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Kaijo Shibuya America Inc.
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How Do Ultrasonic Cleaning Transducers Work?

Ultrasonic cleaning transducers convert the high-frequency electric signal of an ultrasonic cleaning system to sound waves within the cleaning solution. Ultrasonic cleaning systems are made up of an ultrasonic generator, a transducer and a tank to hold the cleaning solution. Frequencies in the lower range from 20 kHz to 160 kHz effectively clean heavy hard to clean contamination from robust part, while higher frequencies up 2 MHz are used for gentle cleaning of delicate components.

Ultrasonic Cleaning Transducer Features
Kaijo’s ultrasonic cleaning transducers have to generate an equal and consistent distribution of sound waves in the cleaning solution while withstanding the vibrations, temperature and the cleaning action of the system. Ultrasonic sound waves create high-energy cavitation bubbles in the cleaning solution, which create a scrubbing and cleaning action, dislodging the dirt and contaminants from the surfaces of the parts immersed in the cleaning solution. The cleaning solution may also contain mild detergent and can also be heated for faster cleaning.

The housing of Kaijo’s ultrasonic cleaning transducer is protected by 316L polished stainless steel so that the transducer are not affected by the cleaning solution and can resist the possible pitting from the cavitation bubbles. They are hermetically sealed and can operate in cleaning solutions of up to 100 degrees centigrade. Lower frequency range transducers are provided with power levels of 600 W or 1200 W, and higher frequency units are available at 1200 W.

There are three types of ultrasonic transducers:

• Immersible transducers – these are independent units and are the most flexible in their application. They can be placed into different tanks, or different transducers can be placed in the same tank.
• Bolt-on transducers– they can be semi-permanent placement on a cleaning tank.
• Mounted transducers– they are integrated in the tank.

If you would like additional information, read the complete article entitled “How Do Ultrasonic Cleaning Transducers Work?” You may also contact Kaijo at 408-657-5575 or email info@kaijo-shibuya.com to discuss what kind of ultrasonic transducer and cleaning system should be used for your application.
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Can Kaijo Create a Custom-Built Ultrasonic Cleaner for My Application?

Aside from standard ultrasonic cleaning solutions, there are also industrial ultrasonic cleaners that are custom-built solutions that cater to the clients' specifications. Kaijo’s extensive knowledge of ultrasonic cleaning technology allows them to analyze cleaning requirements to make needed adjustments to standard equipment for superior cleaning performance.

Industrial ultrasonic cleaners consist of an ultrasonic generator, a cleaning tank and a transducer. Each of these components can be selected from a line of standard components but custom features can be added and a custom system can be assembled to respond to unusual cleaning conditions or requirements.

Kaijo first looks at the cleaning application, and considers the factors affecting the cleaning system. These include the type of parts to be cleaned, nature or level of dirt or contamination to be removed, and whether the system is mainly used for a single cleaning task or whether many different types of cleaning have to be carried out.

Based on these factors, Kaijo decides on the ideal frequencies or frequency ranges as well as the system power. A lower frequency is usually used for removing tough dirt from rugged parts in a single use application, while a higher frequency is ideal for removing light contaminants from delicate parts. Also, the system power must be high enough to evenly fill the cleaning tanks with ultrasonic waves.

Once Kaijo has chosen the frequencies and the power, the company looks at the physical installation, determining the right kind of transducer and tank. Transducers can be immersible or mounted on the tank. Tanks could be existing ones or new ones. The size of tanks and materials used could influence the cleaning process.

Once these characteristics are determined, Kaijo chooses the components from its complete line of ultrasonic cleaning equipment. The company decides whether it's the standard off the shelf components can be used or if custom components will be required by the client.

The complete article “Can Kaijo Create a Custom-Built Ultrasonic Cleaner for My Application?” provides additional information. If you have questions after reading the article or would like to set up a free consultation to discuss your needs, please call 408-675-5575 or send an email to info@kaijo-shibuya.com.
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Why Industrial Cleaners Are Used by Plastic Manufacturers

Manufacturers of plastic products need to clean their equipment between production runs. They also often need to clean the plastic products they manufacture as well.

Also manufacturing plastic products have various cleanliness standards, depending on the end use of these products. For instance, products that are meant for use in food and medicine must have more stringent cleanliness requirements. Other plastic products used in industry applications may require less strict levels of cleanliness.

More plastic product manufacturers have turned to industrial ultrasonic cleaners from the old traditional cleaning methods that require intense mechanical scrubbing and the use of harsh chemicals.

High performance industrial ultrasonic cleaners can deliver different levels of cleaning action by choosing the right frequency and power. The microscopic cleaning bubbles produced by Ultrasonic cleaners penetrate wherever there is cleaning liquid in the cleaning tank. These bubbles completely and effectively remove contaminants down to the plastic base or tool material.

