Tag Archives: ultrasonic cleaning

Bringing the Heat in Ultrasonic Cleaning

Bringing the Heat in Ultrasonic Cleaningheat in ultrasoinc cleaning

If you’ve used ultrasonic cleaning before, you’ve probably noticed that it’s hot stuff. We don’t mean results-wise (though ultrasonic cleaning is the best industrial cleaning technology available), we mean in terms of actual temperature. Most ultrasonic cleaners come with a heating system onboard and tank temperatures of 180°F are seen in some applications.

So what is the role of heat in ultrasonic cleaning, exactly? And how can you use it to your best advantage? Let’s take a look.

How does it work?

In most ultrasonic systems, one or more heating plates are mounted to the side of the cleaning tank. These plates transfer the output of simple electrically powered heating elements through the steel wall of the tank into the cleaning medium.

What is the usual temperature range?

Most ultrasonic cleaning units operate between 130° and 180°F, though some processes operate at as little as 90°F.

What’s the best temperature for cleaning?

This will depend on three factors: Your cleaning solution, the item being cleaned and the contaminants being removed.

  • Cleaning solution—Some products carry a manufacturer’s recommendation for operating temperature, so be sure to account for this.
  • Item being cleaned—Most ultrasonic cleaning targets can easily handle temperatures throughout the usual cleaning range, but others (such as circuit boards) can warp or suffer other damage in high temperatures.
  • Contaminants—Some contaminants need to subjected to high temperatures to be removed in an efficient manner. More importantly, some contaminants become more stubborn when heated beyond a certain point. For example, proteins in blood will harden significantly above about 100°F. In cases like this, there should be little or no heating applied to the solution.

What factors need to be taken into account?

Obviously, the heat delivered into solution by the heating unit on the cleaner is predictable and easily controlled. But we also need to consider the heat created by the cleaning process itself.

The transducers also produce a small amount of heat. A 500 Watt group of transducers will produce around 90 Watts of heat at full intensity. So let’s say a 6 gallon tank configured with 500 Watts of ultrasonics has the heating system set to 140°F and is maintaining that temperature. If the ultrasonics is left on for 4 straight hours beyond that time, the tank’s temperature could increase to over 160°F.

For this reason, it’s important to monitor the cleaning process and ensure that the temperature in the medium doesn’t stray outside the envelope dictated by your cleaning medium, pieces and contaminants.

How does heat affect the process?

Heat has three main roles in the cleaning process.

  1. Increasing the effectiveness of soaking—In general, warmer liquids are more effective at removing a wide variety of contaminants.
  2. Gas removal—Dissolved air and other gasses inhibit cavitation; a warmer solution helps these gasses escape, increasing cleaning effectiveness.
  3. Reduced viscosity—Warmer liquids are less viscous, and lower viscosity means more effective cavitation.

Can we save energy or time when heating?

With the new Sonic Touch® II control system, it’s a simple matter to set up a weekly schedule that automatically heats solutions prior to the cleaning session. This saves time and labor. Plus, the advanced data collection capabilities of the Sonic Touch® II allow operators to analyze the performance of all cleaner subsystems. This makes it possible to determine how to achieve the best heat profile for optimal cleaning.

Contact our knowledgeable staff today and let us guide you through your ultrasonic cleaning questions.

Customize Your Ultrasonic Cleaning Process

 

Whoever said “Change is the only true constant,” was probably talking about business. And the growing pace of change means any equipment investment you make must deliver the ability to adapt to changing customer demands.

In a previous blog, we discussed how the Sonic Touch® II console delivers better control, performance, and data collection, as well as ease of use. In addition, a major benefit of this new console is that operators have the ability to adapt it to changes in or additions to their cleaning operation.

Control anywhere…

Even without any customization, the updated control capability of the Sonic Touch® II allows users to adapt to changes in workflows and schedules.

