ULTRAREIN | Multisensor system for monitoring the ultrasonic effect chain

Process monitoring in ultrasonic cleaning

The technical cleanliness of components is often of great importance for downstream processing steps. Especially for painting and coating, joining and welding, but also for many measuring methods in quality control, a clean surface is urgently required. Many types of soiling can only be removed inadequately by simple washing processes and blasting processes are sometimes too aggressive, depending on the component properties. The right solution for such cases is often ultrasonic cleaning.

The principle of ultrasonic cleaning is already used in many companies. Often, however, the relationships between the possible process parameters and measured variables are for the most part still unclear. The design of the cleaning processes is often based on the experience of employees working on the cleaning systems. Reliable predictions of cleanliness as a function of the set process parameters are therefore hardly possible to date.

Measurement of the cleaning effect using a multi-sensor system

Within the ULTRAREIN project, a multi-sensor system is being developed with which the measured variables of the ultrasonic bath can be recorded under comparable boundary conditions. An intelligent algorithm for data evaluation is then to link the cleaning result with the measured variables and set parameters of the ultrasonic bath. By using a standardized, predefined component contamination, the cleaning process itself can be examined. Differences in the cleaning effect on different component geometries become clear in this way. Partner institute of the project is the Fraunhofer IVV in Dresden.

Dirty gear wheel in the measuring chamber to determine the contamination
© Fraunhofer IGCV
Dirty gear wheel in the measuring chamber to determine the contamination

Derivation of forecasts and saving potentials

Fluorescence measurement to determine the amount of dirt on a dirty gear wheel
© Fraunhofer IGCV
Fluorescence measurement to determine the amount of dirt on a dirty gear wheel

The evaluation of the cleanliness measurements, parameter studies and measured variables will then be correlated with the components and the geometric elements on them. In this way, the cleaning processes of new components with known geometric elements can be better designed in advance. In addition, predictions can be made about the achievable cleanliness under given conditions (e.g. maximum cleaning time, minimum energy input, etc.). Especially in the case of large quantities of components, this results in enormous savings potentials, for example in terms of costs, time or energy consumption.

Cooperation with Fraunhofer IGCV

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Industry solutions

The key sectors of Fraunhofer IGCV:

  • Mechanical and plant engineering
  • Aerospace
  • Automotive and commercial vehicles


We are shaping the way into the future of efficient engineering, networked production and intelligent multi-material solutions.