1500×460×400mm Effective Cleaning Size | Ultrasonic Vapor Phase Cleaning Machine

Product Specification

1. Product Overview

This closed-loop ultrasonic vapor phase cleaner is specifically designed for oil removal and drying of plate-fin heat exchanger components (aluminum composite materials, aluminum fins, etc.), meeting cleanliness requirements for vacuum brazing after cleaning. Featuring a robotic arm conveyor mechanism, process basket loading, step-by-step cleaning process, and pneumatic lift loading/unloading, it uses trichloroethylene as cleaning medium with a distillation recovery system. Typical applications include high-volume, high-cleanliness cleaning production lines for heat exchanger cores and aluminum cooling components.

2. Industry Challenges & Root Cause Analysis

Cleaning cleanliness cannot meet vacuum brazing requirements:Residual oil on aluminum heat exchanger part surfaces causes porosity and weak joints during brazing. Root cause: single cleaning method – lacks combined effect of ultrasonic cavitation and vapor phase cleaning.

High solvent consumption and operating costs:Trichloroethylene and other organic solvents are expensive – traditional cleaning methods waste significant solvent through evaporation. Root cause: lack of distillation recovery and circulation systems.

Low cleaning efficiency and high labor dependence:Multi-tank cleaning requires manual transfer between tanks – labor-intensive and unstable cycle times. Root cause: lack of automated material conveying and timing control systems.

Exhaust emissions non-compliant:Organic solvent vapors directly discharged – harm operator health and violate environmental regulations. Root cause: lack of exhaust gas adsorption purification devices.

Uncontrollable process parameters:Cleaning temperature, time, ultrasonic power cannot be precisely set and monitored – inconsistent cleaning results. Root cause: control system lacks automated programming and data recording.

3. Solution

3.1 Ultrasonic Cavitation + Vapor Phase Composite Cleaning Process:Cleaning sequence: hot soaking rough wash → ultrasonic cleaning → ultrasonic fine wash → vapor bath cleaning + freeze drying. Ultrasonic high-frequency oscillation generates cavitation – bubble collapse creates instantaneous impact exceeding 1000 atmospheres – thoroughly removes oil from surfaces and crevices. Vapor bath cleaning condenses pure solvent vapor on workpiece surfaces forming a clean liquid film – final precision cleaning with simultaneous freeze drying.

3.2 Distillation Recovery & Circulation System:Equipped with both online and offline distillation modes. Online distillation continuously purifies solvent from vapor bath tank during operation – clean solvent returns to tank. Offline distillation pumps dirty solvent from each tank into distillation tower after shutdown – purified solvent returns to each tank. Significantly improves solvent utilization and reduces operating costs.

3.3 Fully Automatic Step-by-Step Material Conveying:Workpieces loaded into process baskets (1500×460×400mm, SUS304 stainless steel, 8 baskets per machine) – manually placed on loading/unloading lift platform – automatically lifted into position – overhead crane horizontal conveyor (vertical stroke 1200mm, variable frequency speed control) sequentially transfers to each cleaning station – cycle time adjustable above 270 seconds – max load 200kg. After full process, automatically conveyed to discharge point for manual unloading – single operator can manage multiple machines.

3.4 Activated Carbon Fiber Exhaust Gas Purification System:Equipped with activated carbon fiber organic gas purifier – adsorption capacity over 10 times that of standard activated carbon – purification efficiency ≥95%. Exhaust gas passes through inlet section → carbon fiber filter section (4 filter cartridges) → outlet section – discharged via exhaust duct – small footprint, high temperature resistance, easy maintenance, no secondary pollution.

3.5 Precise Temperature Control & Liquid Level Protection:Each cleaning tank equipped with stainless steel electric heating elements and intelligent temperature controllers – automatic heating control (hot soak 40-60℃, vapor tank 87.4℃ solvent boiling point). Stainless steel liquid level sensors monitor levels in real-time – automatic alarm and heating shutoff on low level – prevents dry burning.

3.6 PLC Fully Automatic Control System:PLC centralized control + 7-inch color touchscreen HMI. Cleaning time adjustable 100-600 seconds – automatic sequence of all station movements. Positioning via photoelectric proximity switches – contactors and air switches from Schneider. Fault alarms and status display clear at a glance.

4. Technical Specifications  

5. Selection Guide

5.1 Recommended Scenarios

• High-volume cleaning of plate-fin heat exchangers and aluminum cooling components

• Parts requiring high-cleanliness surface treatment before vacuum brazing

• Environmentally conscious cleaning lines using organic solvents (trichloroethylene) with distillation recovery

5.2 Key Selection Considerations

1. Workpiece dimensions: Verify maximum size fits 1500×460×400mm process basket

2. Capacity requirements: Design capacity ~3 tons/day – calculate against daily output

3. Cleaning medium: Trichloroethylene – verify site environmental and safety conditions

4. Site conditions: Equipment requires exhaust duct and ventilation system – installation by user

5. Utilities: User to supply 3-phase 4-wire power (total power ≥100KW)

6. FAQ

Q1: Can cleaned parts meet vacuum brazing requirements?

A: Yes. Ultrasonic cavitation thoroughly removes oil – vapor bath condensation provides final precision cleaning with simultaneous freeze drying. Parts are oil-free after cleaning – meeting vacuum brazing cleanliness requirements.

Q2: How is trichloroethylene recovered and reused?

A: Dual-mode online/offline distillation. Online distillation continuously purifies solvent from vapor bath during operation. Offline distillation pumps dirty solvent from all tanks into distillation tower after shutdown – purified solvent returned to each tank for circulation – significantly reduces solvent consumption.

Q3: How does the equipment prevent environmental pollution?

A: Activated carbon fiber organic gas purifier – adsorption capacity over 10 times standard activated carbon – purification efficiency ≥95%. Exhaust gas passes through carbon fiber filtration for compliant discharge – meets environmental standards.

Q4: What are the ultrasonic system features?

A: TMU-4000 computer-controlled ultrasonic generator – continuous power adjustment – frequency fine-tuning (optimizes transducer operation) and frequency sweep (improves cleaning efficiency).

Q5: Can cleaning cycle time be adjusted?

A: Yes. Cleaning time adjustable 100-600 seconds – overall cycle ≥270 seconds – set via touchscreen per process requirements.