“You can access the system from anywhere in your facility,” Manufacturing Engineer Felipe Benalcazar says, so long as the facility has a Virtual Private Network (VPN). This allows employees to either use their phone to set timers according to an optimal schedule, or control the cleaning unit directly.

The panel also allows users to set seven day timer schemes for the system, including the sonics, heater, pumps, and oil skimmer. A cleaning unit can be up and ready at exactly the right time, instead of requiring employees to spend time warming up the system.

Choose how you control…

Because the Sonic Touch® II console has a screen-based interface, operators can decide what controls are included and how their interface is arranged. This makes it simple to create an arrangement that is best for the user and the cleaning procedures being used each day.

Easy to reconfigure, with no need for long periods of downtime…

Previous generations of control technology made adding or changing controls a difficult proposition. In the past adding additional controls to an existing machine would have required making physical alterations to the sheet metal. Then, the switch would have to be wired to the new equipment, and other parts of the ultrasonic cleaner might have to be disassembled before the connection was made. In any case, the cleaning unit would be offline for some time. This might have a ripple effect, creating other costs or losses as other processes in a facility were put on hold waiting for the cleaning unit to be back online; it would definitely reduce the ROI gained from adding new equipment to a cleaner.

With the Sonic Touch® II, components can be added with a simple standard connection, and the tablet-style panel allows new controls to be added to a graphic user interface instead of being mounted in a physical panel. This drastically reduces the cost of making such a change, and the downtime required to make it.

Coding changes instead of physical changes…

A similar advantage of the Sonic Touch® II is the ability to change the interface with new code, uploaded to the unit via a USB. This makes specialized cleaning easier and less expensive, but it also reduces the cost and risk of refining your cleaning process.

With previous generations, adding a new piece of equipment or control carried the risk that if it delivered suboptimal results, changing it would require another investment and more downtime as the changes were accomplished. With the Sonic Touch® II, alterations to the code make it a simple matter to adapt the control panel to new equipment and change the interface to match.

As we mentioned in a previous blog, when a UPCORP customer needed a “rehoming” sequence and additional sensors to their automated system, Electrical Engineer Will Pedroza was able to help them develop code that integrated the new technology without major inconveniences, costs or even a site visit. “I never had to step in front of the machine,” he says. “It was just email correspondence followed by sending them a USB stick, and their system was updated with new functionality.”

Conclusion

By integrating advanced digital technology, the Sonic Touch® II provides ultrasonic cleaning operators remote access, improved ROI and simple customization.
Contact Ultrasonic Power Corporation today and let our Sonic Touch® II technology provide your facility with transformative cleaning capabilities.

 

 

 

The Sonic Touch® II improves ROI with Ultrasonic Cleaning Systems

Ultrasonic cleaning technology already has a clear edge in ROI over other methods. The right controls can increase ROI even further. That’s why Ultrasonic Power Corporation has introduced the Sonic Touch® II console.

“Previously, UPC’s precision industrial ultrasonic cleaning systems had basic controls and digital components,” Manufacturing Engineer Felipe Benalcazar says. “Now you have, essentially, a computer. With the Sonic Touch® II, the most important benefits are increased function control, performance monitoring and data collection. Putting the three benefits together allows you to create more efficient processes in your cleaning facility, and to know the status of your system at all times.”

Electrical Engineer Will Pedroza also points to ease of use. “You’re able to display a lot more information more concisely, in a way that people are used to interacting with information,” he says. “It’s especially useful in work environments where people are wearing personal protective equipment such as gloves, because the Sonic Touch® II has a resistive screen, and does not require a person to remove their gloves to operate.”

Control from anywhere, and ahead of time

The Sonic Touch® II can be operated remotely from a telephone or tablet which improves the ROI by allowing staff to be more flexible with their time.

“You can access the system from anywhere in your facility,” says Benalcazar, “as long as the facility has a Virtual Private Network (VPN). This allows employees to either use their phone to set timers according to an optimal schedule, or control the cleaning system directly.”

