System and method for surface cleaning

A system for cleaning an object may include an acoustic device configured to deliver acoustic waves to the object, a cleaning medium dispenser configured to deliver a cleaning medium to a surface of the object, a rinsing medium dispenser configured to deliver a rinsing medium to the surface, a vacuum configured to deliver a vacuum airflow proximate the surface, wherein the acoustic waves generate acoustic vibrations in the object to dislodge debris from the surface, acoustically treat the cleaning medium and the rinsing medium, and atomize the cleaning medium, the debris collected by the cleaning medium and the rinsing medium.

FIELD

The present disclosure is generally related to surface cleaning and, more particularly, to systems and methods employing cleaning mediums, acoustic waves and vacuum suction to remove debris from a surface of an object.

BACKGROUND

Besides just aesthetic appearance, cleaning the surfaces of objects (e.g., workpieces or other manufactured parts) is an essential, and in many applications required, process to prepare the part for further processing, such as applying a new finish or assembling the part into a larger component. The choice of cleaning methods may depend on many factors, such as the nature of the contamination, the degree of the contamination, cleanliness requirements, and the shape, size or complexity of the object.

Conventional cleaning methods have various limitations, such as inconsistent cleaning quality and certain surfaces (e.g., complex surfaces or interior surfaces) may be difficult to reach or access.

Accordingly, those skilled in the art continue with research and development efforts in the field of surface cleaning of objects.

SUMMARY

In one aspect, the disclosed system for cleaning an object may include an acoustic device configured to deliver acoustic waves to the object, a cleaning medium dispenser configured to deliver a cleaning medium to a surface of the object, a rinsing medium dispenser configured to deliver a rinsing medium to the surface, a vacuum configured to deliver a vacuum airflow proximate to the surface, wherein the acoustic waves generate acoustic vibrations in the object to dislodge debris from the surface, acoustically treat the cleaning medium and the rinsing medium, and atomize the cleaning medium, the debris collected by the cleaning medium and the rinsing medium.

In another aspect, the disclosed system for cleaning an object may include an acoustic device configured to deliver acoustic waves to the object, a fluid dispenser configured to deliver a fluid to the surface, a vacuum configured to deliver a vacuum airflow proximate the surface, wherein the acoustic waves dislodge debris from the surface, acoustically treat the fluid, and atomize the fluid and the debris collected by the fluid.

In another aspect, the disclosed system may include an acoustic device configured to deliver acoustic waves to the object, a cleaning medium dispenser configured to deliver a cleaning medium to the surface, a rinsing medium dispenser configured to deliver a rinsing medium to the surface, and a vacuum configured to deliver a vacuum airflow proximate the surface, wherein the acoustic waves generate acoustic vibrations in the object to dislodge debris from the surface, acoustically treat the cleaning medium and the rinsing medium, and atomize the cleaning medium, the debris collected by the cleaning medium and the rinsing medium.

In yet another aspect, disclosed is a method for cleaning an object, the method may include the steps of: (1) delivering acoustic waves to the object to dislodge debris from the surface, (2) delivering a cleaning medium to the surface to collect dislodged debris, (3) delivering the acoustic waves to the object to acoustically treat and atomize the cleaning medium and the dislodged debris, (4) applying a vacuum airflow to collect atomized cleaning medium and dislodged debris, (5) delivering a rinsing medium to the surface, (6) delivering the acoustic waves to the object to acoustically treat and atomize the rinsing medium, and (7) applying a vacuum airflow to collect atomized rinsing medium

Other aspects of the disclosed system and method will become apparent from the following detailed description, the accompanying drawings and the appended claims.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings, which illustrate specific aspects of the disclosure. Other aspects having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same element or component in the different drawings.

Referring toFIG. 1, one aspect of the disclosed system, generally designated10, for surface cleaning of an object may include a cleaning assembly12utilized for cleaning debris14from one or more surfaces16of one or more objects18, such as during fabrication, assembly and/or maintenance of the object18. For example, the object18may include any manufactured part, component, assembly or sub-assembly having large, complex and/or delicate surfaces16, including, but not limited to, complex three-dimensional objects18and/or large two-dimensional objects18, such as aircraft components.

As used herein, debris14may include any contaminant, substance and/or other unwanted constituent material disposed on the surface16of the object18. Debris14may include any solid, semi-solid, liquid and/or semi-liquid material of any type, without limitation.

The cleaning assembly12may include at least one acoustic device20, at least one cleaning medium dispenser22, at least one rinsing medium dispenser24and at least one vacuum26. The acoustic device20may deliver acoustic (e.g., sound) waves28to the surface16of the object18to generate vibrations on the surface16of the object18and/or within (e.g., throughout at least a portion of) the object18. The cleaning medium dispenser22may deliver a cleaning medium30to the surface16of the object18. The rinsing medium dispenser24may deliver a rinsing medium32to the surface16of the object18. The vacuum26may deliver a vacuum airflow34(e.g., vacuum suction) proximate (e.g., at or near) and/or directed to the surface16of the object18.

The acoustic vibrations on the surface16of the object18and/or through the object18may dislodge the debris14from the surface16of the object18. For example, the acoustic vibrations may reduce adhesion between the debris14and the surface16and/or break up the debris14into smaller particles of debris14(e.g., particulate material). The cleaning medium30may absorb, capture and/or suspend any debris14dislodged from the surface16of the object18in response to the vibrational effects of the acoustic waves28. The acoustic vibrations on the surface16of the object18and/or through the object18may atomize the cleaning medium30and any dislodged debris14(e.g., particles of debris14captured within a cleaning medium envelope). The rinsing medium32may rinse away any cleaning medium30and debris14remaining on the surface16. The acoustic vibrations on the surface16of the object18and/or through the object18may atomize the rinsing medium32. The vacuum26may remove the atomized cleaning medium30along with any debris14collected by the cleaning medium30and the atomized rinsing medium32from the surface16of the object18.

The acoustic device20may include a sonic device configured to emit sonic waves that generate acoustic (specifically, sonic) vibrations in the object18and/or an ultrasonic device configured to emit ultrasonic waves that generate acoustic (specifically, ultrasonic) vibrations in the object18. As used herein the terms sonic waves and ultrasonic waves may refer to oscillating mechanical waves (e.g., pressure waves), wherein the frequencies of the mechanical waves may vary from a few hertz to billions of hertz. For example, sonic waves may include waves having a frequency between approximately 1,000 Hz and 10,000 Hz. As another example, ultrasonic waves may include waves having a frequency between approximately 20 kHz and 20 MHz.

Those skilled in the art will appreciate that the vibrational effects of the sonic waves and/or ultrasonic waves utilized to atomize droplets of cleaning medium30and/or rinsing medium32into a mist are not related to human hearing and, as such, the terms sonic and ultrasonic are not necessarily limited by common definition.

One or more acoustic devices20(e.g., sonic devices and/or ultrasonic devices) may be positioned at various locations with respect to the object18and tuned to generate various types of acoustic (e.g., sonic and/or ultrasonic) guided wave modes, including acoustic streaming (e.g., movement of the cleaning medium30and/or the rinsing medium32in response to the acoustic waves28), on the surface16of the object18at desired locations. In an example implementation, one or more acoustic devices20may be air coupled to (e.g., proximate to) the object18and/or the surface16of the object18. In another example implementation, one or more acoustic devices20may be physically coupled to (e.g., in contact with) the object18and/or the surface16of the object18. In yet another example implementation, one or more acoustic devices20may be air coupled to the object18and/or the surface16of the object18and one or more acoustic devices20may be physically coupled to the object18and/or the surface16of the object18.

