超声波清洗机的原理与使用方法详解

　　Detailed explanation of the principle and usage of ultrasonic cleaning machine

　　超声波清洗机是一种利用高频声波能量进行高效清洁的设备，广泛应用于工业、医疗、实验室和家庭等领域。其独特的清洗原理使其能够有效清除复杂形状物体表面的顽固污垢。下面将从工作原理、设备结构、使用方法及注意事项等方面进行全面介绍。

　　Ultrasonic cleaning machine is a device that uses high-frequency sound wave energy for efficient cleaning, widely used in industrial, medical, laboratory, and household fields. Its unique cleaning principle enables it to effectively remove stubborn dirt from the surface of complex shaped objects. The following will provide a comprehensive introduction from the aspects of working principle, equipment structure, usage method, and precautions.

　　超声波清洗机的工作原理

　　The working principle of ultrasonic cleaning machine

　　超声波清洗机的核心工作原理基于超声波空化效应。当高频声波在液体介质中传播时，会产生一系列物理化学作用，从而实现高效清洁。具体过程如下：

　　The core working principle of ultrasonic cleaning machine is based on ultrasonic cavitation effect. When high-frequency sound waves propagate in liquid media, a series of physical and chemical reactions are generated, thereby achieving efficient cleaning. The specific process is as follows:

　　超声波发生器产生20kHz至400kHz的高频电信号，通过换能器转换为机械振动。这些振动通过清洗槽壁传递到清洗液中，使液体分子产生高频往复运动。在声波的负压半周期，液体被"拉开"形成微米级的真空空化泡；在正压半周期，这些空化泡迅速崩溃闭合，瞬间产生高达10,000psi(约69MPa)的局部压力和20,000°F(约11,000°C)的高温。这种空化泡的持续形成和崩溃过程会产生强大的微射流冲击波，能够渗透到物体最细微的缝隙中，将附着在表面的污垢层层剥离。

　　The ultrasonic generator generates high-frequency electrical signals ranging from 20kHz to 400kHz, which are converted into mechanical vibrations through a transducer. These vibrations are transmitted through the walls of the cleaning tank to the cleaning solution, causing high-frequency reciprocating motion of liquid molecules. During the negative pressure half cycle of sound waves, the liquid is "pulled apart" to form micro scale vacuum cavitation bubbles; During the positive pressure half cycle, these cavitation bubbles rapidly collapse and close, instantly generating local pressures of up to 10000 psi (approximately 69 MPa) and high temperatures of 20000 ° F (approximately 11000 ° C). The continuous formation and collapse process of this cavitation bubble will generate powerful micro jet shock waves, which can penetrate into the smallest gaps of the object and peel off the dirt layer by layer attached to the surface.

　　空化作用的强度与超声波频率密切相关。低频超声波(20-30kHz)产生的空化泡较大，爆破力更强，适合清洗大型、重型零件或去除严重污垢；高频超声波(40kHz以上)产生的空化泡更小更密集，适合精密零件和微小颗粒的清洗，且对工件表面损伤更小。一些特殊应用如半导体清洗甚至使用高达400kHz的频率。

　　The intensity of cavitation is closely related to the frequency of ultrasonic waves. Low frequency ultrasound (20-30kHz) generates larger cavitation bubbles with stronger explosive force, making it suitable for cleaning large and heavy parts or removing severe dirt; The cavitation bubbles generated by high-frequency ultrasound (above 40kHz) are smaller and denser, suitable for cleaning precision parts and small particles, and have less damage to the surface of the workpiece. Some special applications, such as semiconductor cleaning, even use frequencies up to 400kHz.

　　除了主要的空化作用外，超声波清洗还伴随以下辅助效应：声流效应增强液体搅拌和扩散；非线性效应产生微声流；化学清洗剂的乳化分散作用在超声波作用下被加速。这些效应共同作用，使超声波清洗能够处理各种复杂形状的工件，包括带有盲孔、微细孔道的零件。

　　In addition to the main cavitation effect, ultrasonic cleaning is also accompanied by the following auxiliary effects: acoustic flow effect enhances liquid stirring and diffusion; Nonlinear effects generate micro acoustic flow; The emulsifying and dispersing effect of chemical cleaning agents is accelerated under the action of ultrasound. These effects work together to enable ultrasonic cleaning to handle various complex shaped workpieces, including parts with blind holes and micro pores.