The Sonic Touch® II panel also allows users to set seven day timer schemes for the system, including the ultrasonics, heater, pumps, and oil skimmer. A cleaning unit can be up and ready at exactly the right work time, instead of requiring employees to spend time warming up the system; it’s a real time saver and adds to productivity.

Optimizing cleaning with better monitoring

“We’re very proud of our patented Liquid Condition Sensor, or LCS technology,” Benalcazar says. “Ultrasonics is half of the equation. You also have the fluid media.” LCS technology allows operators to monitor the condition of their cleaning liquid medium and how effective their settings are when cleaning various items.

“LCS can monitor what your cleaning status is and display how effectively you’re cleaning. For example, an aluminum part versus a stainless steel part,” Benalcazar says. “Or, say you’re cleaning pump impellers versus drive shafts, and you see better or worse cleaning results. The LCS provides data that may explain why the results are not the same.”

Since the Sonic Touch® II allows control of sweep, intensity, temperature, etc., users can adjust settings to deliver the best results for unique parts and contaminants. “If you’re seeing different results under the same settings,” he says, “the LCS data lets you set it right, and choose the best configurations for certain parts. Your ROI will grow because you’re spending less time cleaning as you have more efficient cleaning results. You spend less on detergents because you’re making your detergents last longer, and this is a real pay back because you avoid premature change out of detergent, changing only when necessary.”

Digital technology makes specialized cleaning easier and cheaper

Adapting the Sonic Touch® II to special situations is much easier than with earlier generations.

For example, a customer had purchased an automated system to move parts through the cleaning sequence. But they soon found they needed to add capabilities. In addition to the actuators it already controlled, they needed the ultrasonic system to be able to “re-home” the system to keep it in alignment, and they needed additional automated controls to ensure parts remained properly processed.

Instead of modifying physical hardware at the client site, Pedroza simply wrote new code. “I never had to step in front of the machine,” he says. “It was just email correspondence followed by sending them a USB stick, and their system was updated with new functionality.”

Data collection allows you to find efficiencies and potential problems

With the Sonic Touch® II, the run times and performance of all subsystems is recorded. It also logs alarms, and the resulting data can be downloaded to a flash drive. It can also be set to provide email or text alerts.

This allows analysis of data to find inefficiencies. For example, if cleaning effectiveness, run time or the number of alarms varies between certain shifts or certain days this highlights an opportunity to improve your cleaning process, or possibly address user understanding of the ultrasonic cleaning process.

This data gathering function is even more helpful in identifying components that need to be replaced. In the past, if an ultrasonic generator was delivering reduced performance and needed to be replaced, it might remain undetected for weeks or months. It also may not be possible to determine when the problem occurred. “With the Sonic Touch® II,” Pedroza says, “the troubleshooting is done for you, including the precise time that the event occurred. You can immediately identify what needs attention and we can help you right away.”

Ultrasonic Power experts are ready to work with you and answer more questions about what we’ve covered. Contact us to learn what kind of precision industrial ultrasonic cleaning system will work best for your unique cleaning application. Get in touch with us today, and together we’ll happily answer other questions you have. Remember, “Our Technology, Your Solution”SM is just a telephone call away.

A Mini-Glossary of Jargon Associated With Precision Industrial Ultrasonic Cleaning Systems

Ultrasonic Cleaning Jargon

More often than we like, industry jargon gets in the way of understanding. Fortunately, the good people at Ultrasonic Power can relate and are here to clarify the jargon and better explain precision industrial ultrasonic cleaning technology and design.  It’s always a good idea to get rid of jargon when reasonable, but when dealing with an advanced technology—and one that’s used across many industries—technical terms can become a second language.

Let’s have a look at some industry jargon that may need some explanation:

 Cavitation— It’s what drives the process

Ultrasonic cleaning works because of the effect high frequency sound has in a liquid. As the sound waves move through the liquid medium and strike solid objects, they create bubbles filled with vapor. When these bubbles collapse, heated jets of water strike the surface of the solid object and dislodge contaminants.

