing solution though the working zone) for nested masses of parts and/or complex shapes with recessed passages whereas the short stroke is used to provide quicker oscillations and faster cleaning of simple parts and/or part configurations. Flexibility in stroke ranges and speeds produce more comprehensive cleaning.

HOT AIR KNIFE DRYING - The final stage of the process is the drying phase. ACT Hot Air Knife Blow-Off Dryers are very effective for rapidly drying parts without using excessive heat. The key to the process is the process elevator. It is used to produce changing flow patterns that result in a dynamic drying mode (i.e. platform oscillation combined with hot air flow). The effect of "dynamic flow combination" is better coverage of component surfaces, maximum evaporation and accelerated processing times.

Armour Industry

Weapon cleaning :

Our Ultrasonic Weapon Cleaning Systems and Solutions safely clean firearms more effectively than manual methods by providing a uniform standard of cleanliness. That's why government, law enforcement agencies and gunsmiths trust our products to clean their weapons carefully and efficiently. We were one of the first companies to apply the process of ultrasonic cleaning to firearms in India.

The Largest standard tank size, offering greatest flexibility for long-barrel and handgun cleaning, with dual tanks for simultaneous cleaning and lubricating. Length of tanks 52".

Why use ultrasonic cleaning for firearms?

Firearms frequently need to be thoroughly cleaned and lubricated to ensure continued operational reliability. This is due to carbon; oils, products of combustion black powder; copper and lead fouling that can accumulate over time and cause malfunctions. Ultrasonic cleaning provides an unsurpassed clean for all firearm surfaces, both interior and exterior.

Our water repellant displaces residual water in minutes, leaving each weapon lubricated and with a "factory new" look, feel and appearance. Weapon Cleaning Neutral Solution Concentrate Non-Ammoniated Designed to replace Solvents for removing Oils, soils and light Greases from metal or plastic surface.

All of our ultrasonic cleaning systems and solutions :

• Remove dirt, crud, light rust, loose lead, powder, buildup and copper residue
• Are environmentally safe
• Clean in minutes, saving valuable time
• Clean areas impossible to reach by hand
• Work on any size gun, including handguns, long arms, tactical weapons and machine guns
• Lubricate, condition and help ensure proper gun function
• Feature a full line of systems, sizes and accessories to fit your specific needs
• Are accepted by leading gun manufacturers

Our ultrasonic cleaning systems can be used in every sector of firearms cleaning includes :

• Police Departments
• Armories
• Firing Ranges
• Military
• City, State and Federal Agencies
• Gun Dealers
• Gunsmiths
• Gun Enthusiasts
• Sporting Goods Stores
• Collectors
• Firearms Manufacturers
• Prisons

Tips for Cleaning

Semi-Automatic hand guns :

• Make sure weapon is unloaded.
• Field strip in conjunction with manufacturer's instructions.
• Remove grips where convenient.
• Lock the hammer back and depress the de chocking lever to open mechanisms where applicable.

Rifles and shotguns :

• Separate the stock and forearm from the barreled action.
• Remove the magazine spring, if necessary.
• Remove the barrel from the action if removal is simple.
• Shotgun trigger groups fit in smaller machines.

Revolvers

• Make sure the weapon is unloaded.
• Remove grips.
• Place hammer in chocked position.
• Remove yoke and cylinder assembly from frame if required.
• Separate yoke and cylinder parts.
• Remove side plates for first ultrasonic treatment.
• For cylinders, lift star and place a small spacer between the star and cylinder to enhance cleaning performance.

Our Ultrasonic Weapon Cleaning Systems are available in several models for a variety of applications. From handguns to tactical weapons to shotguns and rifles, we've got a system and solution that will get even your toughest cleaning challenges looking brand new. All provide hands-free cleaning, lubricating and conditioning in minutes.

Automobile Industry

In automobile industries Ultrasonic cleaning can be done for different applications like Piston Cleaning, Bearing Cleaning, Crank shafts, Gears, Engine assembly blocks, Carburetors, Fuel Injectors, & automobile air conditioning components.