The acoustic device20may be any suitable acoustic transducer that generates acoustic signals when driven by an electric voltage. In an example construction, the acoustic device20may be a piezoelectric transducer (e.g., a sonic transducer or an ultrasonic transducer) that converts electrical energy into acoustic energy (e.g., sound). Piezoelectric crystals may change size when a voltage is applied, thus applying an alternating current (“AC”) across the piezoelectric transducer may cause it to oscillate at a very high frequency and produce very high frequency sound waves (e.g., acoustic waves28).

A plurality of acoustic devices20(e.g., a plurality of sonic devices and/or ultrasonic devices) may be arranged in an array38of acoustic devices20. The array38may be any arrangement of acoustic devices20connected to common source (e.g., acoustic generator40). In one example, the plurality of acoustic devices20may be arranged in a parametric array of acoustic devices. In another example, the plurality of acoustic devices20may be arranged in a phased array of acoustic devices. The array38of acoustic devices20may include a geometry that directs and concentrates the acoustic waves28onto particular areas (e.g., cleaning zones62) on the surface16of the object18to be cleaned.

As used herein, a parametric array may include a plurality of acoustic devices20(e.g., high-intensity piezoelectric transducers) configured to produce a narrow primary beam of sound (e.g., acoustic waves28). In general, the larger the dimensions of the parametric array, the narrower the beam. As a general, non-limiting example, the parametric array may be driven at two closely spaced ultrasonic frequencies (e.g., ω1 and ω2) at high enough amplitudes to produce a difference frequency (e.g., ω2−ω1).

As used herein, a phased array may include a plurality of acoustic devices20(e.g., piezoelectric transducers) individually connected so that the signals they transmit or receive may be treated separately or combined as desired. For example, multiple acoustic devices20may be arranged in patterns in a common housing. The patterns may include, but are not limited to, linear, matrix, and/or annular in shape. The acoustic devices20may be pulsed simultaneously or independently of each other in varying patterns to achieve specific beam characteristics.

An acoustic generator40may be coupled to the acoustic devices20. The acoustic generator40(e.g., a sonic and/or ultrasonic power amplifier and function generator) may supply energy to the acoustic devices20. An acoustic supply line42(e.g., a flexible acoustic waveguide) may couple the acoustic generator40to the acoustic devices20such that acoustic waves28may be applied from the acoustic devices20to the surface16of the object18(e.g., about the cleaning zone62).

The cleaning medium dispenser22, the rinsing medium dispenser24and/or the vacuum26may be mounted to a cleaning head36. The cleaning head36may deliver cleaning medium30(e.g., from the cleaning medium dispenser22), rinsing medium32(e.g., from the rinsing medium dispenser24) and vacuum airflow34(e.g., from the vacuum26) directly to a cleaning zone62on the surface16of the object18.

A cleaning medium source44may be fluidly coupled to the cleaning head36. The cleaning medium source44may supply the cleaning medium30to the cleaning medium dispenser22. A cleaning medium supply line46may fluidly couple the cleaning medium source44to the cleaning head36such that cleaning medium30may be provided from the cleaning medium dispenser22to the surface16of the object18(e.g., about the cleaning zone62).

A rinsing medium source48may be fluidly coupled to the cleaning head36. The rinsing medium source48may supply the rinsing medium32to the rinsing medium dispenser24. A rinsing medium supply line50may fluidly couple the rinsing medium source48to the cleaning head36such that rinsing medium32may be provided from the rinsing medium dispenser24to the surface16of the object18(e.g., about the cleaning zone62).

The cleaning medium30may include any suitable substance and/or material that are able to perform a cleaning action in combination with the ultrasonic waves28and vacuum airflow34. The rinsing medium32may include any suitable substance and/or material that are able to perform a rinsing action in combination with the ultrasonic waves28and vacuum airflow34.

The cleaning medium30may include any cleaning fluid. The cleaning fluid may include a liquid or a gas. As an example, the cleaning medium30may include liquid water (e.g., hot water and/or cold water). As another example, the cleaning medium30may include any aqueous solutions (e.g., organic solvents, surfactants, detergents or other chemicals). As another example, the cleaning medium30may be steam (e.g., vaporized water). As another example, the cleaning medium30may be air (e.g., forced and/or pressurized air). As another example, the cleaning medium30may include a blasting media (e.g., solid plastic pellets, sand, gel capsules, liquid CO2, solid CO2, and the like). As yet another example, the cleaning medium30may include any combination of cleaning fluids and/or blasting media.

The rinsing medium32may include any rinsing fluid. The rinsing fluid may include a liquid or a gas. As an example, the rinsing medium32may include liquid water (e.g., hot water and/or cold water). As another example, the rinsing medium32may include any aqueous solutions (e.g., organic solvents, surfactants, detergents or other chemicals). As another example, the rinsing medium32may be steam (e.g., vaporized water). As another example, the rinsing medium32may be air (e.g., forced and/or pressurized air). As yet another example, the rinsing medium32may include any combination of rinsing fluids.

A vacuum source52may be fluidly coupled to the cleaning head36. The vacuum source52may supply the vacuum airflow34(e.g., vacuum suction) to the vacuum26. A vacuum supply line54may fluidly couple the vacuum source52to the cleaning head36such that vacuum suctioning (e.g., vacuum airflow34) may be applied from the vacuum26to the surface16of the object18(e.g., about the cleaning zone62).

The acoustic waves28may promote and/or facilitate both removal of debris14and acoustic treatment of the cleaning medium30and rinsing medium32to atomize the cleaning medium30and rinsing medium32from the surface16of the object18(e.g., about the cleaning zone62). Acoustic treatment may include any treatment of an object with acoustic energy.

Thus, the removal (e.g., cleaning and rinsing) of debris14may be achieved by the combination of the acoustic waves28, the cleaning medium30, the rinsing medium32and the vacuum airflow34and, therefore, may be completely non-contact. For example, the acoustic devices20, the cleaning medium dispenser22, the rinsing medium dispenser24and the vacuum26may be positioned at a distance (e.g., spaced away) from the object18to be cleaned and do not impose any risk of contamination of the surface16of the object18. More particularly, the acoustic devices20, the cleaning medium dispenser22, the rinsing medium dispenser24and the vacuum26may be positioned in close proximity to the surface16of the object18

As used herein, close proximity may include a position close to the surface16of the object18without touching the object18. As an example, close proximity may include positions of at most approximately 12 inches from the surface16. As another example, close proximity may include positions of at most approximately 6 inches from the surface16. As another example, close proximity may include positions of at most approximately 3 inches from the surface16. As another example, close proximity may include positions of at most approximately 1 inch from the surface16. As yet another example, close proximity may include positions as close to the surface16as possible without contacting the surface16.

Those skilled in the art will appreciate that the proximity to the surface16of the object18may depend upon the size, power and/or configuration of the acoustic devices20, the cleaning medium dispenser22, the rinsing medium dispenser24and the vacuum26in order to effectively perform a cleaning operation.

The acoustic waves28(e.g., beams of focused acoustic energy) may radiate and sweep across the surface16of the object18while, at the same time, the cleaning medium30is delivered onto the surface16, for example, in the form of droplets and/or a thin film. Within the droplets and/or the thin film of cleaning medium30, the acoustic energy from the acoustic waves28may create micro-streaming forces, dynamic fluid boundaries and other microfluidic capabilities that lead to the formation of airborne mist particulates of the cleaning medium30and the debris14. At the same time, the acoustic waves28may additionally energize the cleaning medium30and the rinsing medium32and transfer the acoustic energy down to the droplets and/or thin film of cleaning medium30and rinsing medium32delivered onto the surface16. Thus, the acoustic vibrations generated by the acoustic waves28may perform the cleaning action. The cleaning action may be accomplished by forming an airborne mist (e.g., atomized or aerosolized) of cleaning medium30having particulates of debris14suspended therein and/or rinsing medium32.