Sparger— Assuring clean stays clean

Once those contaminants are cleaned off the target object, where do they go? If they hang around in the vicinity, they will simply end up back on the target object when it’s removed from the tank. For most contaminants, this can be solved by filtering the tank medium. But what if the contaminant being cleaned is oil or other lighter than water substances? Contaminants won’t arrive in the filter and will redeposit on the part when it’s raised out of the tank.

 

The answer is a sparger. This technology design pumps streams of liquid across the tank liquid surface, pushing light contaminants out of the way.

Weir— Parting the waters

But doesn’t the oily contaminant/residue just hit the “downstream” side of the tank opposite the Sparger and remain an obstacle to clean parts? This is where the handoff occurs, from the Sparger to the Weir. Contaminant are “pushed” by the Sparger across the cleaning liquid column and falls over the Weir into an awaiting tank collecting contaminants. The cleaning liquid is then put through some sort of filter and returned to the cleaning tank.

The word Weir is commonly used to describe a type of dam that changes the liquid volume flow characteristics and maintains a constant height (depth) of the liquid rather than stopping it up. In the case of ultrasonic cleaners, a Weir is a simple technology design for separating contaminants from the cleaning liquid and prevents recontamination of any parts being cleaned. (in other words, contaminated cleaning liquid gets cleaned too!)

Spargers and Weirs are essential cleaning technology designs in any situation where greases and oils are involved, and are available and appropriate for most ultrasonic cleaner models. Here’s how they look like in action:

[Video: https://www.youtube.com/watch?v=P2Te7Ymon30]

Transducer— Making waves

A transducer is a mechanical and electrical technology for converting one form of energy into another. In the case of ultrasonic cleaning, transducers are like high frequency speakers that change electrical energy into acoustic energy.

 

PZT— Creating good vibrations

Most ultrasonic transducers use piezoelectric action. Piezoelectric substances change shape when they are subjected to an electric field. With the right application of current, they can be made to vibrate at high frequencies, so they form the heart of the ultrasonic transducer and create the high frequency vibrations that clean with cavitation.

So, what is PZT? Lead zirconate titanate is the most common piezoelectric substance used in ultrasonic transducers. Why is it called PZT instead of LZT? That’s because the symbol for Lead is Pb. Don’t roll your eyes, it was the chemists that designated lead as Pb.

PZT is a ceramic, so it is strong, chemically inert, and easily tailored to specific applications. For this technical reason and many more piezoelectric transducers have replaced other transducer designs across the precision industrial ultrasonic cleaning industry.

Conclusion

There you have it, explanations for industry jargon. So go ahead and put this with your important files, be a pack rat and save this mini-glossary. We hope it is useful. Ultrasonic Power experts are ready to work with you and answer more questions about what we’ve covered. Contact us to learn what kind of ultrasonic cleaning design will work best for your unique cleaning application. Get in touch with us today, and together we’ll happily answer other questions you have. Remember, “Our Technology, Your Solution”SM is just a telephone call away.

How Ultrasonic Cleaning Can Help Speed Up Aircraft Maintenance

Aerospace Ultrasonic CleaningIn aviation, there’s no substitute for a fast turnaround. Aircraft don’t make money sitting on the ground, so anything that gets them back in the air quickly has a direct impact on the bottom line. And since every level of aviation maintenance involves cleaning tasks, faster cleaning means faster maintenance.

Ultrasonic cleaning can save significant amounts of time in any technical setting, and aviation is no exception.

Just faster cleaning
Ultrasonic cleaning has a much shorter run time than other methods, especially those which depend on hand cleaning or soaking.

Soaking can reduce the time your workers spend on hand cleaning as well as help preserve solvents or other media used later in the process. But in most cases, soaking is not necessary or even helpful when using ultrasonics. The ultrasonic cleaner uses sound waves to form and collapse millions of microscopic bubbles, which scrub contaminants from the surface. There’s no need to soften up dirt before the cleaning begins.

