The BRIO Ultrasonics difference: a new level of energy efficiency, cleaning power and durability in ultrasonic cleaning
In the parts cleaning industry, the external appearance and finishes of the machines are highly valued to the customer, but what is most important?
The most important thing is the heart of the machine. Like the engine of a car, ultrasonic cleaning machines have ultrasonic emitters made of transducers or transducers directly attached to the tanks. These emitters/transducers, powered by an ultrasonic generator, produce the ultrasonic cleaning effect together with the appropriate detergent in cleaning liquid, temperature and time. The choice of the right technology, especially for the heart of the machine, will determine the energy consumption, cleaning times, cleaning quality and durability of the main components. It is very important to be sure of what is inside the machine, compare technologies, perform cleaning tests, etc. to know for sure if it is the best choice for your cleaning needs.
BRIO Ultrasonics is a Spanish company dedicated to the design and manufacture of ultrasonic cleaning machines and customised solutions for a wide variety of industrial applications. With more than 30 years of experience, we have developed and evolved a unique ultrasonic cleaning technology that achieves a new level of energy efficiency, high cleaning performance and superior durability. As a result, we provide all our customers with significant savings in washing times, energy consumption and maintenance costs.
How do we maximise ultrasonic cleaning performance while minimising energy consumption?
The key lies in the design of our ultrasonic emitters, which we manufacture using a specific process of hot bonding the transducers to the emitter plate.
How does the BRIO hot bonding process work?
The transducers are bonded to the emitter plate by means of a thin elastic sheet made from special resins used primarily in the aerospace industry. The use of these resins maximises the surface area for ultrasonic vibrations transmission to the bath, maximising the power of the transducers. Moreover, they provide maximum durability to the assembly. However, to achieve this effect, a specific combination of temperature, pressure and time is required in the bonding process.
Our R&D department has come a long way to understand the properties of these resins and learn how to apply them to ultrasonic cleaning. After years of research, they have determined the specific parameters best suited to achieve the best results in terms of ultrasonic vibration transmission and mechanical strength.
Why is it so important to maximise the vibration transmission surface?
In a standard cold gluing process, the vibration transmission surface is limited to the contact area of the transducers. In the case of our hot bonding process, the vibration transmission surface is the entire BRIO emitter plate (the entire surface with the elastic aerospace foil) and not just the surface of the transducers. This results in a greater and more homogeneous impact of the ultrasonic implosions on the entire geometry of the parts and not only on specific areas.
We achieve a 3-fold increase in the transmission surface and a more homogeneous and effective cleaning effect inside the bath. In this way we maximise the cleaning power while achieving faster cleaning cycles and optimising energy consumption.
COMPARISON OF ULTRASONIC ENERGY TRANSMISSION SURFACES
Emitter with 12 transducers and different bonding processes. Dimensions: 700 x 180 mm
Why is it so important to have a high mechanical resistance?
The attachment of the transducer assembly to the emitter plate is such that we achieve a much higher mechanical resistance than standard ultrasonic cleaning technologies. This is especially important when it comes to the removal of heavy soiling, carbon deposits and other strongly adhering contamination. In these cases, transducers with an ultrasonic frequency of 28kHz are highly recommended.
The 28 kHz frequency produces more intense micro-implosions in the fluid due to larger bubbles (longer wave period). As a result, a more powerful cleaning effect is produced than in the case of higher frequencies such as 40 or 80 kHz. High mechanical strength is a must if high power transducers (28kHz) are to be used effectively without compromising their integrity after some time of use.
In addition, the best ultrasonic performance is achieved when the fluid and emitter are in a temperature range between 60 and 85 degrees Celsius. In this temperature range, the mechanical strength provided by our hot bonding system is around 4000 N/cm2. In contrast, cold bonding systems provide about 500 N/cm2, which is not sufficient for long-lasting work at 28kHz.
COMPARISON OF THE MECHANICAL RESISTANCE OF TRANSDUCER BONDING SYSTEMS
Fixation in aluminium (transducers) with stainless steel (surface of the machine).
Other improvements allow us to optimise the efficiency and lifetime of the transducers and emitters.
Firstly, we electrically mount the transducers in parallel, which means that each transducer is wired independently. This is important for two reasons:
- We can control the impedance drawn by each transducer from the BRIO generator, resulting in better transmission of ultrasonic energy. If the transducers are wired in series (the same cable from one to the other, in series), the change in impedance can result in a loss of efficiency and an increased risk of failure.
- In the event of an electrical incident in one transducer, as they are wired in parallel, the rest continue to operate without problem. If the wiring is in series, all the power is lost.
Secondly, our transmitters have two Teflon-sealed anchor points. The possibility of leakage is reduced to a few millimetres and in the event of leakage, water cannot enter the emitter. In addition, the two-point connection also allows the necessary elasticity so that the emitters can expand and contract without risk with temperature changes.
On the other hand, standard technologies such as multi-screw emitters have a large leakage area (many connection points) and suffer more from changes in temperature. Another case is that of transducers directly bonded to the cleaning tank. In this case, changes in the shape of the tank due to temperature can cause the transducers to detach and break.
In summary, the BRIO hot bonding process has a great impact on the overall performance of the ultrasonic cleaning system. It allows for more powerful and homogeneous cleaning in less time, optimises energy consumption and extends the lifetime of its components.
On the other hand, standard technologies such as multi-screw emitters have a large leakage area (many connection points) and suffer more from changes in temperature. Another case is that of transducers directly bonded to the cleaning tank. In this case, changes in the shape of the tank due to temperature can cause the transducers to detach and break.
In summary, the BRIO hot bonding process has a great impact on the overall performance of the ultrasonic cleaning system. It allows for more powerful and homogeneous cleaning in less time, optimises energy consumption and extends the lifetime of its components.
Despite the high demand for our technology from other manufacturers, we maintain our exclusivity policy and it can only be found in our ultrasonic cleaning machines.
Do not hesitate to contact us to solve any doubt and share with us your parts cleaning and/or surface treatment needs. We will be happy to advise you and provide you with the best ultrasonic cleaning solution for your case.
We also invite you to visit us and get to know our machines and solutions first-hand at the Advanced Manufacturing · Metalmadrid 2021 trade fair. The fair will take place on the 17th and 18th of November at the IFEMA exhibition centre in Madrid with all the necessary safety measures. We look forward to seeing you at stand 7A19!
METALMADRID 2021 · 17 - 18 November 2021
HALL 7, STAND A19
