WHAT IS W3 ULTRASONICS LLC?

W3 ULTRASONICS LLC has been performing process development, manufacturing, and marketing of ultrasonic equipment and systems for industry for many years. That will remain a mainstay for W3 as it brings that experience into the manufacturing and marketing of the Water Recovery processes and operations developed by WAT&R and W3 Development to daily operational reality.

The Guiding Criteria for apparatus MANUFACTURING are:

• SIMPLICITY OF CONSTRUCTION
• OPERATIONAL RELIABILITY
• COMPONENT AVAILABILITY AND INTERCHANGEABILITY
• SUPPLY CHAIN RELIABILITY
• EASE OF SERVICE

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PROCESS DETERMINES THE TYPE OF EQUIPMENT OR SYSTEM

Whether you are cleaning parts or cleaning liquids, the process determines the equipment or systems configuration. Often, the error is made to select the equipment and try to make the process fit into the constraints of the equipment or arrangement. That is why it is critical to determine the process to be followed before configuring the system to perform the process. W3 has experience and capability to design and supply equipment to meet the different requirements demanded by the process that fits the application.

Processing of water, or other liquids, whether for WATER RECOVERY OR WATER PRODUCTION, the only economically viable way is a CONTINUOUS FLOW SYSTEM wherein the product being processed, in this case the liquid itself, is transported through the cleaning system continuously. Until the development of the acoustic technologies utilized by WAT&R and W3 Development, that was not an option. The equipment to perform those processes function entirely differently than current systems.

Essentially DISCRETE PARTS OR ASSEMBLIES have two options for the product to be processed is passed through the process stages: BATCH or CONTINUOUS FLOW. In the case of discrete parts/assemblies, manufacturing conditions generally dictate which method will be used. Below are numerous examples of equipment W3 can provide for either method of product flow.

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PROCESSING FLOWING WATER OR OTHER LIQUIDS (SURROUND)

With WATER RECOVERY, the purpose of the process is to remove the Total Dissolved Solids (TDS) from the water which can generally be done by the action of the sound waves only. The result are two streams, the PERMEATE, which is the water and the EFFLUENT, which is the waste, or brine in the case of seawater.

Processing of the resultant EFFLUENT is generally a COMBINATION OF CONTINUOUS FLOW with interspaced SEPARATE BATCH DWELL STATIONS to perform such operations as MINING, which are generally timed and/or chemical dependent operations.

The technologies are so new as to have patents pending and processes, equipment and systems currently under development as you read this. As they evolve, W3 Ultrasonics LLC is uniquely capable of supplying those systems because of the cooperation with W3 Development, access and understanding of the new technologies and equipment and the vast experience with manufacturing and operation of sonic systems.

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BATCH TRANSFER PRODUCT FLOW (CONSOLES) (SCMS) (MCMS)

PARTS CLEANING operations generally fall under two types of definitions: continuous individual product flow or batches of individual parts contained together constituting a 'load'. W3 product philosophy is based in making the product fit the application rather than making the application fit the product.

Batch processing machines process products in discrete loads, or batches. These can be an individual larger part or a collection of smaller parts. Many smaller parts batches together present a particularly nasty problem called “nesting”. Nested parts are hard to penetrate with either fresh solution or sufficient scrubbing action.

Batch handling has traditionally been more common but modern manufacturing methods and demands to produce more and faster part loads have led to innovations to systems such as:

• Multiple Variations of Load Transfer
• Single Chamber, Multi-Stage
• Multi-Chamber, Multi-Stage
• Open and Closed Enclosed Chambers
• Continuous Belt
• Continuous Submersion
• Part Reorientation Stages

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CONTINUOUS PRODUCT FLOW (SURROUND) (IN-LINE) (CONTINUOUS IN-LINE)

In-line equipments are those that process product in a relatively continuous, uninterrupted product flow either with individual parts or liquids. A good example of individual parts would be a screw machine which can exit parts into a tote tray or onto a continuously moving belt. Continuous flow presents unique problems including speed, layout and orientation factors to name a couple. The limited amount of time to scrub, rinse and dry the part causes floor space and handling concerns. Conversely, being able to do cleaning inline allows users flexibility in production.

Product flow can be integral to manufacturing production as an extension of a previous, or a following, manufacturing step or it can be a separate off line system for cleaning or processing. Indirectly, continuous product flow can reduce WIP and material handling. W3 has unique and innovative products and experience in these applications and machines for many years.

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EQUIPMENT AND SYSTEM TYPES

W3 evolved over 40 years of application, design and manufacture of powerful ultrasonic based equipment and systems. Below are representative examples of the variety and scope of those systems. They demonstrate the wide range of applications that can be effectively served and while most are cleaning based, they also represent the capability to produce systems for Water Recovery and Production. A brief description of each category is included but for further information regarding a particular application, contact W3

Ultrasonic Equipment Features:

• Powerful 20 kHz magnetostrictive families rated 1000W
• 20 kHz and 34 kHz piezoelectric families rated 250W to 2000W

Sheet Metal and Tankage Features:

• tainless steel wetted surfaces in 304, 316 or 316L
• Stainless steel or powder coated color panels

Automation and Control Features:

• Integral or separately housed power supplies, controls, filtration, etc.
• Manual, semi-automatic or fully automatic parts handling options

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W3 ULTRASONIC COMPONENT FAMILIES FOR INDUSTRIAL APPLICATIONS

W3 Ultrasonic components are standard individual component apparatus designed to be incorporated into existing equipment or to provide the flexibility to be designed into custom and automated systems to perform specific process functions.