Since those bubbles reach everywhere liquid can reach and remove contaminants from the surface completely, disassembling parts prior to cleaning process is seldom necessary, and much less common than with hand or spray cleaning.

With no soaking and no disassembly, you save time before the cleaning begins, but the cleaning process itself is usually much shorter. A typical cycle cleans multiple parts in five to seven minutes, less time than it would take to thoroughly hand clean a single part in most cases.

Reduced rework or replacement
Because ultrasonic cleaning reaches all of every submerged surface, there won’t be cases where a worker misses a spot or a spray washer fails to achieve 100% coverage. That means parts won’t need to be recleaned, and contaminants won’t interfere with later steps requiring inspection or recoating.

In the case of moving from hand scrubbing to ultrasonic cleaning, the amount of handling the part undergoes is dramatically reduced. As a result, the chances a component will be damaged by simple human error are decreased proportionally. Reducing this risk will reduce the total time spent on maintenance.

The little things
Putting on a face shield is probably not the most time-consuming task your team takes on. But the gentle nature of the chemicals in ultrasonic cleaning baths can help you gain time back in a number of ways.

While hand cleaning and spray washing often rely on harsh chemicals to move grime off surfaces, ultrasonic cleaners need only water and a mild detergent. That eliminates the need for protective gear, safety training, compliance with associated regulations and the time spent on specialized disposal.

Even small time savings add up over time, and your employees will have greater comfort and safety.

Automation and advanced control
Our cleaners employ the Sonic Touch® II control system, which will increase efficiency in a number of ways. Each features a countdown timer system, not a new technology for sure, but a definite time and money saver as it will shut the cleaner down and alert staff when the cleaning process is complete. It also has a seven day schedule feature for the unit’s heating system, pump and filtration system and oil skimmer. This means that you can schedule activation of these subsystems so that the unit will be ready “just-in-time.”

There are also custom automation options which allow you to change your cleaning setup so that workers are engaged in other tasks instead of moving parts or monitoring a cleaning process.

Our custom automation options allow workers to simply place baskets in a zone monitored by sensors, with an automated carry system moving it through the remainder of the process. This offers significant time savings in setups where a part may enter multiple baths and rinses. Instead of a worker moving the parts and monitoring the amount of time they spend in each bath, the system will do the work. This is a further opportunity to remove human error from the process, since it’s impossible for the system to forget to come to work with the parts or be distracted and leave them in longer than is necessary.

Shorter run times and prep times. No do-overs on cleaning, and no waiting to replace a damaged part. Easier and safer use with milder chemicals, saving time on multiple tasks. Automated processes that save time for your workforce and free them for other tasks. All these benefits can be delivered by ultrasonic cleaning. With this technology, you can keep ‘em flying, and do it faster.

What To Do When Your Customer (Or Boss) Mandates Ultrasonic Cleaning

Change is the only constant, and a fresh batch of change arrived on your desk today. Someone higher up in the org chart (or downstream in the supply chain) has made the decision to require ultrasonic cleaning for your aerospace operation.

So, now what? Now that the mandate is there, the question is how to make the transition in the most effective way. Fortunately, we have some tips on how to make the change to ultrasonic cleaning a smooth and profitable one. In fact, you may find that this decision gives you a number of advantages.

  1.  Establish a cleaning validation program

A mandate for ultrasonic cleaning will usually include a cleanliness standard for the finished product you move on to the customer. In aerospace, the required cleanliness usually falls between 0.01 grams and 0.001 grams per cm2.

If you don’t yet have a cleaning validation program, now is the time to put one in place. The right validation method(s) can vary widely and depend on the nature of the products you’re validating and of the soils that contaminate them. The good news: It’s not rocket science, if you’ll excuse the phrase. We’ve done two recent blogs posts here and here that can serve as a resource to start from.

