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Ultrasonic Wire Cleaning Systems                                     Click To View

Wire cleaning is a difficult task when compared to most traditional ultrasonic cleaning applications.  The contaminant, typically a sodium-based dry lubricant, is pressed deeply into the surface of the material as it passes through the wire drawing process.  In some cases, liquid lubricants may also be used which are less difficult to remove.  Not only are the contaminants highly bonded to the surface, wire manufacturing processes are performed at elevated speeds, which reduces the contact time between the wire and the cleaning operation.

To overcome the difficulties associated with wire cleaning operations, Zenith modified its SSS-960 Ultrasonic Strip Cleaning System to address wire cleaning, in a system called the SSW-960 and SSW-132.  These systems include an extended ultrasonic cleaning chamber, an ultrasonic rinsing chamber, and high-speed compressed air drying systems to clean wire with the most stubborn contaminants at high rates of speed.  Additional features, such as an additional blow-off operation between cleaning and rinsing areas, conserve the use of water, and ensure perfect results with little equipment maintenance.

In the past, manufacturers of wire relied on spray washing systems to address the removal of oils and particles from the product.  However, there are limitations to these designs.  The primary complaint of customers owning spray washing systems for wire is the consumption of water, leaking seals and spray which contaminates the environment, and continuous spray nozzle maintenance.  All of these issues are non-existent on a Zenith SSW wire cleaning system.

A Zenith Ultrasonic Wire Cleaning System overcomes the limitations of a spray washing system by utilizing the precision, low-maintenance cleaning capabilities of ultrasonic cleaning technology.  By incorporating this technology, and extending the length of the ultrasonic cleaning chamber, dry and liquid wire lubricants are quickly and effectively removed.

Wire is passed horizontally through a series of ports and chambers in the system, and connected to wire take-up equipment on the exit end of the system.   Loading is an easy task, thanks to the stainless steel hinged access cover which includes polycarbonate viewports.  The system can be loaded in under 1 minute.

Wire entering the ultrasonic cleaning system is first subjected to the ultrasonic cleaning chamber, which bombards the material with CROSSFIRE Multiple Frequency Ultrasonics to rapidly remove all contaminants from the surface of the wire.   The included Spray Under Submersion Nozzles add to the effectiveness of the cleaning chamber by removing the largest volumes of oils, and can be used to directly address detailed part areas.  The ultrasonic system has the ability to penetrate the microscopic "hills & valleys" on the surface of the material, leaving no residues behind, even in the most detailed areas of the wire.

Lubricants which are removed from the product are siphoned to the heated Cleaning Fluid Holding Tank, which stores the fluid, heating it to operating temperature, and filtering it with optional Filtration Systems, if required, to maximize the life of the cleaning fluid.  Wire cleaning system designs also include exclusive Cleaning Chamber Filtration Ports which divert the contaminants which collect on the bottom of the ultrasonic cleaning chamber to the fluid holding tank, where the existing filtration system can remove it from the process.

As the strip material exits the cleaning chamber, excess cleaning fluid is removed by the included Cleaning Fluid Removal Chamber.  By removing the detergent from the wire before it enters the rinsing chamber, rinse water integrity is preserved which minimizes rinse water consumption, while simultaneously preventing detergent spotting on the material being cleaned.

Next, the wire enters the included ultrasonic rinsing chamber which includes high frequency ultrasonics to penetrate every area of the material, ensuring that all detergent residues have been removed.  The use of ultrasonic components in the rinse tank provides mechanical scrubbing of the wire surface with the even energy distribution of high-frequency ultrasonics.  Additional information regarding frequencies and their effects can be found under the "Technical Info" drop down list under Frequency Selection.

The wire is then dried using a custom air wipe assembly in the Drying Chamber.  All water removed from the wire is siphoned back to the Rinse Fluid Holding Tank.  The material then exits the system and is recoiled immediately using existing take-up equipment. 

Maintaining a Zenith ultrasonic wire washing system is simplicity itself.  The system requires only periodic cleaning and replacement of cleaning and rinsing fluids when required.  Optional filtration systems will further reduce required holding tank cleaning operations, which are easily performed using the included ball valve-equipped drain and fill ports.

With a Zenith Wire Cleaning System, evaporative losses are reduced drastically since water is never vaporized by spray nozzles.  As a result, operational costs are reduced since heating systems can be smaller in size.  Heating systems represent the largest electrical consumption devices on any cleaning system.Ultrasonic Cleaning Chamber

Zenith wire cleaning systems are manufactured largely of type 304 stainless steel for superior long-term corrosion resistance.  All wetted surfaces are either stainless steel, or compatible plastic materials.  Smooth-transition Wire Guides are included throughout the machine to support the wire and prevent damage.  Internally-mounted components are conveniently positioned near the front of the machine.  Filtration housings are externally mounted for convenient access.  Level switches prevent operation of the heating or ultrasonic systems in the event of low liquid levels.

Optional equipment includes Automatic Water Level Maintenance, Signal Towers to indicate when holding tanks require additional liquid, Closed Loop Deionization Systems if medical-quality results are required and no deionized water supply exists, and Rinse Water Quality Meters to indicate when rinse water requires replacement.

Contact Zenith Manufacturing for more information on our line of Ultrasonic Wire Cleaning Systems. 

For a downloadable PDF Brochure, click here.

 

 

 

 

 

 

Zenith Ultrasonics
85 Oak St.
Norwood, NJ  07648-0412
800-432-SONIC (7664)
FAX: 201-768-6999
sales@zenith-ultrasonics.com

 

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