The benefits that industrial ultrasonic cleaners provide to plastic manufacturers include the following:

• Reduced costs due to the absence of harsh cleaning chemicals;
• Reduced labor costs because there's no more manual scrubbing, scraping, or pressure washing;
• Increased worker safety because the ultrasonic cleaning process is safe and needs little human supervision;
• Less time spent on cleaning because the ultrasonic cleaner's quick one-step cleaning process;
• Superior cleaning performance as the ultrasonic bubbles penetrate holes and crevices of the surfaces being cleaned;
• Longer tool and mold life because ultrasonic cleaning does not cause damage to the molds and tools;
• Better output quality because the ultrasonic cleaning parameters can be selected to specific cleaning application requirements by using appropriate frequencies and power levels.

Kaijo Shibuya, a leader among ultrasonic equipment manufacturers, can provide an ultrasonic cleaning system that meets the requirements of a customer’s application. If you would like additional information, or want a free consultation or quote after reading our complete article “Why Industrial Ultrasonic Cleaners Are Used by Plastic Manufacturers”, call Kaijo’s office at 408-675-5575 or email info@kaijo-shibuya.com.
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How to Buy the Right Ultrasonic Cleaner for Your Application – Part 2

The most important things to consider in choosing an ultrasonic cleaning system are the size of the tank, the frequency of the system and the power it can provide. Aside from these the accessories such as a tank temperature heater and holding basket should also be considered when choosing the right system for a cleaning application.

Cleaning tank heater:
Ultrasonic cleaners work by generating tiny cavitation bubbles which clean and scrub surfaces of parts to remove contamination. However when contaminants on surfaces are hard deposits that are difficult to clean, the cleaning action of the bubbles will take more time. In these cases using a heating the liquid in the cleaning tank will help to soften or loosen the hardened contamination from the surfaces being cleaned. That's where the cleaning tank heater enters the picture.

While cleaning tank heaters are a useful option for ultrasonic cleaning systems, they should be designed for the application. Untreated plain water (below 100 degrees centigrade) may be used most of the time but mild cleaning solutions can also be used. If the cleaning solution is considered, the heat settings should be controlled so that solution won't start boiling. The ultrasonic transducer should also be designed in a way that it will be able to withstand high temperatures.

Using sweep frequencies:
Kaijo’s ultrasonic cleaning systems operate at certain frequencies and are designed to achieve the optimum cleaning results according to the size of the cavitation bubbles and their cleaning intensity. However, a system may experience some unpredictable negative effects. This results to the ultrasonic waves canceling each other and no cleaning occurs. Using sweep frequencies will reduce this effect.

Water resonance system
The water resonance system helps ensure even cleaning action throughout the tank. The water treatment of a water resonance system provides an even distribution of nuclei essential for bubble formation. This allows bubbles to form everywhere within the cleaning solution rather than mostly above the ultrasonic transducer. This provides an even cleaning action on everything placed in the cleaning tank.

If you’re considering the purchase of an ultrasonic cleaner and have questions after reading the complete article “How to Buy the Right Ultrasonic Cleaner for Your Application – Part 2”, contact Kaijo for a free consultation or quote at 408-675-5575 or email info@kaijo-shibuya.com.
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How to Buy the Right Ultrasonic Cleaner for Your Application – Part I

Industrial ultrasonic cleaners can effectively clean parts rapidly and completely if they are correctly configured for the specific cleaning application.

An ultrasonic cleaning system typically consists of: a signal generator, a transducer, and a cleaning tank. Each component of an ultrasonic cleaning system should be carefully selected, and they must work together so that the entire system can clean parts and tools effectively.

Cleaning application – Ultrasonic cleaners usually remove light contamination like dusts, films and residues quickly and effectively. For cleaning parts that have heavy contamination (such as grease), the application of heat or mild solvents may be added.

Size and power – Effective cleaning also depends on the size of the parts to be cleaned, as well as the power selection. For bigger parts or parts that have unusual shapes, a custom-made tank may be appropriate. Naturally, bigger tanks will require more power than tanks of a standard size. However, too much power can cause pitting on the surfaces of the parts being cleaned, that's why selecting the right amount of power is as important as selecting the right tank size. The bottom line is that the ultrasonic waves need to be evenly distributed in the cleaning tank so that it can clean parts thoroughly and effectively.

Since industrial ultrasonic cleaning is carried out by the high-frequency sound waves in the cleaning solution, the cleaning tank (and the parts inside it) may vibrate slightly as cleaning takes place. This means that the parts should be suspended in the cleaning solution to avoid contact with the walls and the bottom of the cleaning tank, as even slight vibrations can cause damage.