  1. Examine your workflow for new efficiencies

Ultrasonic cleaning will mean less time assembling and disassembling items, less rework and re-cleaning. That’s because ultrasonic cavitation will reach anywhere on a component that water will reach, and it scrubs grime of any type from the surface of the part. In addition, ultrasonic cleaning takes less time and no one will need to manually clean the items. That means you have an opportunity to use both time and personnel in a more efficient manner.

Take as an example a station where an employee is assigned to manually remove grime from batches of components before they are recoated. Such a station would no longer need to be constantly manned, and the ultrasonic cleaning process would most likely involve a typical five to seven minute immersion for each batch instead of thirty minutes or so of scrubbing. What could that worker be doing now instead of scrubbing parts? How much of their time is currently spent re-cleaning parts which failed the coating stage because of incomplete cleaning?

This is time you’ll now have available, so why not begin planning how you’ll make use of it?

  1. Consider automation

Depending on your specific cleaning needs, you may need to take the items to be cleaned through multiple baths and rinses. Rather than have a worker oversee this process, consider our custom automation installations, which can move batches of items through a predetermined process without any worker intervention other than placing the batch in a start zone monitored by a smart sensor.

  1. Get in touch

At Ultrasonic Power Corporation, we believe that customer satisfaction isn’t just about building them high-quality cleaning units. It’s also about helping them make the transition to ultrasonic cleaning successfully. We also offer free parts testing so you can get more information on the best cleaning options for the unique challenges you face. Contact us today and we’ll see how we can help move you forward.

What Can We Clean? Ultrasonic Cleaning and Aerospace Applications

Ultrasonic Cleaning – Aerospace Industry

In our previous blogs, we’ve looked at how you can make your aerospace operation more efficient with ultrasonic cleaning. But you may still be wondering if it will clean the specific items you work with.

The short answer? Ultrasonic cleaning will remove almost any contaminant from anything that can be immersed. But let’s take a look at that in detail. We need to cover two main subjects: Why it works and what aerospace items it works with.

The Why: Ultrasonic Cavitation

An object only needs to meet two “eligibility requirements” for ultrasonic cleaning: It needs to be immersible and able to be dried relatively easily.

When ultrasonic waves travel through liquid and meet a solid surface, they create millions of microscopic bubbles on the surface of the item in a phenomenon called cavitation. As these bubbles form and collapse, they blast away contaminants. So the items need to be submerged, but it also means areas a human worker or spray washer would have great difficulty reaching are scrubbed spotless.

As for “relatively easy” drying, most items meet this requirement unless they are especially absorbent. Anything that can be air dried (with or without a blower) can be cleaned ultrasonically.

That leaves us with an immense list of cleanable objects, encompassing everything from nuclear waste cleaning robots to jewelry. But what about the specifics of aerospace?

The What: Aerospace Applications

It might be easier to list the items in this field ultrasonics can’t clean, but here’s a review of common items:

Vehicle components

Whether you’re cleaning parts before you reinstall them on an airframe or clearing grime from a hydraulic part prior to refurbishment, ultrasonic cleaners will remove contamination more thoroughly and quickly than personnel can. Because cavitation works through a mechanical scrubbing action, there’s no need to attack the contaminant with specific chemical compounds. Any type of dirt seen in the aerospace sphere–including oils and greases–can be completely removed.

When you need tools or equipment from your aerospace operation cleaned, you can use the same ultrasonic cleaners and be sure the gear will be spotless in just minutes.

Newly manufactured parts

Of course, this category covers parts that are formed in a CNC machine, items that are bored out on a press, etc. But we’re including some others here, such as certain ceramics, glass and polished metals. If an item has been machined, honed, lapped, buffed, or polished, there will be residue on it in the form of chips, dust, polishing compounds or cutting oils.

Here the strength of ultrasonic cleaning is in its versatility—the cavitation in the cleaner will remove oils just as easily as chips or dust—and its thoroughness. You won’t have to worry about something being missed and ruining a later step where paint or some other coating is applied.