The acoustic waves28may be modulated, such that the interaction of the modulated acoustic waves28with the object18and an air medium (e.g., air between the acoustic devices20and the surface16of the object18) generates desired patterns of acoustic vibrations. For example, the acoustic devices20may generate acoustic waves28having different frequencies and/or amplitudes such that when the acoustic waves28impinge on the object18, desired patterns of acoustic vibrations may be generated in the air medium, on the surface16of the object18and/or in the object18.

Specific acoustic mode and frequency excitation over a frequency range (e.g., from 1 Hz to 500 MHz) may be provided, wherein frequency tuning over a selected frequency range may be achieved by optimally positioning the acoustic devices20and/or by modal vibration combinations. Those skilled in the art will appreciate that how the acoustic waves28(e.g., acoustic vibrations and acoustic stresses generated by the acoustic waves28) are focused to effectively break up and/or dislodge debris14and atomize cleaning medium30and particulate debris14and rinsing medium32from the surface16of the object18may depend on the particular cleaning operation. For example, the type of debris14, the thickness of the debris14, the structural geometry of the object18, environmental conditions and the like may affect the configuration of the acoustic devices20.

As an example, the frequency of one or more of the ultrasonic devices20may be tuned to a particular frequency or frequency range depending upon the particle size of the debris14. As an example, relatively low frequencies (e.g., below approximately 20 kHz) may atomize the cleaning medium30into a relatively large mist (e.g., approximately 10 microns and above). Thus, the mist of atomized cleaning medium30may capture relatively large particles of debris14(e.g., approximately 10 microns and above). As another example, relatively high frequencies (e.g., above approximately 1 MHz) may atomize the cleaning medium30into a relatively small mist (e.g., approximately 3 microns and below). Thus, the mist of atomized cleaning medium30may capture relatively small particles of debris14(e.g., approximately 3 microns and below).

As another example, the frequency of one or more of the ultrasonic devices20may be tuned to a particular frequency or frequency range depending upon the size and/or shape of the surface16to be cleaned. As an example, large and/or generally flat surfaces may have relatively large particles of debris14(e.g., approximately 10 microns and above). Thus, relatively low frequencies (e.g., below approximately 20 kHz) may be used to atomize the cleaning medium30and the debris30and/or the rinsing medium32from the surface16. As another example, small and/or complex surfaces may have relatively small particles of debris14(e.g., approximately 3 microns and below). Thus, relatively high frequencies (e.g., above approximately 1 MHz) may be used to atomize the cleaning medium30and the debris14and/or the rinsing medium32from the surface16.

The initial patterns generated by the acoustic waves28may be complex but eventually, after many reflections and as the acoustic waves28travel from one boundary to another, a modal pattern may be established at a resonant frequency. There may be many resonant frequencies fairly close together because of acoustic excitation. Removal of the cleaning medium30and the debris14and/or the rinsing medium32may often occur at a resonant or a non-resonant situation.

Various types of guided ultrasonic wave modes and stress focal points may be created on the surface16of the object18at desired locations (e.g., the cleaning zone62) by placing, activating and tuning the acoustic devices20to form an acoustically resonating system. The acoustically resonating system may deliver the desired patterns of acoustic vibrations to the entire object18, which, for example, may be mounted to or fixed with a holding fixture64. Air coupled acoustic devices20, which are located outside the object18, may create the desired patterns of acoustic vibrations directed about the cleaning zone62. Focusing acoustic stresses may be achieved electronically (e g, tuning the acoustic devices20) and/or mechanically (e.g., positioning the acoustic devices20). Air-coupled and/or physically coupled, arrays38(e.g., parametric arrays and/or phased arrays) of acoustic devices20may be specifically configured to impinge acoustic vibrations on complex three-dimensional objects18to facilitate removal of debris14and atomization of cleaning medium30containing the debris14(e.g., particles of debris) and the rinsing medium32.

Referring toFIG. 2, the cleaning head36may include a vacuum chamber66having an open end68. For example, a plurality of sidewalls70may define a partially enclosed vacuum chamber66having a rectangular cross-sectional shape. As another example, a continuous sidewall70may define a partially enclosed vacuum chamber66having an annular cross-sectional shape. The vacuum chamber66may be sized and configured according to a given cleaning operation and/or application, such as the size of the object18, the shape of the object18and/or the complexity of the object18. Similarly, the size of the cleaning zone62may be determined by the size and/or configuration of the cleaning head36(e.g., the area covered by the cleaning medium30, the rinsing medium32and the vacuum airflow34) and/or the area covered by the acoustic waves28.

The cleaning medium dispenser22may be located within the vacuum chamber66at an orientation sufficient to deliver the cleaning medium30to the surface16of the object18. The cleaning medium dispenser22may include a nozzle72fluidly coupled to the cleaning medium supply line46. The nozzle72may include a nozzle outlet74configured to discharge the cleaning medium30directly into the vacuum chamber66and/or on the surface16of the object18(e.g., within the cleaning zone62). The cleaning medium30may facilitate the removal of particulate debris14(FIG. 1) dislodged from the surface16of the object18by the acoustic vibrations on the surface16of the object18and/or within the object18.

The cleaning medium dispenser22(e.g., the nozzle72) may be configured to discharge cleaning medium30in a manner such that one or more surfaces16of the object18may be exposed to the cleaning medium30to capture dislodged debris14(FIG. 1) from the surface16of the object18. For example, the nozzle72may be configured to discharge cleaning medium30along a generally axial direction toward one or more surfaces16of the object18proximate (e.g., at or near) the open end68of the vacuum chamber66. However, the nozzle72may be configured to discharge cleaning medium30in any one of a variety of directions and/or angles. As another example, the nozzle outlet74may be configured to discharge the cleaning medium30in the form of a stream or a spray having various cross-sectional dimensions to apply droplets or a thin film of cleaning medium30to the surface16. However, the nozzle outlet74may be configured to discharge the cleaning medium30in any one of a variety of forms and/or dimensions.

Although a single nozzle72with a single nozzle outlet74is shown, any number of nozzles72and/or nozzle outlets74in any size and location may be provided. For example, a plurality of nozzles72and/or a plurality of nozzle outlets74may extend into the vacuum chamber66at different locations to provide a more uniform distribution of cleaning medium30about the cleaning zone62. Further, although the nozzle72is illustrated as being fluidly coupled to an end (e.g., opposite the open end68) of the vacuum chamber66, one or more nozzles72may be included to provide cleaning medium30from one or more locations along the sidewalls70of the vacuum chamber66(e.g., proximate the open end68).

In an example implementation, the cleaning medium30may be water (e.g., hot water), the cleaning medium dispenser22may include a nozzle72suitable to discharge water (e.g., in the form of a drip, a stream, a spray or a mist), the cleaning medium supply line46may be a water supply line, and the cleaning medium source44may be a water source (e.g., water tank). Optionally, the cleaning medium source44may include a heating mechanism76(FIG. 1) to heat the cleaning water to a desired cleaning temperature.

The temperature and/or the pressure of the cleaning medium30(e.g., water temperature and/or pressure) may be regulated, adjusted and/or otherwise controlled to correspond to a given cleaning operation. For example, the temperature may of the cleaning medium30be controlled to provide cleaning medium30at a temperature that may avoid heat damage to the material composition of the object18and/or the surface16being cleaned. Similarly, the pressure of the cleaning medium30may be regulated (e.g., by means of a valve or the configuration of the nozzle outlet74) such that cleaning medium30may be discharged from the nozzle outlet74in a manner that the velocity of the cleaning medium30is high enough to contact the surface16of the object18prior to atomization of the cleaning medium30(e.g., by the acoustic waves28) and vacuum suctioning of the cleaning medium30and any collected debris14into the vacuum26(FIG. 1). Control of cleaning medium30from the cleaning medium source44(FIG. 1) may be preprogrammed and/or automatically controlled.