　　超声波清洗机的结构与组成

　　Structure and composition of ultrasonic cleaning machine

　　一台完整的超声波清洗设备通常由以下几个核心部件构成，每个部件都有其特定功能：

　　A complete ultrasonic cleaning equipment usually consists of the following core components, each with its specific function:

　　超声波发生器：作为设备的核心控制单元，它将市电转换为高频电信号，通常频率在20kHz至100kHz之间可调。现代超声波发生器还具有功率调节、频率自动跟踪、定时控制和温度保护等功能。

　　Ultrasonic generator: As the core control unit of the equipment, it converts mains electricity into high-frequency electrical signals, typically adjustable in frequency between 20kHz and 100kHz. Modern ultrasonic generators also have functions such as power regulation, automatic frequency tracking, timing control, and temperature protection.

　　换能器：负责将电能转换为机械振动。主要有两种类型：压电式换能器（采用锆钛酸铅等陶瓷材料，利用压电效应）和磁致伸缩换能器（采用镍或镍合金，利用磁变形效应）。压电换能器因其高效率和小型化优势更为常用。

　　Transducers: responsible for converting electrical energy into mechanical vibrations. There are mainly two types: piezoelectric transducers (using ceramic materials such as lead zirconate titanate, utilizing the piezoelectric effect) and magnetostrictive transducers (using nickel or nickel alloys, utilizing the magnetic deformation effect). Piezoelectric transducers are more commonly used due to their high efficiency and miniaturization advantages.

　　清洗槽：通常由耐腐蚀、耐高温的不锈钢制成，用于盛放清洗液和待清洗工件。槽体设计需考虑声学特性，确保超声波均匀分布。一些高端设备还在槽内设置侧壁换能器，实现多方向清洗。

　　Cleaning tank: usually made of corrosion-resistant and high-temperature resistant stainless steel, used to hold cleaning solution and workpieces to be cleaned. The design of the tank body needs to consider acoustic characteristics to ensure uniform distribution of ultrasonic waves. Some high-end devices also have side wall transducers installed in the slot to achieve multi-directional cleaning.

　　清洗液系统：包括清洗液本身及其循环过滤、加热装置。清洗液可以是水基溶液、有机溶剂或专用配方，根据清洗对象选择。加热系统一般将液温维持在40-60°C以增强清洗效果。过滤系统用于去除液体中的污染物，延长使用寿命。

　　Cleaning solution system: including the cleaning solution itself and its circulating filtration and heating devices. The cleaning solution can be a water-based solution, organic solvent, or specialized formula, depending on the cleaning target. The heating system generally maintains the liquid temperature at 40-60 ° C to enhance the cleaning effect. The filtration system is used to remove pollutants from liquids and extend their service life.

　　辅助系统：包括自动进排水装置、溢流除油装置、干燥系统等。全自动机型还配备传送带、机械臂等自动化组件，实现连续作业。

　　Auxiliary system: including automatic water inlet and outlet device, overflow oil removal device, drying system, etc. The fully automatic model is also equipped with automation components such as conveyor belts and robotic arms to achieve continuous operation.

　　表：超声波清洗机主要组件及功能

　　Table: Main components and functions of ultrasonic cleaning machine

　　组件名称主要功能技术特点

　　Component Name Main Function Technical Features

　　超声波发生器产生高频电信号频率可调，功率可控，具备保护功能

　　The ultrasonic generator generates high-frequency electrical signals with adjustable frequency, controllable power, and protective function

　　换能器电-机械能量转换压电式或磁致伸缩式，安装于槽底或侧壁

　　Transducers for electrical mechanical energy conversion, piezoelectric or magnetostrictive, installed at the bottom or sidewall of the groove

　　清洗槽容纳清洗液和工件不锈钢材质，声学优化设计

　　The cleaning tank contains cleaning solution and stainless steel material for workpieces, with acoustic optimization design

　　加热系统控制清洗液温度恒温控制，通常40-60°C

　　Heating system control cleaning solution temperature constant temperature control, usually 40-60 ° C

　　过滤系统净化清洗液循环过滤，延长液体使用寿命

　　The filtration system purifies the cleaning solution through circulating filtration, extending the service life of the liquid

　　超声波清洗机的使用方法

　　The usage method of ultrasonic cleaning machine

　　正确使用超声波清洗机不仅能获得最佳清洗效果，还能延长设备寿命。以下是标准操作流程及注意事项：

　　Proper use of ultrasonic cleaning machines can not only achieve optimal cleaning results, but also extend equipment lifespan. The following are standard operating procedures and precautions:

　　准备工作

　　preparation

　　设备安装：将清洗机放置在平稳、通风的工作台上，连接好电源（小型机用普通插座，大型工业机可能需要三相电）。确保设备良好接地，电源电压符合要求。对于有外接管路的设备，需正确连接进水管、排水管和溢流管。

　　Equipment installation: Place the cleaning machine on a stable and ventilated workbench, connect the power supply (small machines use ordinary sockets, large industrial machines may require three-phase electricity). Ensure that the equipment is well grounded and the power supply voltage meets the requirements. For equipment with external pipelines, it is necessary to correctly connect the inlet pipe, drainage pipe, and overflow pipe.

　　清洗液选择与添加：根据被清洗物的材质和污垢性质选择合适的清洗剂。水基清洗剂按1-2%比例稀释（约5-9公斤清洗剂兑水），有机溶剂则直接使用。向槽内加入液体至推荐液位（通常浸没过换能器或标记线），液面高度应保证放入工件后不溢出。

　　Selection and addition of cleaning solution: Choose the appropriate cleaning agent based on the material and nature of the dirt being cleaned. Water based cleaning agents are diluted at a ratio of 1-2% (about 5-9 kilograms of cleaning agent mixed with water), while organic solvents are used directly. Add liquid to the tank to the recommended level (usually submerged over the transducer or marking line), and the liquid level should be high enough to prevent overflow after placing the workpiece.

　　清洗操作步骤

　　Cleaning operation steps

　　工件放置：将待清洗物品放入专用清洗篮中，确保工件间不重叠，均匀分布。清洗量应达到槽容积的60%以上以避免"啸叫"现象。切勿将工件直接放入槽底，以免损坏换能器。

　　Workpiece placement: Place the items to be cleaned into a dedicated cleaning basket, ensuring that the workpieces do not overlap and are evenly distributed. The cleaning volume should reach more than 60% of the tank capacity to avoid the phenomenon of "whistling". Do not place the workpiece directly into the bottom of the groove to avoid damaging the transducer.

　　参数设置：根据工件材质和污染程度设置合适参数：

　　Parameter setting: Set appropriate parameters based on the material of the workpiece and the degree of contamination:

　　温度：一般设置在40-60°C之间，夏季可稍低(50-55°C)，冬季稍高(60-65°C)，最高不超过70°C。

　　Temperature: Generally set between 40-60 ° C, slightly lower in summer (50-55 ° C) and slightly higher in winter (60-65 ° C), with a maximum not exceeding 70 ° C.

　　时间：轻度污染3-5分钟，重度污染10-15分钟，特别顽固污垢可延长至20分钟。

　　Time: 3-5 minutes for mild pollution, 10-15 minutes for severe pollution, and up to 20 minutes for particularly stubborn dirt.

　　功率：从较低功率开始，逐渐调高至所需水平。功率过高可能损伤工件，过低则影响效果。

　　Power: Start from a lower power and gradually increase to the desired level. Excessive power may damage the workpiece, while insufficient power may affect the effectiveness.

　　启动清洗：按下启动按钮，超声波开始工作。观察清洗过程，如有异常噪音或振动应立即停机检查。定时功能启用后，设备将在设定时间自动停止。

　　Start cleaning: Press the start button, and the ultrasonic wave will start working. Observe the cleaning process and immediately stop the machine for inspection if there is any abnormal noise or vibration. After the timer function is enabled, the device will automatically stop at the set time.

　　后处理与维护

　　Post processing and maintenance

　　工件取出与干燥：清洗结束后，先关闭超声波电源再取出工件。用压缩空气吹干孔道和表面的残留液体，防止二次污染和水渍形成。有条件时可进行漂洗和热风干燥。

　　Workpiece removal and drying: After cleaning, turn off the ultrasonic power before removing the workpiece. Blow dry the residual liquid in the pores and surface with compressed air to prevent secondary pollution and water stains from forming. When conditions permit, rinsing and hot air drying can be performed.

　　液体处理：当液面出现过多浮油时，打开溢流阀排除油污。严重污染的清洗液应及时更换。溶剂型清洗液可通过蒸馏回收再利用。

　　Liquid handling: When there is too much floating oil on the liquid surface, open the overflow valve to remove the oil stains. Severely contaminated cleaning solution should be replaced in a timely manner. Solvent based cleaning solutions can be recycled and reused through distillation.