Avionics and other electronic items

Most of us would recoil with horror at the idea of combining expensive avionics and water. However, as long as proper drying techniques are used, an ultrasonic cleaner will not only clean electronic devices, but clean them more quickly and completely than any other method. It will also do so in a safe and green way. In the past, it was common to use trichlorethylene to clean avionics, but ultrasonic cleaning usually requires only water and a mild detergent additive.

Glass and other fragile items

After years of entertainment media portrayals of high frequency sound shattering glass into bits, it may seem like an atrocious idea to clean fragile components with powerful sound waves above the human hearing range. But ultrasonic cleaning is perfectly safe for these items, and can actually save you money in the long run because they will experience less handling and therefore fewer opportunities for scratches or other damage.

Being sure

In a field where quality expectations and manufacturing and repair costs are stratospheric, ultrasonic cleaning excels. But if there’s any doubt whether this technology is the right fit for items you clean, we offer free testing. You can arrange to submit a typical item from your facility and our staff will test clean it, providing you with detailed results.

Peak Performance: A Case Study of How Ultrasonic Cleaning Protected High Performance Engines and Lowered Costs

They seem to be surging ahead even when standing still. Two pro-stock drag racers, one bright yellow, one emerald green, sit in their lanes, their engines loud even at idle. Once it begins, the race will last less than seven seconds.

Suddenly the yellow lights on the “Christmas tree” between the lanes flash in sequence from top to bottom, then green! With a deafening roar the cars streak down the track. But then, disaster! Just a second into the race, the yellow car is pulling slightly ahead when fire blossoms from beneath its hood. The hood scoop is launched into the air by the force of the explosion and bounces down the strip. The car falters; flames continue to peek out from beneath the destroyed hood and it veers off the center line before rolling to a stop. The driver emerges, throwing his gloves down in disgust. Track crew members rush in to put out the flames and pour absorbent on the fluids that have poured out onto the pavement. They also pick up twisted parts and place them on a divider wall, the only remains of an engine tens of thousands of dollars were invested in.

What does this have to do with your aerospace operation? Cagnazzi Racing faced this situation all too often, and their solution—ultrasonic cleaning—is perfect for any industry with expensive components, close tolerances, massive pressures and sizable investments riding on performance.

The Cagnazzi Problem

Victor Cagnazzi founded his Mooresville, North Carolina company in 2000 and competed in NHRA Pro Stock truck races beginning the following February. His vision was to combine cutting edge technology with proven methods to secure championships. As the racing seasons rolled past, they formed a Pro Stock car team and began to rack up wins and records.

But they also racked up failures and disappointments from engine damage. They traced the problem to tiny impurities remaining on engine parts even after they were cleaned in an industrial spray washer that could supposedly remove contamination of any type. Impurities plus high temperatures and enormous pressures equaled investments and opportunities lost.

The Ultrasonic Solution

Fortunately, there was a better way to clean. In 2007 the Cagnazzi team changed to ultrasonic cleaning and chose Ultrasonic Power Corporation as their provider. Ultrasonic cleaning matched the Cagnazzi philosophy: a cutting edge technology that’s also a proven method.

But the main reason was effectiveness. Ultrasonic cavitation reaches everywhere liquid can go, so there are no “shadows” where a spray would fail to reach, no particular pressure threshold needed to blast a substance away and no need for special chemicals. Instead, microscopic bubbles forming and collapsing under the pressure of ultrasonic waves scrub impurities off the surface with localized bursts of enormous pressure and heat. It’s therefore more powerful, more gentle, more effective and less expensive than spray washing.

“Pro Stock is the most competitive form of racing on the planet,” Cagnazzi said. “We can win or lose a race by less than a thousandth of a second, so any advantage we can get on the track, or back in the shop is important to the team. The Ultrasonic Cleaning System gives us one of those advantages.”

Joe Hornick, Director of Engine Development, agreed: “Having a system like this allows us to use the latest technology to make sure our engine components are as clean as possible before final assembly. Now we can do that better, cheaper, and in an environmentally friendly way.”