The rinsing medium dispenser24may be located within the vacuum chamber66at an orientation sufficient to deliver the rinsing medium32to the surface16of the object18. The rinsing medium dispenser24may include a nozzle78fluidly coupled to the rinsing medium supply line50. The nozzle78may include a nozzle outlet80configured to discharge the rinsing medium32directly into the vacuum chamber66and/or on the surface16of the object18(e.g., within the cleaning zone62). The rinsing medium32may facilitate the removal of any cleaning medium30(and any particulate debris14) remaining on the surface16of the object18. The rinsing medium32may be atomized by the acoustic vibrations on the surface16of the object18and/or within the object18.

The rinsing medium dispenser24(e.g., the nozzle78) may be configured to discharge rinsing medium32in a manner such that one or more surfaces16of the object18may be exposed to the rinsing medium32to rinse the surface16of the object18. For example, the nozzle78may be configured to discharge rinsing medium32along a generally axial direction toward one or more surfaces16of the object18proximate the open end68of the vacuum chamber66. However, the nozzle78may be configured to discharge rinsing medium32in any one of a variety of directions and/or angles. As another example, the nozzle outlet80may be configured to discharge the rinsing medium32in the form of a stream or a spray having various cross-sectional dimensions to apply droplets or a thin film of rinsing medium32to the surface16. However, the nozzle outlet80may be configured to discharge the rinsing medium32in any one of a variety of forms and/or dimensions.

Although a single nozzle78with a single nozzle outlet80is shown, any number of nozzles78and/or nozzle outlets80in any size and location may be provided. For example, a plurality of nozzles78and/or a plurality of nozzle outlets80may extend into the vacuum chamber66at different locations to provide a more uniform distribution of rinsing medium32about the cleaning zone62. Further, although the nozzle78is illustrated as being fluidly coupled to an end (e.g., opposite the open end68) of the vacuum chamber66, one or more nozzles78may be included to provide rinsing medium32from one or more locations along the sidewalls70of the vacuum chamber66(e.g., proximate the open end68).

In an example implementation, the rinsing medium32may be water (e.g., hot water), the rinsing medium dispenser24may include a nozzle78suitable to discharge water (e.g., in the form of a drip, a stream, a spray or a mist), the rinsing medium supply line50may be a water supply line, and the rinsing medium source48may be a water source (e.g., water tank). Optionally, the rinsing medium source48may include a heating mechanism82(FIG. 1) to heat the rinsing water to a desired cleaning temperature.

The temperature and/or the pressure of the rinsing medium32(e.g., water temperature and/or pressure) may be regulated, adjusted and/or otherwise controlled to correspond to a given cleaning operation. For example, the temperature may of the rinsing medium32be controlled to provide rinsing medium32at a temperature that may avoid heat damage to the material composition of the object18and/or the surface16being cleaned. Similarly, the pressure of the rinsing medium32may be regulated (e.g., by means of a valve or the configuration of the nozzle outlet80) such that rinsing medium32may be discharged from the nozzle outlet80in a manner that the velocity of the rinsing medium32is high enough to contact the surface16of the object18and rinse away any remaining cleaning medium30(and any remaining particles of debris14) prior to atomization of the rinsing medium32(e.g., by the acoustic waves28) and vacuum suctioning of the rinsing medium32into the vacuum26(FIG. 1). Control of rinsing medium32from the rinsing medium source48(FIG. 1) may be preprogrammed and/or automatically controlled.

Although the cleaning medium dispenser22and the rinsing medium dispenser24are shown as being discrete components, the cleaning medium30and the rinsing medium32may be delivered (e.g., dispensed) from a single (e.g., common) fluid dispenser, generally designated134(FIG. 2). As an example, two different fluids, generally designated136, (e.g., the cleaning medium30and the rinsing medium32) may be used for cleaning and rinsing the surface16, respectively. The two fluids136may include different compositions. Two different fluid supply lines (e.g., the cleaning medium supply line46and the rinsing medium supply line50) may be fluidly coupled between two different fluid sources (e.g., the cleaning medium source44and the rinsing medium source48) and the single fluid dispenser134. As another example, a single fluid136(e.g., the cleaning medium30and the rinsing medium32) may be used for both cleaning and rinsing the surface16. A single fluid supply line (not shown) may be fluidly coupled between a single fluid source (not shown) and the single fluid dispenser134.

Removing debris14from the surface16(e.g., a cleaning operation) may include two stages, namely a cleaning stage and a rinsing stage. During the cleaning stage, the cleaning medium30is delivered to the surface16and is subsequently atomized by the acoustic waves28delivered by the acoustic devices20. During the rinsing stage, the rinsing medium32is delivered to the surface16and is subsequently atomized by the acoustic waves28. In an example implementation, one or more cleaning stages and one or more rinsing stages may occur separately and consecutively (e.g., the rinsing stage begins after completion of the cleaning stage). As another example, one or more cleaning stages and one or more rinsing stages may occur simultaneously. As yet another example, one or more cleaning stages and one or more rinsing stages may overlap (e.g., the rinsing stage begins before completion of the cleaning stage and continues past termination of the cleaning stage).

The vacuum26(FIG. 1) may be fluidly coupled to the vacuum supply line54(e.g., a vacuum hose) to provide the vacuum airflow34(e.g., vacuum suctioning) within the vacuum chamber66and/or to the surface16of the object18. The corresponding vacuum airflow34may be directed to the vacuum source52(FIG. 1) through one or more vacuum inlet manifolds85. The vacuum inlet manifold85may be located inside the vacuum chamber66. The vacuum26may collect the atomized cleaning medium30and dislodged debris14(e.g., particles of debris) within the vacuum airflow34. Thus, the generated mist of cleaning medium30, captured debris14and/or rinsing medium32may be substantially instantaneously removed from the cleaning zone62by the vacuum airflow34upon the cleaning medium30and/or rinsing medium32being atomized by the acoustic waves28.

During a cleaning operation, the cleaning head36may approximate (e.g., in close proximity to) the surface16of the object18to be cleaned. The size and/or complexity of the object18and/or the location, relative position, orientation angle, and/or distance from the surface16of the object18may be considered when sizing and configuring the cleaning head36for a given cleaning operation. Similarly, the overall size, shape, and configuration of the cleaning head36may be configured complementary to the size, shape, complexity and configuration of the object18to be cleaned.

Referring toFIG. 1, the cleaning assembly12may include a cleaning solution injection unit56. The cleaning solution injection unit56may inject a cleaning solution84into the cleaning medium supply line46for mixing with the cleaning medium30that is provided to the cleaning head36(e.g., to the cleaning medium dispenser22). Alternatively, the cleaning solution84may be discharged directly to the surface16of the object18(e.g., by the cleaning head36).

The cleaning solution84may be provided in a composition that may promote or expedite the cleaning of the object18. For example, the cleaning solution84may include detergent and/or chemicals for injection into the cleaning medium supply line46, which results in a mixture of molecules of detergent and/or chemicals in the cleaning medium30. The detergent and/or chemicals may include, but are not limited to, solvents for breaking up or dissolving certain type of debris14into smaller debris particles. The detergent and/or chemicals may surround the debris14once particles of debris14are broken loose from the surface16of the object18by the acoustic waves28. The detergent and/or chemicals may encapsulate the debris14and prevent the debris14from re-attaching to one another and/or re-bonding to the surface16of the object18.

