UPC Ultrasonic Cleaning Technology
Ultrasonic cleaning is a versatile method for precision cleaning a broad range of objects. To find out more, read our 101 guide to ultrasonic cleaning.
At Ultrasonic Power Corporation (UPC), we use science and technology to deliver the best results with ultrasonic cleaning.
Engineered for Precision and Versatility
UPC cleaners can be used in a wide range of cleaning applications, from heavy industrial machinery to delicate medical and electronic equipment.
Different applications require different ultrasonic frequencies. Low frequencies generate a strong, vigorous scrubbing action that can remove tough contaminants like grease and oil. High frequencies create gentle, precise cleaning that works in hard to reach areas and doesn’t damage fragile objects.
Using a single frequency in an ultrasonic cleaner has disadvantages:
- Ultrasonic waves bounce off surfaces in the cleaning tank. With a single frequency, the waves mostly travel the same course and land in the same areas. This produces standing wave patterns that result in alternate layers of good and poor cleaning throughout the tank, leading to incomplete cleaning of parts.
- Many applications need a combination of frequencies to achieve optimum results. For example, machinery with intricate designs, such as tapped holes or undercuts, may need precision cleaning to loosen soiling in inaccessible areas as well as robust action to remove tough contaminates.
We’ve designed our technology to overcome these challenges and offer effective and versatile ultrasonic cleaners.
Simultaneous Multi-Frequency®
UPC equipment is designed to operate at a range of ultrasonic frequencies simultaneously. For example, at the standard base frequency of 40 kHz, a range of frequencies between 40 and 90 kHz will be generated in the cleaner. The base frequency is dominant, but significant energy is produced at higher frequencies.
Simultaneous Multi-Frequency technology delivers a number of benefits over conventional ultrasonic tanks:
- Uniform and thorough cleaning action as the higher frequencies penetrate inaccessible areas and the base frequency ensures an overall effective cleaning process
- Reduced risk of damage to parts that are sensitive to frequency as the presence of multiple frequencies prevents a single strong resonance from developing
- No “dead spots” in the cleaning tank caused by the standing wave patterns that can form in cleaners with a single frequency
- Longer life for transducers as diaphragms tend to erode much more quickly with single frequency cleaners
- Efficient degassing of the cleaning solution
Modulation Sweep Control
Individual transducers each have a resonant frequency that depends on the exact size and shape of the transducer. Manufacturing tolerances mean there’s a natural variation in the resonant frequencies of each member of a multi-transducer ultrasonic array.
UPC equipment operates with a frequency sweeping capability to generate a signal at various frequencies in a small range (+2 kHz and -2 kHz) around the base frequency. This ensures that all transducers are operating as efficiently as possible, delivering a faster, better cleaning performance.
The rate of the sweep can be adjusted depending on the cleaning solution – a higher rate is required for more viscous solutions and a lower rate for aqueous solutions.
Power Intensity Control
In ultrasonic cleaning, power (measured in watts) is the rate at which energy is transferred from a generator to the transducers that convert it into ultrasound waves.
The optimum power level depends on factors such as the tank shape and size, the objects to be cleaned, and the contaminants to remove. Too little power can result in ineffective cleaning, but too much power can lead to cavitation erosion and unnecessary energy costs.
UPC generators have a power intensity control to adjust the amount of power applied to the transducers. Combining the right level of output power with the right frequencies for the application provides maximum flexibility and optimum cleaning results.
UPC Core Components: Transducers and Generators
The core components in an ultrasonic cleaner are the transducers and generators. The quality of these components and how they operate together determines how well the cleaner will perform.
UPC Transducers and Vibra-bar® Modules
UPC manufactures patented Vibra-bar modules fitted with our high quality transducers.
Each module has a rectangular radiating bar fitted with two active piezoelectric (PZT) stacks. The bar is permanently attached to the stainless steel radiating surface using high-temperature bonding, ensuring durability and reliability. The generator drives the piezoelectric stacks, which vibrate and resonate in complex modes, generating a dominant base frequency and significant energy at other and higher frequencies.
Vibra-bar modules are designed to achieve low dissipation, high density, and low porosity, leading to improved performance and longer lifespans. They are fitted in our cleaners during the manufacturing process or placed in sealed containers for adding to cleaning tanks.
UPC uses a specialized PZT formulation. The PZT elements are thin and kept under compression, resulting in exceptionally strong structures. Some PZT elements can change characteristics after field usage. In contrast, field aging of UPC elements is less than 1%.
The quality of the transducers that we fit into the Vibra-bar modules is critical. For example, ultrasonic cavitation can cause “etching” or erosion to the surface of transducer diaphragms. Our transducers are designed to reduce erosion by bonding more of the transducer to the diaphragm – about three times more compared to some other designs. Increased bonding ensures more uniform energy distribution. This and the use of higher frequencies with the base frequency are key to minimizing erosion.
UPC transducers are designed to operate optimally as a group. Our transducers have a low “Q”. This means they aren’t highly sensitive to changes in the driving frequency and don’t have to be critically matched to other transducers in the module.
The range of frequencies delivered using UPC’s Simultaneous Multi-Frequency and modulation sweep capabilities ensures that all transducers in a module are uniformly driven, producing the optimum cleaning effect.
UPC Generators for Ultrasonic Cleaners
UPC generators are designed to power a number of transducer modules. Multiple generators can be banked to deliver enough power to handle tanks as large as 2000 gallons.
A UPC generator provides a number of benefits for powering an ultrasonic cleaner:
- Delivers constant output power even if the temperature of the cleaning solution changes and regardless of the load in the tank
- Compensates for a wide variety of load conditions and protects against damage if the output is short-circuited or open-circuited for a short period of time
- Provides a precise output control to adjust how much power is applied to the transducers, from zero watts to maximum power
The sophisticated Vibra-bar modules means our generators don’t need complicated techniques to match output frequencies with individual transducers. A simple feedback mechanism is sufficient to detect changes in the load and adjust generator performance automatically.
This simplicity means we can use a minimal number of components in our generators – about a third of the number used by some competitors. The simple design and the use of all solid-state components ensure our generators deliver high reliability and performance.
UPC generators can be used to power non-UPC transducer modules and are replacing other generators in many installations.
Reliability and Flexibility
The well-established design of our generators, transducers, and Vibra-bar modules is the reason we can deliver high quality, reliable results with all our ultrasonic cleaners. These standard elements are used in our entire product line, ensuring that every product benefits from tried-and-tested production tooling and facilities to ensure consistent product quality control.
With years of field experience in ultrasonic cleaning applications, we can also build on our standard modules to deliver new system designs and fabrication to meet our customers’ requirements.
All our cleaners have our sophisticated Simultaneous Multi-Frequency capability, modulation sweep control, and power intensity control. This means they can be used for a wide variety of applications by choosing the right parameters and cleaning solution to meet the requirements of a specific application.
Find Out More
If you have any questions, please feel free to get in touch. We can answer your questions about our advanced ultrasonic technology and advise on the right ultrasonic cleaner for your requirements.