Results also spoke loud and clear. One of Cagnazzi’s Pro Stock drivers, Jeg Coughlin Jr., won back-to-back championships in 2007 and 2008. In the years since, the company remains at the top of the sport, garnering wins and national top speed and elapsed time records in multiple classes.

The space and aviation fields demand performance under high stresses at high temperatures, and your customers are demanding greater cleanliness. Ultrasonic cleaning and an effective validation program will allow you—and them—to be certain you’re delivering a spotless product. Get in touch with us today, and let’s explore how our systems can meet the exact needs of your operation.

UPC Introduces Groundbreaking New Features

The Ultrasonic Power Corporation is one of the pioneers in providing the best line of precision washing systems. These world-class cleaners use the ultrasonic vibrations to generate millions of microscopic bubbles and provide the force for the bubbles to reach the smallest crevices on precision machined equipment.  Watch the ultrasonic cleaning in action here!

The Annual Midwest Clinic International Band, Orchestra and Music Conference is held each year, which displays the top music groups to showcase the latest ideas and skills throughout the music conference. From students to professionals, performers have a chance to exhibit their talents to a supportive and enthusiastic audience with an interest in furthering music education. The 68th conference is held this year in Chicago’s McCormick Place from December 17 – 20, 2014.

In this conference, Ultrasonic Power Corporation will be exhibiting the 90 gallon portable, self-contained, ultrasonic cleaning system with Sonic Touch technology, which easily accommodates trumpets, flutes, saxophones, trombones, baritones, sousaphones and tubas.  The BT 2424SE will also be showcased, which cleans trumpets, flutes, saxophones, clarinets and euphoniums.  Both systems clean quickly and eliminate the need for strong acids.

The cleaning system used by Ultrasonic Power Corporation is environmental friendly and built using stainless steel. They clean both inside and outside the instruments and prolong the life of the instruments.

Some of the new features include:

  • The new horn flush and holster design, which is used to send a blast of water to contamination and hangs in the tank without dripping externally.
  • The wedge control panel, which offers an easier to read control panel and more ergonomic design function.
  • The double boiler pan, which is used for cleaning small items or when the operator decides to use multiple detergents within the same tank.

Lisa SerafiniFor more information, you can visit Booth Number 537 where Lisa Serafini will be available to answer your queries.

Vibra-bar® Technology: Taking our Ultrasonic Cleaning to the Next Level

At Ultrasonic Power Corporation, our highly engineered and reliable technology provides the solution to meet the various needs of our customers. One important part of our ultrasonic cleaning technology is our own Vibra-bar® transducer module, which enables us to take our ultrasonic cleaning to the next level. With two-point vibration, low “Q” broadband interference, and the ability to create multiple frequency levels in multiple planes, the Vibra-bar® transducer module provides an unmatched level of performance in ultrasonic cleaning.

The Vibra-bar® transducer module consists of a radiating bar that is permanently bonded to the inside of the ultrasonic cleaning tank. The radiating bar measures 2” by 5 ¼” and features a high temperature permanent bonding. Additionally, each bar has two integrated piezo-electric (PZT) stacks that are bolted together between the radiating bar and the “backing plate.” The PZT elements are formulated to provide low dissipation, high density, and low porosity, the characteristics needed for high performance cleaning.

The complete design of the Vibra-bar® transducer module allows for a rugged construction that will provide long and efficient operation. The PZT element is stabilized during the manufacturing process at 400° F and the curie temperature is above 620° F. All parts and mating surfaces are engineered to allow clamping through a single stainless bolt and are adhesive-free. Therefore, the Vibra-bar® transducer module is free to vibrate and distort in many different places for efficient use.Vibra-bar® transducer module

With its unique construction and design, the the Vibra-bar® transducer module allows for our systems to thoroughly operate and clean in any given application, ensuring our customers consistently receive the highest level of performance. Visit our Technical Information page to learn more. At Ultrasonic Power Corporation, our technology is your solution!