For example, the cleaning solution84may include a composition for enhancing the cleaning of certain types of debris14, such as water- and/or oil-based fluids (e.g., hydraulic fluids and greases). The cleaning solution84may be injected into the cleaning medium30in a predetermined amount (e.g., upon activation of a release valve). For example, an aqueous cleaning solution may include a mixture of hot water (e.g., cleaning medium30) and detergents and/or chemicals (e.g., cleaning solution84) that may penetrate the relatively cooler debris14on the surface16of the object18and may further facilitate dislodgment of the debris14. In this regard, the cleaning solution84may include any one of a variety of other compositions, without limitation, for expediting or enhancing the cleaning of certain types of debris14.

The cleaning assembly12may include a filter58and a debris receptacle60(e.g., a waste receptacle). The debris receptacle60may be coupled to the vacuum supply line54for receiving cleaning medium30, the debris14and/or rinsing medium32(e.g., water, surfactants, detergent, chemicals, contaminates or other materials) that may be suctioned from the surface16of the object18.

Referring toFIG. 2, the cleaning medium30and/or the rinsing medium32may facilitate the cleaning action as the droplets of cleaning medium30and/or the rinsing medium32are atomized into a mist by the acoustic vibrations on the surface16of the object18and/or through the object18. One or more acoustic devices (not shown inFIG. 2) may be positioned proximate to (e.g., air-coupled) the object18or may be in contact with (e.g., physically coupled) the object18. For example, the acoustic devices20may be mounted and/or connected to one or more holding fixtures88(FIG. 1). The acoustic devices20may be positioned at a fixed location relative to the object18or may be movable (e.g., manually or electromechanically) relative to the object18via an associated holding fixture88.

The ultrasonic devices20may be configured to generate a variety of different types of acoustic waves (e.g., sonic waves and/or ultrasonic waves) applied to the surface16of the object18, including, but not limited to, longitudinal waves, shear waves, surface waves and/or plate waves. For example, one or more acoustic devices (e.g., an array of acoustic devices) may be configured to generate acoustic waves28a(e.g., longitudinal and/or shear waves) in the object18and one or more acoustic devices (e.g., an array of acoustic devices) may be configured to generate acoustic waves28b(e.g., surface and/or plate waves) on the surface16of the object18.

Those skilled in the art will appreciate that any individual acoustic devices20, combinations of acoustic devices20and/or arrays38(e.g., parametric and/or phased arrays) (FIG. 1) of acoustic devices20may be configured to generate any combination of acoustic waves28(e.g., longitudinal waves and/or shear waves in the object18and/or surface waves and/or plate waves on the surface16of the object18). For example, a plurality of acoustic devices20(e.g., a parametric and/or phased array of acoustic devices20) may be tuned and/or positioned to alter wave interference phenomenon in order to create a one or more acoustic interference zones or stress focal points (e.g., at the cleaning zones62) that may be moved around the object18as position, frequency and/or wave mode is changed. The cleaning zone62may be moved, through user selection, allowing cleaning at specific points on the surface16of the object18.

For example, the different types of acoustic waves28(e.g., longitudinal waves, shear waves, surface waves and/or plate waves) may be generated by adjusting the angles of incidence of the acoustic devices20relative to the surface16of the object18. As an example, positioning (e.g., rotating) the acoustic device20approximately 10° from normal (e.g., from the plane of the surface16) may generate plate waves perpendicular to and on the surface16of the object18. As another example, positioning (e.g., rotating) the acoustic device20approximately 0° from normal (e.g., parallel to the plane of the surface16) may generate longitudinal waves in the object18. As another example, shear waves may be generated under any angle of incidence and may propagate perpendicularly relative to the wave into the object18. As yet another example, surface waves may be generated under any angle of incidence and may propagate concentrically (e.g., elliptically) on the surface16of the object18.

Additionally, the acoustic devices20may also be used for non-destructive inspection of the object18and/or structural health monitoring of the object18. For example, at least two ultrasonic devices20(e.g., transmitter and receiver) may be positioned above the surface16of the object18. The positions of the devices20may be adjusted relative to each other and relative to and along the surface16in order to define the directions of sonic propagation at appropriate angles to generate and detect surface and/or plate waves on the surface16. The generation and detection of the acoustic waves28may depend on several factors including, but not limited to, the elastic properties of the material of the surface16and the presence of contamination (e.g., debris30) and water. A reference library of various patterns of the ultrasonic waves28generated and detected by the ultrasonic devices20on the reference surfaces may be built and used in non-destructive inspection of the conditions (e.g., cleanliness) of the monitored surface16of the object18.

Referring toFIGS. 3-5, the disclosed system10may be beneficially utilized for cleaning one or more objects18having one or more complex surfaces16. For example and as illustrated inFIGS. 3 and 4, the object18may be a fastener, such as a bolt, a screw or the like.

The objects18may be placed on, mounted to or otherwise fixed to the holding fixture64. For example, the holding fixture64may include a support stand90and the objects18may be held within a holder92, which is held to or supported by the support stand90. For example, the holder92may include an open volume suitable to receive one or more objects18(e.g., fasteners). As a specific, non-limiting example, the holder92may be a basket having non-solid walls (e.g., mesh walls) suitable to allow the acoustic waves28to propagate through the basket and to the objects18.

The holding fixture64may include one or more acoustic absorbers94. For example, an acoustic absorber94may be positioned between the holder92and the support stand90to absorb acoustic energy and prevent transmission and/or propagation of the acoustic vibrations from the objects18to the holding fixture64.

During a cleaning operation, the cleaning head36may be positioned in close proximity to the objects18to be cleaned. For example, the cleaning head36may be positioned at a suitable position to direct the cleaning medium, rinsing medium and vacuum airflow (not shown inFIGS. 3 and 4) to the surfaces16of the objects18.

At least one acoustic device20may be air coupled to the objects18. For example, the acoustic devices20may be positioned in close proximity to the one or more surfaces16of the objects18.

As illustrated inFIG. 3, a plurality of acoustic devices20may be configured into an air coupled array38(e.g., a parametric or phased array) of acoustic devices20configured to direct acoustic waves28(e.g., longitudinal waves and/or shear waves) at the surfaces16of the objects18. The acoustic waves28may generate acoustic vibrations in the object18to dislodge any debris14and atomize any cleaning medium30and/or rinsing medium32(FIG. 1) from the surfaces16of the objects18.

As illustration inFIG. 4, a plurality of acoustic devices20may be configured into an air coupled first array38a(e.g., a parametric or phased array) of acoustic devices20configured to direct acoustic waves28a(e.g., longitudinal waves and/or shear waves) at the surfaces16of the objects18. A plurality of acoustic devices20may be configured into an air coupled second array38b(e.g., a parametric or phased array) of acoustic devices20configured to direct acoustic waves28b(e.g., longitudinal waves and/or shear waves) at the surfaces16of the objects18. The first array38aof acoustic devices20and the second array38bof acoustic devices20may be positioned in generally axially opposed positions, such that acoustic waves28aand acoustic waves28bare focused toward the object18and interfere with each other at the object18. The interfering acoustic waves28aand28bmay create specific patterns of acoustic vibrations on the surface16of the object18to dislodge any debris14and atomize any cleaning medium30and/or rinsing medium32(FIG. 1) from the surfaces16of the objects18.

The plurality of acoustic devices20may be mounted to the holding fixture88. The holding fixture88may adjust and/or fix the location, orientation and/or distance of the array38of acoustic devices20or the first array38aof acoustic devices20and second array38bof acoustic devices20with respect to the objects18. The holding fixture88may provide for automatic, semi-automatic or manual positioning of the plurality of acoustic devices20with respect to the object18.

One or more acoustic absorbers96may be positioned to contain the acoustic waves28(FIG. 3) or acoustic waves28aand28b(FIG. 4) within a relatively confined space. For example, one or more acoustic absorbers96may be positioned in a generally axially opposed position to the plurality of acoustic devices20to absorb the acoustic energy and prevent transmission of the acoustic waves28or acoustic waves28aand28bto nearby articles. The acoustic absorber96may be mounted to a holding fixture (not shown). The holding fixture may provide for automatic, semi-automatic or manual positioning of the acoustic absorber96.

