Ultrasonic Flow Sensor / Flow Meter for Cleaning Process

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In industrial 4.0 manufacturing processes, any surface deposits, impurities, inclusions, or adsorbed substances that could degrade the chemical, physical, or electrical properties of a product may pose potential quality risks.

Once residual contaminants combine with moisture or dust, they can form corrosive media, leading to corrosion, electro-migration, or even short circuits, thereby affecting product reliability.

For manufacturers pursuing parts-per-million (PPM) level reliability, this means stricter cleaning and control processes must be adopted. Stable and controllable cleaning fluid flow is a critical part of this process.

Wet Cleaning Processes Flow Rate Measurement

In wet cleaning processes, insufficient liquid flow can lead to incomplete cleaning and increased risk of residues, while excessive flow may cause chemical waste, increase the burden of wastewater treatment, and even mechanically impact precision components.

Different wet cleaning equipment has varying requirements for cleaning liquid flow control, but all require accurate flow rate measurement to ensure cleaning effectiveness and consistency, for example:
1.Spray cleaning relies on high-pressure pumps to spray cleaning fluid onto surfaces. In addition to pressure control, the actual flow reaching the target surface is equally important, as it determines whether the cleaning fluid can effectively penetrate under components and into blind spots to remove residues.
2.Multi-stage in-line cleaning involves multiple tanks for cleaning, rinsing, and drying. Flow balance affects the takt time and consistency of the entire production line.

Therefore, real-time flow rate measurement and flow data feedback control have become core functions of wet cleaning equipment.

Challenges in Wet Cleaning Equipment Flow Rate Measurement
1. Complex Media Characteristics
Cleaning and rinsing fluids include deionized water, ultra-pure water, surfactants, or mild acids and bases. These are often corrosive and require extremely high cleanliness, so any contact-type sensor poses a contamination risk.
2. Restricted Installation Spaces
Cleaning device tubing is generally multi-branched and has complex routing. This makes flow sensor / flow meters installation and placement with restrictions; the pump turbulence may affect measurement stability.
3. High Process Requirements

Production cycles are fast and highly sensitive to downtime and fluctuations. Even short-term flow deviations can cause incomplete cleaning, chemical waste, or reduced yield, demanding extremely high measurement accuracy and response speed.

clamp-on ultrasonic flow sensor

To address these challenges, the CPD series clamp-on ultrasonic flow sensors/flow meters, with the non-invasive flow measurement, no-tube-cutting features, have become the ideal choice for cleaning water/ chemicals flow measurement.
1. Clamp-on Installation: 0 Contamination, 0 Downtime
Directly clamps onto existing tubing without cutting the tubing, resulting in 0 downtime. It can be easily retrofitted even after equipment delivery, providing flexibility for future upgrades.
2. Measure Multiple Cleaning Liquid
Suitable for measuring a variety of cleaning liquids such as deionized water, ultrapure water, and chemical solutions.
3. Non-Invasive Flow Rate Measurement, No Pressure Loss
The measurement process does not contact the cleaning fluid, eliminating risks of contamination, clogging, or leakage.
No internal components obstructing fluid flow, resulting in 0 pressure loss, energy savings for the system, and extended service life for pumps and related components.
4. Integrated Design, Reduced Wiring
The flow sensor is compact in size for space-saving installation.
5. High Flow Rate Measurement Accuracy
Repeatability up to ±0.1% F.S., with reading accuracy up to ±2%.
6. Real-Time Flow Rate Monitoring
Equipped with a display screen for intuitive flow data visualization, with a response time of less than 1s.
7. Multiple Signal Output Modes
Supports a variety of output methods, including RS-485, 4-20mA, and pulse output (customizable), meeting automation requirements.
8. Small-Diameter Tubing Measurement
Supports measurement of tubing OD as small as 6 mm.
9. Low Maintenance Cost
No moving parts, no need for regular leaning, low maintenance costs.
10. Covers Multiple Cleaning Scenarios

Simplifies inventory management and reduces procurement complexity.

flow viewer software

Classic Applications
1. Real-Time Monitoring of Cleaning Fluid Flow
Provides real-time measurement and monitoring of cleaning and rinsing fluid flow, helping engineers keep track of flow status in each process step and ensuring stable and consistent cleaning performance.
2. Data Feedback and Process Control
The CPD clamp-on ultrasonic flow sensor / flow meters can send real-time flow data to MES or PLC systems for process monitoring and automatic control. Through data analysis, potential anomalies can be detected in advance, and cleaning flow parameters can be optimized, making the entire cleaning process more controllable, efficient, and traceable.
3. Chemical Usage and Cost Optimization
Precise flow rate measurement helps prevent chemical waste caused by excessive cleaning, while ensuring thorough cleaning and reducing operating costs. The non-invasive flow rate measurement eliminates the risk of secondary contamination, making it safe for corrosive liquids such as acids and alkalis.
4. High-End Process Compatibility

CPD ultrasonic flow sensor / flow meters are suitable for cleaning processes requiring high cleanliness levels, providing stable and reliable flow assurance without contamination, thus supporting high-end manufacturing applications.

Overall, the CPD ultrasonic flow sensors/flow meters, with real-time data feedback and process optimization, not only improve cleaning quality and equipment safety but also support enterprises in reducing cleaning process costs and enhancing production efficiency.

For more flow sensor / flow meter information, please visit TGU introduction page at https://xy-tek.com/Products/show?id=6

Contact XY-TEK team at global@xy-tek.cn

XYTEK engineers would be delighted to arrange the flow sensor/flow meter demonstration or provide further information to help make the flow meter selection choice.