　　设备保养：每次使用后清洁槽内外表面；定期检查换能器性能；长期不用时应排空液体并保持干燥。按照制造商建议定期更换过滤器滤芯。

　　Equipment maintenance: Clean the inner and outer surfaces of the tank after each use; Regularly check the performance of the transducer; When not in use for a long time, the liquid should be emptied and kept dry. Regularly replace the filter cartridge according to the manufacturer's recommendations.

　　应用注意事项与常见问题

　　Application precautions and common problems

　　为确保超声波清洗的安全性和有效性，使用时需特别注意以下事项：

　　To ensure the safety and effectiveness of ultrasonic cleaning, special attention should be paid to the following matters when using:

　　安全注意事项

　　Safety precautions

　　个人防护：使用溶剂型清洗液时应佩戴手套和护目镜，确保工作区域通风良好。高温操作时注意防烫伤。

　　Personal protection: When using solvent based cleaning solutions, gloves and goggles should be worn to ensure good ventilation in the work area. Pay attention to preventing burns during high-temperature operations.

　　电气安全：定期检查设备绝缘性能，避免水汽进入电控箱。设备必须可靠接地，电气维修应由专业人员进行。

　　Electrical safety: Regularly check the insulation performance of equipment to prevent water vapor from entering the electrical control box. The equipment must be reliably grounded, and electrical maintenance should be carried out by professionals.

　　材料兼容性：某些材料如软金属(铝、铜)、镀层、软质塑料等可能被超声波损伤，应降低功率和缩短时间。橡胶等吸声材料会减弱超声波效果。

　　Material compatibility: Some materials such as soft metals (aluminum, copper), coatings, soft plastics, etc. may be damaged by ultrasonic waves, and power and time should be reduced. Rubber and other sound-absorbing materials can weaken the ultrasonic effect.

　　常见问题处理

　　Common problem handling

　　清洗效果不佳：可能原因包括功率设置过低、频率不匹配、清洗液选择不当或温度不合适。应逐步检查调整参数，或更换新鲜清洗液。

　　Poor cleaning effect: Possible reasons may include low power settings, mismatched frequencies, improper selection of cleaning solution, or inappropriate temperature. Gradually check and adjust the parameters, or replace with fresh cleaning solution.

　　异常噪音：可能是工件放置不当、清洗篮与槽体接触或换能器故障。应重新布置工件或联系售后服务。

　　Abnormal noise: It may be due to improper placement of the workpiece, contact between the cleaning basket and the tank, or a malfunction of the transducer. Workpieces should be rearranged or after-sales service should be contacted.

　　加热失效：检查温控系统设定和加热元件连接，确保温度传感器工作正常。

　　Heating failure: Check the temperature control system settings and heating element connections to ensure that the temperature sensor is working properly.

　　特殊应用技巧

　　Special application skills

　　精密零件清洗：使用高频(80kHz以上)和小功率，配合专用清洗剂，避免表面损伤。

　　Precision parts cleaning: Use high frequency (above 80kHz) and low power, combined with specialized cleaning agents, to avoid surface damage.

　　重度油污处理：可采用多槽式清洗，先进行超声波溶剂清洗，再用水基清洗剂漂洗。

　　Heavy oil pollution treatment: Multi tank cleaning can be used, first using ultrasonic solvent cleaning, and then rinsing with water-based cleaning agent.

　　杀菌消毒：利用超声波空化产生的高温高压，配合消毒液，可对医疗器械进行高效灭菌。

　　Sterilization and disinfection: By utilizing the high temperature and high pressure generated by ultrasonic cavitation, combined with disinfectant, medical devices can be efficiently sterilized.

　　超声波清洗技术凭借其高效、均匀和可深入复杂结构的优势，已成为现代清洁工艺中不可或缺的工具。通过合理选择设备参数和操作条件，可满足从工业零件到精密光学元件、从珠宝首饰到医疗器具的各种清洗需求。掌握正确的使用方法和维护知识，不仅能充分发挥设备性能，还能显著延长其使用寿命。

　　Ultrasonic cleaning technology, with its advantages of high efficiency, uniformity, and the ability to penetrate complex structures, has become an indispensable tool in modern cleaning processes. By selecting appropriate equipment parameters and operating conditions, various cleaning needs from industrial parts to precision optical components, from jewelry to medical equipment can be met. Mastering the correct usage and maintenance knowledge can not only fully utilize equipment performance, but also significantly extend its service life.

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