UCMSmartLine - Ultrasonic cleaning of précision parts

UCMSmartLine – Ultra flexible and modular ultrasonic precision cleaning system. A smart solution for effective precision cleaning.

In many areas and in many markets, companies have to meet increasing demands for cleanliness of parts. Often they can only be satisfied with precision cleaning processes. For these applications, UCM has developed UCMSmartLine, a new range of efficient and economical Ultrasonic installations. It is designed from standardized modules with integrated electrical and control technology for the stages of cleaning, rinsing, drying, loading and unloading as well as a flexible transport system. On this basis, individual plants for pre-cleaning, intermediate cleaning and final cleaning can be configured and expanded as required.

With the new range of UCMSmartLine serial immersion systems, the Swiss company UCM AG, the branch of the SBS Ecoclean Group specializing in fine and precision cleaning, responds to a trend that has been emerging for some time in various industries and which is confirmed: new and higher product requirements, developments in manufacturing, assembly and coating processes as well as partially stricter regulatory requirements further increase the requirements for component cleanliness. Companies, for example, in the biomedical engineering, watchmaking and jewelery sectors, optics, precision mechanics and microtechnology, the automotive sector and its equipment suppliers, machine manufacturing- tools and the coatings industry, then have the challenge of meeting the increasing cleanliness specifications for particles and films with reliable processes and at competitive costs. The same phenomenon is observed in the fields of MRO (maintenance, repair, overhaul) and in the reprocessing of products from the aeronautical industry, electronics and the medical sector, among others.

Optimal adaptability, a scalable system

Thanks to the well-thought-out modular concept of the new UCMSmartLine, the very compact ultrasonic serial immersion systems with three to nine cleaning and rinsing stages for pre-cleaning, intermediate cleaning and final cleaning can be individually configured thus covering a wide range of applications to adapt at any time to market developments. For this purpose, modules of two and three are available for cleaning and rinsing steps, eg Cleaning, Cleaning and Rinsing to be combined as desired. Another module makes it possible to integrate fine and ultra-fine rinsing processes in two stages with osmosis water or demineralized water brought in cascade.

Ultrasonic cleaning units equipped as standard with heating and in-line filtration can also be flexibly adapted. This allows the use of mono (25, 40, 80 kHz), bi (25/50, 40/80 kHz) and multi-frequency (40/80/120 kHz) ultrasound. The ultrasonic transducers are placed on the floor and/or on one side of the tanks measuring 370 x 420 x 390 mm (L x W x H). The parts are dried by the heat of infrared radiation, hot air or vacuum. Depending on the application, the two drying technologies can also be combined. For loading and unloading, the UCMSmartLine adapts to the conditions of its location, with stations arranged at the front or on the side. They can be operated manually or automatically.

For cleaning applications that require a very clean environment, the installation can be equipped, depending on its length, with one or two HEPA filters on the roof of the enclosure. Usually two modules are used to produce a clean room atmosphere in the area from the last rinsing station to the unloading. Connection to a clean room is also possible.

Series design for maximum process reliability

The transport of the parts within the installation itself is done by standard robot with servomotor. It makes it possible to adapt the transport speed precisely according to the parts. On the one hand, it guarantees very gentle handling of the parts during the processes. This also helps prevent damage and scratches to sensitive parts as well as floating components. On the other hand, the movement is fast to reach a high rate wherever possible. Another advantage of the servo motor is the part-specific Lift-Out from the last rinsing tank to the pre-drying of the parts. This avoids the formation of stains during the drying process to follow.

As standard, the robot has a static stainless steel transport frame for a maximum load weight of 20 kg. For bulk part cleaning, a horizontally rotating transport frame is available to enhance part movement. Another transport frame allows vertical rotation movements at 200 rpm in the wet stages and up to 1000 rpm for the drying process. It is used, among other things, in optics for cleaning microlenses.

To meet high throughput requirements, the installation can be equipped with a second robot for transport.

The lateral overflow developed by UCM also contributes to the conformity and stability of the cleaning result: in all cleaning and rinsing tanks, the fluids are introduced from below, transported upwards and then overflow on both sides. This creates a permanent flow in the tanks, guaranteeing on the one hand an intensive processing of the parts. On the other hand, the particles and other residues thus detached and cleaned are immediately evacuated from the tanks. This minimizes the risk of recontamination of parts when they are reassembled or moved. In the design of the tanks, particular attention has been paid to ensure that they empty completely and quickly and that no accumulation of dirt forms. This is also applicable to the plant piping, which is designed for temperatures up to 70°C.

High flexibility thanks to the integration of electrical and control technologies

Electrical and control technology is already integrated in every module of the new UCMSmartLine. On the one hand, this "plug-and-play" design is a crucial part of the compact design of ultrasonic series immersion installations. No surface is to be provided specifically for the electrical cabinet. On the other hand, the installations can be commissioned quickly and remain scalable.

Convincing design that enhances work safety and preserves the environment

In addition to its performance and flexibility, the UCMSmartLine can also convince with its design, with its fully enclosed enclosure made of electropolished stainless steel. The standard front cladding made of high-quality safety glass does not only have a visual quality. It prevents system vapors from escaping into the ambient air, which can represent a health risk depending on the detergent used. Compared to the open systems that are frequently offered, the casing also reduces heat loss. This reduces energy requirements, just like covered dryers. They also shorten drying times.

The installation's PC control system can be linked to higher-level production control software (MES) via interfaces.

Thanks to its modularity and its great flexibility both in the configuration of the installation and in the design of the processes, the new UCMSmartLine covers a very wide range of applications in the high-tech industries as well as in the MRO and reprocessing fields. At the same time, the modern modular principle enables cost-effective production and relatively short delivery times.