Do you have questions? For more details read the complete article, “How to Buy the Right Ultrasonic Cleaner for Your Application – Part I”. You may also call Kaijo at 408-675-5575 or email info@kaijo-shibuya.com if you have questions or would like to discuss your industrial cleaning needs.
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Selecting an Ultrasonic Transducer for Your Cleaning Application

An ultrasonic cleaning system consists of a generator, an ultrasonic transducer, and a cleaning tank.

The role of the ultrasonic cleaning transducer is to transform an electrical high-frequency signal from the generator into ultrasonic sound waves in the cleaning solution contained in the tank.

Kaijo's ultrasonic cleaning transducers are made up of an electrical section that receives the electrical high-frequency signal from the generator and a mechanical section that vibrates at a high frequency. Once received, the electric signal is applied across piezoelectric crystals which change the signal into vibrations.

When the transducer is immersed in the liquid or cleaning solution, these vibrations result in corresponding ultrasonic waves in the solution. These ultrasonic waves travel through the liquid as compression peaks and troughs. Cavitation bubbles form in the troughs because of the low pressure, and they collapse again in high-pressure peaks. As bubbles collapse, they release an extremely powerful jet of cleaning solution that dislodges dirt, grime, and other forms of contaminants from the surface of the parts that are being cleaned in the solution.

These bubbles create a fast and effective cleaning action without damaging the underlying surface; they can clean even in the most inaccessible areas of the parts being cleaned. The result is rapid, efficient and thorough cleaning.

Types of ultrasonic cleaning transducers:
• Immersible transducer – A more flexible type of transducer, it can be placed in any tank in the cleaning solution. It can be positioned horizontally or vertically, as long as it is completely submerged in the liquid.
• Bolt-on or mounted transducer – It is permanently installed onto the walls or bottom of the cleaning tank.

For more details read the complete article titled “Selecting an Ultrasonic Transducer for Your Cleaning Application”. If you have questions about Kaijo’s ultrasonic transducers or would like to discuss the specific cleaning requirements for your application call 408-675-5575 or email info@kaijo-shibuya.com.
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How Ultrasonic Generators Work to Provide Optimum Cleaning Results

The role of an ultrasonic generator is essential since it generates the high-frequency electric signal that is required for an ultrasonic cleaning system to operate efficiently. These devices will produce frequencies that range between 20 kHz up to 1 MHz. Ultrasonic generators also ensure that the selected power and frequency are properly controlled and maintained.

Ultrasonic cleaning systems work by creating high-frequency sound waves within a cleaning solution to remove surface contaminants and dirt from various parts and devices. The parts and components being cleaned are immersed within a cleaning tank. When the right frequency is selected, the ultrasonic cleaning system will clean the parts and components quickly and effectively – even for items that have holes, irregular shapes, curves and crevices.

The cleaning performance of the ultrasonic cleaning system depends on the action of the cavitation bubbles created by the high-frequency sound waves within the cleaning solution. These bubbles are formed in the wave pressure troughs and disappear in the pressure peaks – this action creates a powerful and intense scrubbing and cleaning action, dislodging contaminants from the surface of the immersed parts.

An Ultrasonic generator needs to fit the production environment and also match cleaning application requirements. Once the specific cleaning application requirements are defined, selecting the right ultrasonic generator which produces the appropriate frequency, as well as the corresponding transducers and cleaning tank is clear. If an ultrasonic cleaner is used the same way, to clean one kind of part made of the same material with the same contaminants, a single-frequency generator is usually the most cost effective option. The power of the ultrasonic generator must also be high enough to fill the cleaning tank with ultrasonic waves and the design must ensure that the wave pattern is uniform for effective cleaning.

For further details read the complete article titled “How Ultrasonic Generators Work to Provide Cleaning Results”. Call Kaijo at 408 675-5575 or email info@kaijo-shibuya.com for a free quote or consultation on selecting the right ultrasonic generator and system for your cleaning application.

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How to Select the Right Type of Ultrasonic Cleaner

Industrial ultrasonic cleaners come in various types with different configurations and characteristics that are determined by the cleaning application. The size, power, frequency and controls of each ultrasonic cleaner will influence its cleaning capabilities. It’s important to choose the right type of ultrasonic cleaner to achieve the best (and the most desirable) cleaning performance possible.

Ultrasonic cleaners come in different types which include:

• Desktop system – suitable for cleaning small parts of one type with the same contaminants.
• Bench top system – larger system that can be an integrated turnkey system or assembled from individual components. It can clean a wide array of parts and remove different kinds of contaminants.
• Large industrial system – consists of tanks that can accommodate large or bulky products. In this system, ultrasonic generators are mounted separately, and several transducers may require filling the tank with the ultrasonic sound waves.

