Grade Ultrasonic

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Grade Ultrasonic

A program of machine presents a challenge. A new part is manufactured containing different types and grades of steel, brass and other materials. The part is designed with a deep pit, smaller holes, and a series of blind holes surface. Moreover, the party must meet an objective standard of cleanliness dictated by the customer.

This level has more cleaning requirements. The proportion shall be 98% of free oil at the end, as measured by a phase imaging system. A gravimetric method Millipore will have a the weight part, and the filtrate contaminant the weight must not exceed 5 mg per side. In addition, the party can not hold more than 20 micron particle size.

To complete the challenge, the manufacturer must produce 2800 parts per shift of 8 hours. Meeting the need for cleaning, while maintaining the production rate, it will be a difficult task.

Faced with this challenge, many program managers to take a system of ultrasonic cleaning is the best method for cleaning the part. This method creates intense, High frequency vibrations which are used to attack the party and clean.

However, an ultrasonic method may not the best choice for this situation. Washing ultrasound requires strict conditions to succeed. There must be created enough energy to clean the entire surface area and can not be shielded from other parts or material. In addition, there must be sufficient time for the working method to ultrasound. If these conditions are not met, the process becomes less effective.

Energy
The industry standard for determining the amount of energy required is mentioned in the manual cleaning technology, the magazine published by the Clean shares in December 1998. The manual states that:

"The sum of the areas section shall not exceed 70% of the ultrasonic bath of the section. In addition, the workload mass volume must not exceed 30% in parts cleaning and no more than 15% in precision cleaning applications.

Production Rate
If ultrasound is the method used, there are problems in meeting the requirements of production rate. In order to meet the rate and the use of ultrasound process, a large number of parties will be loaded together, clean together, and transferred to the next stage together. When you use this method with ultrasound, problems can arise.

The transfer baskets used for the parts can waste the energy to ultrasound. All exposed surfaces will be cleaned by ultrasound, including the display of the transfer basket. This waste of energy needed to reach the sides. The larger the basket, the more energy wasted. Parts stacked on each other or locked out of the trash will not be clean, because they are not exposed.

The parts can be re-contaminated by the pollutants removed. How does the cleaning, The oil released from the parties will be sent in the tank. Oils with a light weight of water will rise to the surface. When the process is complete, the basket will rise up out water. Of course, we pass through this layer of oil, which leads to the possibility that the parties selecting a po 'of oil during the movement.

Finally, Research cited by Dec. 1998 Parts Cleaning Magazine shows that particles smaller than 25 microns in size are not effectively removed by ultrasonic cleaning, it is unacceptable given that the requirements of our project.

Alternative method
The transport index is an effective alternative to ultrasonic cleaning for the case presented. The carrier is composed of the following steps:

1. Part is manually or robotically loaded onto a specially designed nest or device to be held in place for the transfer from stage to stage.

2nd The party-oriented index to the point where a tire on a manifold with rubber gasket is energized and moved down on the device by swallowing.

3rd Heated, chemically mixed solution by flooding pumped through the collector. This solution discharges the bottom of the unit.

4th The collector is gasketed then withdrawn, while continuing to spray on the solution. Sheer force of the fluid combined with the temperature and chemical flush the oil and particulate all cracks, holes, threads and surfaces.

5th Part is indexed to the next step for the fluid, if necessary, protection against corrosion.

6. It is therefore part indexed to the next stage in which the part is dried under vacuum. Here the party is swallowed with a rubber gasketed manifold that creates a vacuum that allows mechanism to lower the temperature of boiling water so that all the liquid has evaporated before the manifold is released.

7th Part then indexed to download the phase in which the robot or the operator is able to remove a clean, dry part that is neither too hot or too cold.

The sequence of operations can be a time to meet production requirements. This system also offers greater flexibility than the ultrasonic method. Pumps, vacuum dryer, manifolds and all pneumatic actuators can be sized to deliver the actions necessary to adequately flush and evaporate the moisture. Devices such as washer fluid management, filtering, and in the process of all the treatment options can be added to the system as required.

This system is capable to meet effectively the needs of production and cleaning in the challenge presented, making it more attractive the option of the ultrasonic method.