System design :

Considerations in the design of any cleaning system include the contaminants on the part(s), the required cleanliness level, the geometry and material of the part(s), the quantity to be processed, and the previous system design and layout (if applicable). The part geometry, production rate, and cleaning time required will determine the size of the cleaning system, once the overall process has been decided. Typical tanks range from 20 to 400 L (5 to 1000 gal), and some are even larger.

Industrial, heavy-duty applications require industrial, heavy-duty ultrasonic equipment. Other factors that need to be considered are cleaning solutions and temperatures, rinsing (with or without ultrasonics), drying, automation, and load requirements. TRANSONIC will assist in these decisions and will offer laboratory services and technical expertise.

Cleanliness considerations :

In a typical aqueous ultrasonic cleaning system, it is the cleaning stage(s) that will remove or loosen the contaminants. The following rinse stage(s) remove any remaining loosened soils and residual detergent, and a dryer removes any remaining rinse water. The overall process of the system is usually determined experimentally. TRANSONIC have an applications lab where, through a process of experience, trial, and error, a properly designed cleaning process can be determined to meet the cleanliness levels specified.

There are a variety of ways to check for cleanliness. Some are as simple as a water break test on the part to see if most oil has been removed. Others are as elaborate as surface quality monitoring that uses optically stimulated electron emission technology to measure thin films of contaminants down to the Angstrom level.

Part handling :

The geometry of the parts are carefully analyzed to determine how they will be placed in the cleaning tank. Large parts, such as engine blocks, can be suspended directly from a hoist, whereas smaller parts will usually be placed in a basket. The most important factor in parts placement is to be sure that air is not trapped anywhere inside the part. If an air pocket is allowed to form, such as in a blind hole that would be facing downward toward the bottom of the tank, the cleaning solution and effects of cavitations will not be able to reach this particular area. The part will have to be rotated somehow in the tank during the cleaning process to allow the cleaning solution to reach the area where air was previously trapped. This can be accomplished either manually, by the attending operator, or by a rotating arm on an automated lift mechanism.

It is best if small parts can be physically separated when placed in a basket. An example would be to place machined valve bodies in a basket with some type of divider or locator for each one. Many times, however, in high output lines it is not possible to separate parts physically, such as in the manufacture of electrical connector pins where thousands of parts may need to be cleaned at one time because of the high production output and the small size. Ultrasonic agitation will be able to reach between these parts and allow the solution's scrubbing power to remove the contaminants, even if the parts are stacked on top of one another. On the other hand, rinse water may not remove all of the residual detergent , and a dryer has a very hard time removing moisture from embedded parts. The problem is easily solved by having an automated hoist with a constant rotating fixture on the arm that allows the basket to tumble at 1 to 3 rpm. This rotation allows the parts to tumble slowly and exposes the embedded pieces for proper rinsing and drying.

Jewelry Industry

Digital Ultrasonic Cleaner RKT 150, RKT600 :

Professional cleaning results at half the cost of other leading manufacturers! Digital Ultrasonic Cleaner RKT 150. This new digital ultrasonic cleaner is so powerful that it can clean with water alone. This digital ultrasonic cleaner is used for cleaning; Jewelry, Necklaces, Earrings, Rings, Bracelets, Coins, Watches Straps and Bands etc. Eye Care Glasses, Sunglasses, Contact Lens.

Features :

• Isolated-Circuit Design, Keep Water Away for Extra Safety
• Large Digital Timer Display for Precise Cleaning Time Control
• Wide dipping tub with spill proof cover that can safely store tarnish-removing solution between uses. This is perfect to remove tarnish from silver, copper and gold.
• Wide-Diameter Transducer for Best Cleaning Result · Watch and Jewelry holder.

For Extra Cleaning Power: Just add water with our cleaning solution and it creates millions of microscopic cleansing bubbles that goes deep into places not reachable by hand or brush.