Acoustic treatment of the object18may energize the cleaning medium30and rinsing medium32(FIG. 2). For example, the cleaning medium30and rinsing medium32may be delivered to the surface16through an acoustic field generated by the acoustic waves28(FIG. 3) or acoustic waves28a,28b(FIG. 4) and may become energized, transferring the acoustic energy directly through the cleaning medium30and rinsing medium32(e.g., in the form of droplets or thin films).

Referring toFIG. 5, as another example, the object18may have a complex shape including a plurality of surface features (e.g. surfaces16). For example, the object18may include one or more through holes98(e.g., threaded holes and/or smooth holes), one or more hollow cavities100and one or more faying surfaces102. The object18may be mounted to the holding fixture64(not shown inFIG. 5).

During a cleaning operation, the cleaning head36may be positioned proximate the objects18to be cleaned. For example, the cleaning head36may be positioned at a suitable position to direct the cleaning medium, rinsing medium and vacuum airflow34(not shown inFIGS. 3 and 4) to the surfaces16of the object18.

At least one acoustic device20may be air coupled to the object18. For example, the acoustic devices20may be positioned proximate the objects18such that an acoustic coupling media104(e.g., air) is disposed between the acoustic devices20and the object18. A plurality of acoustic devices20may be configured into an air coupled array38(e.g., a parametric or phased array) of acoustic devices20configured to direct acoustic waves28(not shown inFIG. 5) through the object18and to the surface16of the object18. The acoustic waves28(FIG. 1) may generate acoustic vibrations transferred through the acoustic coupling media104and into the object18to dislodge any debris14and atomize any cleaning medium30and/or rinsing medium32(FIG. 1) from the surfaces16of the object18.

The plurality of acoustic devices20may be mounted to the holding fixture88. The holding fixture88may adjust and/or fix the location, orientation and/or distance of the array38of acoustic devices20with respect to the objects18. The holding fixture88may provide for automatic, semi-automatic or manual positioning of the plurality of acoustic devices20with respect to the object18.

Referring toFIG. 6, the disclosed system10may be beneficially utilized for precise cleaning one or more objects18having one or more delicate surfaces16. For example, the object18may be a silicon wafer having a flat surface.

The object18may be mounted to the holding fixture64. For example, the holding fixture64may include a support stand90and the objects18may be mounted to the support stand90. The holding fixture64may include one or more acoustic absorbers94. For example, an acoustic absorber94may be positioned between the object18and the support stand90to absorb acoustic energy and prevent transmission and/or propagation of the acoustic vibrations from the object18to the holding fixture64.

During a cleaning operation, the cleaning head36may be positioned proximate the surface16of the object18to be cleaned. For example, the cleaning head36may be positioned at a suitable position to direct the cleaning medium, rinsing medium and vacuum airflow (not shown inFIGS. 3 and 4) to the surface16of the object18.

At least one acoustic device20may be coupled to the object18. The acoustic device may be air coupled to the object18or may be physically coupled to the object18. A plurality of acoustic devices20may be configured into an acoustically coupled parametric38of acoustic devices20(e.g., a parametric or phased array) configured to direct acoustic waves28(e.g., longitudinal waves and/or shear waves) through the object18and to the surface16of the object18. The acoustic waves28may generate acoustic vibrations transferred into the object18to dislodge any debris14and atomize any cleaning medium30and/or rinsing medium32(FIG. 1) from the surfaces16of the object18.

The plurality of acoustic devices20may be mounted to the holding fixture88. The holding fixture88may adjust and/or fix the location, orientation and/or distance of the array38of acoustic devices20with respect to the objects18. The holding fixture88may provide for automatic, semi-automatic or manual positioning of the plurality of acoustic devices20with respect to the object18.

Referring toFIG. 1, the disclosed system10may be incorporated into a robotic assembly106. The object18(e.g., one or more surfaces16of the object18) may be cleaned with by a combination of the acoustic devices20and the cleaning head36(including the cleaning medium dispenser22, the rinsing medium dispenser24and the vacuum26). The cleaning head36may be moved alongside the object18by the robotic assembly106. A position (e.g., location, orientation and distance) of the cleaning head36with respect to the object18(e.g., the surface16of the object18) may be set, adjusted and/or maintained by the robotic assembly106.

Referring toFIG. 7, the robotic assembly106may provide for automated or semi-automated cleaning of one or more objects18. For example, the cleaning head36may be mounted to an end adaptor108of a robotic arm110of the robotic assembly106. The end adaptor108may be mounted to a movable joint112located on an end of the robotic arm110. The movable joint112may facilitate positioning of the cleaning head36in a desired position approximating the surface16of the object18(FIG. 1) being cleaned. The movable joint112may include a rotary joint for positioning the cleaning head36(e.g., positioning of the end adaptor108) during cleaning of the surface16of the object18.

A supply line114may extend from the cleaning head36to a cleaning source116that may, for example, be mounted to a base118of the robotic assembly106. The supply line114may include the cleaning medium supply line46, the rinsing medium supply line50and the vacuum supply line54. Similarly, the cleaning source116may include the cleaning medium source44, the rinsing medium source48and the vacuum source52. The cleaning solution injection unit56, the filter58and debris receptacle60may be mounted to the robotic assembly106(e.g., to the base118).

Referring toFIG. 8, the robotic assembly106may include one or more manufacturing devices120mounted, for example, on the end adaptor108. The manufacturing device120may include a device for performing one or more manufacturing operations on the object18(FIG. 1). For example, the manufacturing device120may include one or more devices for machining, drilling, painting, sealing, imaging, testing, inspecting, sensing, and other operations on the object18(e.g., during fabrication, assembly and/or maintenance). The manufacturing device120may be coupled via a supply line122to a power supply/material supply unit124mounted, for example, to the base118of the robotic assembly106for delivery of materials and/or power to the manufacturing device120.

The supply line122may deliver lubricant, sealant, coating material, or other materials to the manufacturing device120. The supply line122may also deliver electrical power, pressurized air, hydraulic fluid, and other mediums for operating the manufacturing device120. The cleaning head36may be employed in the robotic assembly106to perform a cleaning operation on the object18prior to, during or following the performance of one or more manufacturing, inspection, repair, or maintenance operations on the object18by one or more of the manufacturing devices120.

In an example construction, the cleaning head36may be removably attached to (e.g., detachable from) the robotic assembly106(e.g., the end effector108of the robotic arm110). In order to facilitate detachment of the cleaning head36and replacement of a cleaning head36having the same or a different configuration, the cleaning head36may include at least one end fitting (not shown). For example, the end fitting may be provided as a quick release mechanism. The quick release mechanism may be provided in any one of a variety of configurations for releasably attaching the cleaning head36to the supply line122and/or the robotic assembly106. The detachable arrangement of the cleaning head36may facilitate mounting of any one of a variety of different cleaning heads36having different sizes, shapes, and configurations (e.g., quantity and/or configurations of cleaning medium dispensers22, rinsing medium dispensers24and/or vacuums26) to correspond to a given cleaning application.

Referring toFIG. 9, the holding fixture64may be configured to hold and/or support the object18. For example, the holding fixture64may be a component assembly fixture used to hold the object18during a fabrication, assembly and/or maintenance operation (e.g., as part of an assembly line) and during a cleaning operation. As another example, the holding fixture64may be used to hold the object18only during a cleaning operation. As yet another example, the holding fixture64may be a part of the object18.