 

 

 

 

 

 

 

 

 

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CONSOLE PRODUCTS

Ultrasonic console workstations are designed to pick up where individual standard ultrasonic console tanks and components need expanded.

 

 

 

 

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IN-LINE PRODUCT FLOW SYSTEMS

In-line machines are those that process product in a relatively continuous, uninterrupted product flow, as opposed to batch processing machines that process product in discrete loads, or batches. In-line products can be continuous, such as wire products, or a flow of individual parts continuously conveyed through the cleaning process.

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SINGLE-CHAMBER, SINGLE AND MULTI-STAGE PRODUCT FLOW SYSTEMS

Single-Chamber, Multi-Stage (SCMS) systems are machines that contain a single load/unload chamber and multiple individual process stages within the machine. Parts stay within a single process chamber and the cleaning stages are introduced to the parts automatically within the machine. This type of machine is ideally suited to cellular manufacturing cleaning operations and lower production capacity environments.

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MULTI-CHAMBER, MULTI-STAGE PRODUCT FLOW SYSTEMS

Multi-Chamber, Multi-Stage (MCMS) systems are machines that contain multiple individual process chambers and multiple individual process stages. Parts are transported manually, semi-automatically or automatically from chamber to chamber. Systems can be smaller, such as multi-tank console units or larger such as open or enclosed combination of individual tanks that function as one.

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MATERIAL HANDLING PRODUCTS

Small parts that can be contained in baskets or carriers can be transported as a nested batch. Part geometry and surface specifications dictate whether parts can remain loose or must be clamped and whether rotation is an option. Or small parts can also be processed individually through a continuous cleaning system, typically feed from an upstream manufacturing process or bulk loading unit.

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HOW TO CHOOSE THE TYPE OF SYSTEM FOR YOUR NEEDS

Below is a partial list of applications and the suggested type of system for initial consideration. The best way to determine which system fits your needs is to contact W3 and discuss your specific situation.

Start the Process Development analysis yourself or Contact W3 directly. email info@w3sonics.com

• Specifically designed for all wire industry products - See Surround or Continuous In-line
• High volume continuous product flow, often with excessive lubricants - See Surround or Continuous In-line
• Individual parts off a machine into totes or downstream conveyance - See Consoles or Continuous In-line.
• Smaller parts batches “nested” together -- See SCMS, or MCMS or Continuous In-line
• Nested parts hard to penetrate with either fresh solution or sufficient scrubbing action- See Consoles or Continuous In-line
• Automatic lift machines to move product in correct orientation - See Consoles or MCMS
• Assemblies or groups of parts masking of one part over another - See Consoles or MCMS
• Material handling options for batch or continuous product flows - See SCMS, or MCMS or Continuous In-line
• Batch processes require product to transfer from immersion chamber to immersion - See MCMS
• Ancillary filtration, oil coalescing or skimming and chemistry - See Consoles or MCMS or SCMS
• Critical tolerance surfaces/finishes scrubbed, rinsed, dried quickly - See SCMS or MCMS or Continuous In-Line
• Small diameter through holes and blind holes filled, emptied and rinsed each stage - See SCMS or MCMS

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SONICS CAN TREAT WATER FROM PRODUCTION WASTE TO RECOVERY

In addition of the obvious use of these technologies for such applications as the desalination of seawater and destruction of microorganisms and invasive species, an enormous need is in the processing of the waste created in the production of products we need for everyday living and in some cases survival. Ultrasonics has been used for decades to clean product during manufacturing. Now sonics can be used in a different form to process waste streams to recover water and often valuable by-products of the cleaning process usually lost in the waste stream.

Here you will see a partial array of the industries W3 Ultrasonics can serve. If it looks like any industry could be in this list, you are correct. W3 has experience in virtually every industry and application.

INDUSTRY OR PROCESS	A TYPICAL APPLICATION YIELDING PROCESS WASTE	PRIMARY MATERIAL TO REMOVE FROM WATER
Aerospace	Blades, Segments, Small Passages	Oil, Total Dissolved Solids (TDS)
Agriculture/livestock	Fertilizers, Livestock Waste	Fertilizer, Organisms
Automotive	Injectors, Critical Parts	Oil, Fuel, Combustion Residue
Desalination	Salt, Microorganisms	Salt, TDS
Fastener	Fasteners, Small Parts	Machine Oils
Forming	Cold stamped, Screw machine	Generally Non Water Based
Foundries	Release Compound, Flashing	Compounds, TSS
General Industry	Assemblies, Component Parts	Oils, Total Suspended Solids (TSS)
General Machining	Machined Parts-Multi Axis	Machine Oils
Medical	Surgical Instruments,	Microorganisms, TDS
Oil and Gas	Fracking Waste	Minerals, Oil, TDS
Plating	Plating and Coating	Machine Oils
Semi Conductor	Printed Circuits	PCB Component Elements
Transportation	Bearings and Assemblies	Oil, Particulates, TSS
Wire	Wire, Strip, Extruded Shapes	Drawing Compounds
Remanufacturing	General Maintenance	Dirt, Oil, TDS
Alternative Energy	H2 Extraction	Hydrogen Gas

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SOME OTHER CLEANING AND NON-CLEANING APPLICATIONS

• Mixing Solutions
• Separation Processes
• Solution Emulsions
• Coating and Phosphating
• Dye Penetrate Cleaning
  

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Examples of the Range of Parts W3 Has Experience

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