More flexible cleaning systems with higher process reliability

3-kW Ultrasound Generator SONOPOWER 3S: With its power of 3 kW, the innovative ultrasound generator is twice as powerful as conventional generators and thus more space-saving and cost-effective than comparable solutions.

Individualization is on the rise – accordingly, more and more components are now being produced in small series. These often have different requirements for part cleaning. To meet these as effectively and efficiently as possible, Weber Ultrasonics has developed an innovative multi-frequency ultrasound concept with vacuum-resistant immersion transducers for chamber cleaning systems. This forward-looking solution allows cleaning tasks to be performed with a single system, which previously required two.

Flexible production of small series is a challenge faced by many part manufacturers today. In addition, component cleanliness remains a key quality criterion. To meet these specifications, chamber cleaning systems with ultrasonic systems are often used. Since the frequency of the sound waves generated by the ultrasonic generator determines the cleaning effect, these systems are usually designed for a specific process. If the cleaning task or the part spectrum changes, the system often cannot optimize the process accordingly. Therefore, flexible cleaning systems are required.

Reduce the number of required cleaning systems

With the SONOPOWER 3S system 25/50 kHz, Weber Ultrasonics, one of the world's leading manufacturers of ultrasonic components, presents an innovative ultrasonic solution that now enables multi-frequency ultrasound to be used in vacuum chamber cleaning systems. The flexibility and application possibilities of these systems are significantly increased by the new system. Vacuum-resistant immersion transducers with switchable ultrasonic frequencies of 25 and 50 kHz ensure an optimized cleaning effect for both rough and fine cleaning. This allows predefined cleanliness specifications to be reliably and efficiently met with a single system, even with changing or varying part spectra. A benefit that pays off especially in small-series component manufacturing, which previously often required two cleaning systems. The basis of this groundbreaking development is the newly designed multi-frequency ultrasonic generator SONOPOWER 3S with up to 3,000 watts output power. The innovative plug-and-play device operates fully digitally and impresses with maximum process safety and performance, as well as ease of handling.

Optimized cleaning effect

An absolute innovation of this advanced ultrasonic solution is the use of immersion transducers in vacuum cleaning processes. This is made possible by the special vacuum-resistant design of the transducers, which was determined through simulation of the forces acting on the transducer during evacuation of the working chamber.

Vacuum lowers the boiling point of the cleaning medium. This enhances the cavitation effect of the surface-radiated sound waves and thus improves the cleaning performance. At the same time, the pressure reduction causes air trapped in holes and other cavities of the parts to be drawn out. This results in more effective cleaning, especially for components with complex geometries. Weber Ultrasonics customizes vacuum-resistant immersion transducers with the latest simulation technology, tailored to each system concept.

Forward-looking solution for many target industries

The new ultrasonic generator covers a wide range of applications in industrial part cleaning with the frequencies 25 and 50 kHz and is particularly an optimal solution for requirements in electroplating technology. The 25 kHz frequency, for example, is used to remove coarse particles after machining, degrease stamped and deep-drawn parts, or remove polishing pastes. At this low frequency, large cavitation bubbles form, whose high energy ensures a high cleaning effect on the part surface. The smaller cavitation bubbles at 50 kHz clean fine particles and contaminants from pores, holes, and structures in a process-safe and material-friendly manner. This frequency is used for cleaning more delicate parts, such as precision mechanical components, optics, circuit boards, and cutlery. Components from the solar industry and parts with sensitive coatings can be cleaned just as effectively as all parts that do not require fine cleaning. The new multi-frequency ultrasound concept offers enormous advantages across a wide range of target industries due to this versatility.

Built-in intelligence for increased process safety

With an output power of 3,000 watts, adjustable in 1% steps, the multi-frequency ultrasonic generator is perfectly designed for these diverse cleaning tasks. Additionally, it features intelligent control based on a 32-bit processor architecture. The SONOPOWER 3S automatically performs numerous settings. During the cleaning process, the selected frequency is continuously monitored and adjusted as needed. This ensures that, even under changing operating conditions such as temperature fluctuations, optimal performance is maintained, and an extra level of process and operational safety is achieved.

The new developments are available both individually and as a package with a generator and two vacuum-resistant immersion transducers.