During a cleaning operation, the cleaning head36may be positioned proximate to the surface16of the object18. For example, the robotic assembly106may be positioned in close proximity to the holding fixture64such that the cleaning head36may be positioned at a suitable position to direct the cleaning medium, rinsing medium and vacuum airflow (not shown inFIG. 9) to the surfaces16of the object18.

At least one of the acoustic devices20may be physically coupled to the holding fixture64. The acoustic devices20may deliver acoustic waves28(FIG. 1) to the object18through the holding fixture64.

The holding fixture64may include at least one object holding fixture126configured to engage at least a portion (e.g., an edge) of the object18to secure the object18to the holding fixture64and fix the position of the object18. For example, each object holding fixture126may include an edge holding fixture128configured to engage at least one edge of the object18.

The object18may be mounted to a support base130. The object18may be in contact with the support base130or may be spaced apart a predetermined distance from the support base130. The holding fixture64may include at least one support base holding fixture132configured to engage at least a portion of the support base130to secure the support base130to the holding fixture64and fix the position of the object18.

At least one acoustic device20may be coupled to one or more of the object holding fixtures126and/or one or more of the support base holding fixtures132to transfer acoustic waves28(FIG. 1) through the object holding fixtures126, the support base holding fixtures132and/or the support base130and into the object18. The acoustic devices20may be physically coupled to the object holding fixtures126and/or the support base holding fixtures132(e.g., a contact sonic and/or ultrasonic transducer) or air coupled to the object holding fixtures126and/or the support base holding fixtures132(e.g., a non-contact sonic and/or ultrasonic transducer).

The object holding fixtures126and/or the support base holding fixtures132may be integral to the holding fixture64or may be installed on or connected to the holding fixture64. The acoustic generator40(FIG. 1) may be integral to the holding fixture64or may be remote and coupled to the acoustic devices20.

The object holding fixtures126, the support base holding fixtures132and/or the support base130may be acoustically coupled such that the acoustic waves28applied to the object holding fixtures126and/or the support base holding fixtures132sufficiently transfer between and through the holding fixture64(including the object holding fixtures126, the support base holding fixtures132and/or the support base130) and into the object18.

As used herein, acoustically coupled means that all parts and/or components of the holding fixture64are connected together such that the entire construction is acoustically available (e.g., an acoustically resonating system) for effective transmission and propagation of acoustic waves28. For example, the holding fixture64may be constructed such that no gaps occur between components and the propagation of acoustic waves28is not lost through component and/or surface interfaces.

Thus, in concert with the acoustic devices20, the object holding fixtures126and/or the support base holding fixtures132may form an acoustically resonating system that delivers acoustic waves28into and through the entire object18to generate acoustic vibrations on the surface16of the object18. The plurality of acoustic devices20may be arranged in any configuration (e.g., in a parametric array of acoustic devices or a phased array of acoustic devices).

Each acoustic device20may have a fixed position or may be movable with respect to the holding fixture64, the object holding fixtures126and/or the support base holding fixtures132. For example, the position, orientation and/or location of a plurality of acoustic devices20may be fixed to one or more object holding fixtures126and/or the support base holding fixtures132. As another example, the position, orientation and/or location of the acoustic devices20may be manually moveable or electromechanically moveable, for example by the holding fixtures88(FIG. 1) associated with the acoustic devices20. Thus, by positioning, activating and tuning the acoustic devices20, various types of guided acoustic waves28(e.g., focused acoustic energy) may be created on the surface16of the object18at desired locations (e.g., cleaning zones62).

Those skilled in the art will appreciate that the holding fixture64may include any combination of object holding fixtures126, support base130and/or support base holding fixtures132having any combination of air coupled acoustic devices20and/or physically coupled acoustic devices20and the construction illustrated inFIG. 9is not meant to limit the present disclosure in any manner.

Thus, a plurality of physically coupled acoustic devices20may generate acoustic waves28directed into the object18(e.g., through the holding fixture64) and/or a plurality of air coupled acoustic devices20may generate acoustic waves28directed to the surface16of the object18. The interference of the ultrasonic waves28may generate longitudinal waves and/or shear waves in the object18and/or the plate waves and/or shear waves on the surface16of the object18to dislodge debris14and atomize the cleaning medium30, debris particles retained by the cleaning medium30and the rinsing medium32.

The power, size, quantity, location, relative position, orientation angle, and distance from the surface16of the object18may be considered when sizing and configuring the acoustic devices20for a given cleaning operation. For example, a relatively small number of ultrasonic devices having high power may be used. As another example, a relatively large number of ultrasonic devices having low power may be used.

Referring toFIG. 10, one aspect of the disclosed method, generally designated200, for surface cleaning of an object may begin at block202by providing an object having at least one surface to be cleaned.

As shown at block204, the object may be mounted to a holding fixture. The holding fixture may define an acoustically resonate system.

As shown at block206, acoustic waves (e.g., sonic waves and/or ultrasonic waves) may be delivered to the surface of the object. The acoustic waves may generate acoustic vibrations (e.g., in response to longitudinal waves, shear waves, surface waves and/or plate waves) on the surface of the object. The acoustic waves may be emitted by one or more acoustic devices (e.g., sonic transducers and/or ultrasonic transducer). The acoustic devices may be air coupled to the object and/or the holding fixture and/or physically coupled to the object and/or the holding fixture.

As shown at block208, the acoustic waves may be focused on a cleaning zone on the surface of the object. As shown at block210, the focused acoustic waves may generate a pattern of acoustic vibrations on the surface of the object and/or in the object. As shown at block212, the pattern of acoustic vibrations may create a one or more acoustic interference zones or stress focal points about at least a portion of the surface of the object (e.g., at the cleaning zone) in response to interference of the acoustic waves.

As shown at block212, any debris on the surface of the object (e.g., within the cleaning zone) may be broken up and/or dislodged from the surface of the object in response to the acoustic vibrations in the object generated by the acoustic waves applied to the object.

As shown at block214, a cleaning medium (e.g., water or an aqueous cleaning solution) may be delivered to the surface of the object. For example, the cleaning medium may be discharged from a cleaning medium dispenser to the cleaning zone. As shown at block216, the cleaning medium may capture and/or collect particles of the debris dislodged from the surface of the object by the acoustic waves.

As shown at block218, the cleaning medium and the particles of debris captured by the cleaning medium (e.g., droplets) may be atomized into a mist in response to the acoustic vibrations in the object generated by the acoustic waves applied to the object.

As shown at block220, a rinsing medium (e.g., water) may be delivered to the surface of the object. For example, the rinsing medium may be discharged from a rinsing medium dispenser to the cleaning zone. As shown at block222, the rinsing medium may rinse any remaining cleaning medium and/or particles of the debris from the surface of the object.

As shown at block224, the rinsing medium may be atomized into a mist in response to the acoustic vibrations in the object generated by the acoustic waves applied to the object.

As shown at block226, a vacuum airflow may be delivered to the surface of the object. As shown at block228, the atomized mist of cleaning medium, debris particles captured by the cleaning medium and/or the rinsing medium may be collected by the vacuum airflow. The vacuum step shown at block220may be performed during and/or throughout the steps shown at blocks210-218.

Accordingly, the disclosed system and method may be used to clean one or more surfaces of a large and/or complex object by combining acoustic vibrations (e.g., via focused acoustic waves), a cleaning medium, a rinsing medium and a vacuum airflow. A plurality of acoustic devices (e.g., an array of acoustic devices) may generate and emit directional acoustic waves that are electronically and mechanically focused on particular areas (e.g., a cleaning zone) on the surface of the object. Activating and tuning the acoustic devices by various electronic and mechanical means may create desired patterns of acoustic vibrations in and on the object to achieve the cleaning effect. As an example, positioning and focusing of the acoustic waves may be achieved through movement of various cleaning heads equipped with cleaning medium dispensers, rinsing medium dispenser and vacuums and/or holding fixtures equipped with acoustic devices. Tuning of the acoustic devices may be achieved with the concept of parametric or phased array to achieve acoustic streaming in the cleaning medium and the rinsing medium.

