Building your own ultrasonic cleaner at home can be a fun do-it-yourself project. While a factory manufactured ultrasonic cleaner will give you a trouble free cleaning experience, the one that you build yourself will give you oodles of satisfaction. To get this off the ground a little knowledge of physics, audio setup, and hardware would come in handy and also help you design the cleaner with a little more ease, not knowing is definitely not a downer at all. You can pick up along the way and what you don't know or understand you can learn on the job!
The materials required for building the parts of the cleaner include an oscilloscope, two ultrasonic transducers, a good sound card, a linear amplifier, a soldering iron, a solder, old RCA audio cables and a container made of stainless steel. The container should be made of just a single layer of steel. So, even a cookie tray will suffice.
If you don't have a linear amplifier and a capable sound card, you can toy with the idea of buying an ultrasonic generator separately. However, this would defeat the main purpose of building a low cost cleaner yourself. Besides, most of the ultrasonic generators currently sold in the market have enough output power to drive only one transducer.
You can buy the ultrasonic transducers online. You need to ensure that the transducers are designed only for cleaning purposes. The 55 watt transducers are good enough. Getting an oscilloscope is not mandatory. It only helps measure the frequency of the sound waves generated when the sound card is put to use. This frequency should be powerful enough to drive the transducers.
It would be a good idea to determine the maximum sampling rate or the frequency response of the sound card after checking its specifications with the manufacturer. This will give you the maximum output frequency of your sound card and will help you decide if it's suitable enough to drive the transducers.
The RMS of the power and the frequency of the linear amplifier must be greater than that required to drive the transducers. Ultrasonic amplifiers are nothing but regular audio amplifiers. The stainless steel container is the best choice as it resistant to corrosion and also resonates sound waves. A temperature-controlled soldering iron is very useful, but optional.
Process of building the ultrasonic cleaner is tres simple:
* The transducers are best placed diagonally in the cleaning tank to ensure even cavitation. The gap between the transducers and the tank must be minimal.
* The ends of the RCA cable should be cut and each end should be soldered to a different pad. One wire per pad is the requirement.
* The other (free) end of the cable must be plugged into the amplifier output. Choosing the right or left channel is of no consequence.
* The sound card is to be plugged into the input of the amplifier. This completes the setup process.
* You can then fill the container with cleaning solution and switch on the amplifier.
And you have a functional unit that should give you, if not top notch cleaning, at least the satisfaction of having built a piece of complex hardware on your own! Of course this DIY neglects the more rigorous testing and quality assurance checks that you would get from get from an off the shelf factory assembled ultrasonic cleaner. But that's not the point is it?
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Dr. Bob Sandor is a Director at Tovatech, a leading North American supplier of ultrasonic cleaners. When not busy running his company, he explores his fascination with the many aspects of various scientific & industrial devices. For more details on the above you can reach him through the ultrasonic cleaner section of his website.
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