The cleaning frequency is essential for the removal of dirt and contaminants. Low frequencies deliver robust cleaning action but can damage delicate parts. High frequencies, on the other hand, deliver provide gentler cleaning but may take longer time to remove contaminants.

In order to insure that the industrial ultrasonic cleaner works as expected for a specific cleaning application the right frequency and power must be provided. For existing cleaning tanks, a separate immersible transducer is typically the easiest solution. For new cleaning tanks, a built-in transducer is mostly preferred to avoid problems with transducer placement and vibrations.

Optional measures such as using heat and/or using mild cleaning chemicals can help in dissolving and removing more difficult contaminants. Heat is often useful in cleaning applications that involve heavy contamination that include grease and oil since higher temperatures soften these contaminants so they are easier to remove.

For more details on this topic read the complete article “How to Select the Right Type of Ultrasonic Cleaner”. For help with selecting the right ultrasonic cleaner for your application contact Kaijo for a free consultation or quote at 408-675-5575 or email info@kaijo-shibuya.com.
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How Ultrasonic Cleaning Systems Are Used to Clean Industrial Lenses

Ultrasonic cleaning systems can effectively clean glass lenses, however due to the special characteristics of lenses, selecting the correct ultrasonic frequency, power and bath is critical.

Industrial lenses that are made of pure glass are ideal candidates for ultrasonic cleaning. The ultrasonic generator produces high-frequency electronic signal, and the transducer immersed in the ultrasonic bath converts that signal to ultrasonic waves within the liquid. The waves within the cleaning bath generate cavitation bubbles in the pressure troughs, and then they collapse in the pressure peaks. The action of the cavitation bubbles produces a powerful scrubbing and cleaning action against the hard surfaces of the lenses, dislodging contaminants from the surface.

While glass itself would not be affected by ultrasonic cleaning systems, it may have been treated with a special coating or surface treatments that can be damaged at certain frequencies, in heated baths or when used with added detergents.

Lower frequencies – Produce larger cavitation bubbles with a more robust cleaning action.

High frequencies – Produce smaller cavitation bubbles with a gentler cleaning action.

The power produced by the ultrasonic system affects the cleaning time. If the power is too low, too few bubbles are generated, and the cleaning process will take longer. The power level should be exactly enough so that it can produce the maximum amount of cavitation bubbles that will allow the quickest and most thorough cleaning action on industrial lenses.

Robust cleaning with the addition of detergents and/or heat will speed up the cleaning process on pure glass lens. However, if the lens has any coating, the same cleaning measures may damage the lens coating. Thus, the required frequency for cleaning coated glass lenses must be high enough to avoid damaging coatings that are softer than pure glass.

The complete article, “How Ultrasonic Cleaning Systems Are Used to Clean Industrial Lenses” goes into more detail. If you would like additional information, or have questions, please contact Kaijo through email at info@kaijo-shibuya.com or call (408) 675-5575.
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How Long Will Ultrasonic Cleaning Take to Clean My Parts?

The amount of time required for an ultrasonic cleaning system to clean a part depends on the system, the material the part is made of and the nature of the contaminants. Typically, industrial ultrasonic cleaners can complete common cleaning tasks between ten and twenty minutes.

While cleaning time depends on the power of system, the material the parts are made from and the degree of contamination also impact the cleaning time. For a light cleaning action, it may take just a few minutes. When cleaning parts that are covered with substantial deposits of hardened grease or carbon, cleaning will take much longer.

Frequency is also a factor that determines how quickly some industrial ultrasonic cleaners can take to clean. A high frequency (100 kHz and above) is ideal for cleaning delicate parts such as semiconductors, while a lower frequency (20 to 40 kHz) is ideal for cleaning more robust components like greasy machine parts. Cleaning parts under high frequency (which produces smaller cavitation bubbles and a gentler cleaning action) will take longer. On the other hand, a low frequency (which produces bigger cavitation bubbles and a more robust cleaning action) allows for quicker cleaning.

The power provided by a high performance ultrasonic cleaner is another factor that affects the system's cleaning speed. A power that's too low generates fewer cavitation bubbles and thus, cleaning time will take longer. Providing the right level of power for the specific size bath will produce the most cavitation bubbles, leading to the fastest cleaning action.

You can learn more about the length of time required for ultrasonic cleaning parts by reading our complete article “How Long Will Ultrasonic Cleaning Take to Clean My Parts.” If you have questions, or would like additional information, please contact Kaijo at (408) 675-5575 or email info@kaijo-shibuya.com.
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