Referring generally toFIG. 1, the various aspects of the disclosed system10for cleaning an object including a surface may include an acoustic device20configured to deliver acoustic waves28to the object18, a fluid dispenser134configured to deliver a fluid136to the surface16, a vacuum26configured to deliver a vacuum airflow34proximate the surface16, wherein the acoustic waves28dislodge debris14from the surface16, acoustically treat the fluid136, and atomize the fluid136and the debris14collected by the fluid136.

In one aspect, the acoustic waves28may generate acoustic vibrations on the surface16of said object18. The acoustic waves28may generate ultrasonic vibrations in the object18. The acoustic waves28may include at least one of longitudinal waves, shear waves, surface waves and plate waves.

In another aspect, the fluid136may include a cleaning medium and a rinsing medium.

In another aspect, a position of said acoustic device20, a position of the fluid dispenser134and a position of the vacuum26may be adjustable with respect to the surface16.

In another aspect, the fluid dispenser134may include a cleaning medium dispenser22configured to deliver a cleaning medium30to the surface16and a rinsing medium dispenser24configured to deliver a rinsing medium32to the surface16. The cleaning medium dispenser22, the rinsing medium dispenser24and the vacuum26may be mounted to a cleaning head36. The cleaning head36may be mounted to a robotic assembly106, wherein the robotic assembly106positions the cleaning head36with respect to the surface16. The cleaning medium30may include at least one of a liquid and a gas, and the rinsing medium32may include at least one of a liquid and a gas. The cleaning medium30and the rinsing medium32may include different compositions.

In another aspect, the acoustic waves28may reduce adhesion between the debris14and the surface16. The fluid136may collect the debris14dislodged from the surface16. The acoustic waves28may be focused on a cleaning zone62on the surface16.

In another aspect, the acoustic device20may include at least one of a sonic transducer and an ultrasonic transducer.

In another aspect, the disclosed system10may include a plurality of acoustic devices20arranged as an array of acoustic devices38. The array of acoustic devices38may be air coupled to the object18. The array of acoustic devices38may deliver focused acoustic waves28to the surface16. Interference of the focused acoustic waves28may define an acoustic wave interference zone on the surface16. The array of acoustic devices38may include at least one of a parametric array and a phased array.

In another aspect, the disclosed system10may include a plurality of acoustic devices20arranged as a first array of acoustic devices38aand a second array of acoustic devices38b. The first array of acoustic devices38amay be air coupled to the object18. The second array of acoustic devices38bmay be physically coupled to the object18.

In another aspect, the disclosed system10may include a holding fixture64configured to hold the object18. The acoustic waves28may generate the acoustic vibrations in the object18. The fluid dispenser134may include a cleaning medium dispenser22configured to deliver a cleaning medium30to the surface16and a rinsing medium dispenser24configured to deliver a rinsing medium32to the surface16. The cleaning medium dispenser22, the rinsing medium dispenser24and said vacuum26may be mounted to a cleaning head36. The acoustic device20may be coupled to the holding fixture56. A position of the cleaning head36may be adjustable with respect to the object18. The acoustic device20may be physically coupled to the holding fixture64. The acoustic device20may be air coupled to at least one of the holding fixture64and the object18. A plurality of acoustic devices20may be arranged as a first array of acoustic devices38aand a second array of acoustic devices38b. The first array of acoustic devices38amay be physically coupled to the holding fixture64. The second array of acoustic devices38bmay be air coupled to at least one of the holding fixture64and the object18. The holding fixture64may define an acoustically resonating system. The holding fixture64may be a part of said object.

In another aspect, the fluid136may include at least one of a liquid and a gas. The fluid136may include at least one of water and an aqueous solution.

In another aspect, the disclosed system10may include an acoustic device20configured to deliver acoustic waves28to the object18, a cleaning medium dispenser22configured to deliver a cleaning medium30to the surface16, a rinsing medium dispenser24configured to deliver a rinsing medium32to the surface16, and a vacuum26configured to deliver a vacuum airflow34proximate the surface16. The acoustic waves28may generate acoustic vibrations in the object18to dislodge debris from the surface16, acoustically treat the cleaning medium30and the rinsing medium32, and atomize the cleaning medium30, the debris14collected by the cleaning medium30and the rinsing medium32.

Referring generally toFIGS. 1 and 10, one aspect of the disclosed method200for cleaning an object including a surface may include: (1) delivering acoustic waves28to the object18to dislodge debris14from the surface16, (2) delivering a cleaning medium30to the surface16to collect dislodged debris14, delivering the acoustic waves28to the object18to acoustically treat and atomize the cleaning medium30and the dislodged debris14, (3) applying a vacuum airflow34to collect atomized cleaning medium30and dislodged debris14, (4) delivering a rinsing medium32to the surface16, (5) delivering the acoustic waves28to the object18to acoustically treat and atomize the rinsing medium32, and applying the vacuum airflow34to collect atomized rinsing medium32.

In another aspect, the acoustic waves28may generate acoustic vibrations in the object18.

In another aspect, the disclosed method200may include the steps of: (6) mounting the object18to a holding fixture64, and (7) delivering the acoustic waves28to at least one of the holding fixture64and the object18to generate acoustic vibrations in the object18. The holding fixture64may define an acoustically resonating system.

In another aspect, the disclosed method200may include the steps of: (8) focusing the acoustic waves28on the cleaning zone62on the surface16, and generating a pattern of the acoustic vibrations in the object18. The step of generating the pattern of the acoustic vibrations may include defining an acoustic interference zone on at least a portion of the surface16through interference of the acoustic waves28.

In another aspect, the acoustic waves28may reduce adhesion between the debris14and the surface16. The cleaning medium30may include at least one of a liquid and a gas. The rinsing medium32may include at least one of a liquid and a gas.

In another aspect, the steps of delivering the cleaning medium30and delivering the rinsing medium32may occur consecutively.

In another aspect, the steps of delivering the cleaning medium30and delivering the rinsing medium32may occur simultaneously.

Examples of the disclosure may be described in the context of an aircraft manufacturing and service method300, as shown inFIG. 11, and an aircraft302, as shown inFIG. 12. During pre-production, the aircraft manufacturing and service method300may include specification and design304of the aircraft302and material procurement306. During production, component/subassembly manufacturing308and system integration310of the aircraft302takes place. Thereafter, the aircraft302may go through certification and delivery312in order to be placed in service314. While in service by a customer, the aircraft302is scheduled for routine maintenance and service316, which may also include modification, reconfiguration, refurbishment and the like.

As shown inFIG. 12, the aircraft302produced by example method300may include an airframe318with a plurality of systems320and an interior322. Examples of the plurality of systems320may include one or more of a propulsion system324, an electrical system326, a hydraulic system328, and an environmental system330. Any number of other systems may be included. Although an aerospace example is shown, the principles of the disclosed system10and method200may be applied to other industries, such as the automotive and the semiconductor industries.

Apparatus and methods embodied herein may be employed during any one or more of the stages of the production and service method300. For example, components or subassemblies corresponding to component/subassembly manufacturing308, system integration310, and or maintenance and service316may be fabricated or manufactured using the disclosed system10and method200. Also, one or more apparatus examples, method examples, or a combination thereof may be utilized during component/subassembly manufacturing308and/or system integration310, for example, by substantially expediting assembly of or reducing the cost of an aircraft302, such as the airframe318and/or the interior322. Similarly, one or more of apparatus examples, method examples, or a combination thereof may be utilized while the aircraft302is in service, for example and without limitation, to maintenance and service316.

Although various aspects of the disclosed system and method have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.