Standard sizes :

Working dimensions

Capacity in Ltrs

Ultrasonic Power

Heaters

Timer

Thermostat

Material of construction

Generator

10 x 6 x 6"

5.5 liters

150 watts

500 watts

Optional

Non Indicating

SS 304, 1.5 MM

Separate

12 x 8 x 6"

8 liters

250 watts

500 watts

Optional

Non indicating

SS 304, 1.5 MM

Separate

15 x 8 x 12"

21 liters

600 watts

1200 watts

Digital

Digital

SS.316, 1.5 MM

Separate

Utensils, Hardware & Brassware Industry

Our high-end Ultrasonic cleaning is extensively utilized in the metal finishing and utensils industry. The cleaning is done after polishing of :

• Cutlery
• Taps
• Pots and pans
• Chandeliers
• Handles, etc

In this process of manual or automatic polishing mixtures with animal or vegetable greases and different abrasive substances like as corundum or corubin, aluminum or tripoli powders,etc., are utilized.

Until now these washing working processes were done with organic boiling solvents, like Tri chloro Ethylene & other chlorinated solvents which is now banned due to its harmful effects to the environment & human health. According to the survey continuous exposes to TCE vapor can cause cancer & effects nervous system. TRANSONIC has a very special solvent equivalent to TCE which is environmental friendly and accepted world wide as a safe replacement of TCE. We can make different types with different stages of ultrasonic cleaner cum vapor degreaser which is best suitable for these solvents. Some of the features of TRANSONIC vapor degreasers are :

• Gradual & indirect heating which does not disintegrate the solvent.
• Double free board zone with maximum number of cooling coils.
• Built in chilling unit
• Proprietary designed Water separator.
• Fully automatic safety features.
• Totally enclosed with automatic handling system.

We also make single tank ultrasonic cleaning systems used widely for removing buffing compounds before electro plating process. Standard sizes available are :

Tank Working Dimensions

Capacity

Ultrasonic Power

Heaters Load

Thermostat

Timer

15 x 13 x 10"

28 Liters

500 watts

1500 watts

Blind type

Optional

24 x 16 x 16"

92 Liters

1000 watts

3000 watts

Digital

Optional

24 x 18 x18"

125 Liters

1500 watts

4000 watts

Digital

Optional

24 x 20 x 30"

236 Liters

2000 watts

5000 watts

Digital

Optional

36 x 20 x 20

236 Liters

2400 watts

5000 watts

Digital

Optional

24 x 24 x 48

450 Liters

4800 watts

10 K.watts

Digital

Optional

Contact TRANSONIC for any other special tank dimensions as per your requirements.

Ball Point Pen Tip Cleaning

Ultrasonics has become indispensable for cleaning turned products. In fact, turned products require thorough cleaning, yet their most delicate parts such as external threads or surface plates must not be damaged in the process. One particular problem is small, deep dead holes, which cannot be treated without the combined action of ultrasonic and slow rotation. Transonic ULTRASONIC, which has been working in this field for many years, is in the vanguard in this and many other applications.

Here is a typical system that we built for cleaning turned metal findings(ballpoint pen tips): It is important to realize that ballpoint pen tips treated with this system are only 9 mm long and 0.9 mm in diameter, and they have a dead hole. They are covered with turning oil and have tiny coil-like shavings stuck inside. After cleaning, the tips are assembled with ink refill. Any oil or shaving inadvertently remaining inside the tip would prevent the ballpoint pen from writing smoothly and flawlessly, causing it to fail the final inspection test.

Only the ultrasonic cleaning process has been able to ensure 100% results. In the beginning, the process used organic solvents (Trichloroethylene, chlorothene, perchloroethylene), but now safer and environmentally-friendly aqueous detergents (Safe Kleen 4053 For Cleaning Chemical is used which is totally bio-degradable chemical. The effective action of the ultrasonic is combined with a special rotation that ensures perfect results throughout the basket.

Here is the work cycle :

1. ULTRASONIC cleaning in warm alkaline detergent

2. ULTRASONIC cleaning in warm alkaline detergent

3. RINSING in cold running water

4. Rinsing with ultrasonics in warm DEMINERALIZED water

5. Rinsing with ultrasonics in warm DEMINERALIZED water

6. DRYING in warm pressure-ventilated air

7. DRYING in warm pressure-ventilated air.

Productivity is quite high,around 3-5 Kg. of material every 5 minutes (60 Kg. per hour).The system can be completely automatic and requires the presence of an operator 5 minutes each 20 minutes. Energy consumption is 12-14 kW, and the cost of detergent per work cycle is very low.