How To Determine Which EXAIR Product Is Right For You

Expert Testing, Professional Results

Expert Testing, Professional Results

Those of you who are frequent readers of the EXAIR blog (we appreciate your loyalty and fine taste, by the way) probably know a little something about our Efficiency Lab. This is where, upon request, we will perform a controlled test of a compressed air product that you’re currently using, and provide a comprehensive report, comparing it to a suitable EXAIR Engineered Compressed Air Product.

It’s a service that we provide at no charge, and to “sweeten the pot,” our goal is a 24-hour turnaround on the testing, from the time we receive your product.

For some folks, however, seeing is believing…and sometimes, critical elements of a particular application just can’t be duplicated in our facility, so a “real world” trial becomes the only way to find out for sure. That’s where our 30 Day Unconditional Guarantee comes in. If you’ll commit the time to give us a try, we’ll commit to allowing you to do, risk free.

Give any EXAIR catalog product a 30 day trial, risk free.

Give any EXAIR catalog product a 30 day trial, risk free.

This was exactly the case with a manufacturer of cable cleaning equipment, who sought an efficient, quiet compressed air solution to dry the cable upon exiting their machinery. Some of the cables that these machines service are very small in diameter, so they wanted to evaluated both an Air Wipe, and an Air Amplifier.  Both had theoretical advantages:

Air Wipes come in sizes from 1/2" to 11".Air Wipes come in sizes from 1/2″ to 11″. The Air Wipe’s 360° converging flow provides for positive contact with the material, which uniformly wipes the entire surface with high velocity air. Its split clamshell design also eliminates the need to thread the material through it.

Air Amplifiers entrain enormous amounts of "free" air, at ratios of up to 25:1!

Air Amplifiers entrain enormous amounts of “free” air, at ratios of up to 25:1!

The Air Amplifier’s compressed air consumption is lower, its operation is quieter, and it’s less expensive.

After trialing both a Model 2430 ½” Aluminum Standard Air Wipe and a Model 120020 ¾” Super Air Amplifier, the Air Amplifier proved itself out, and became their standard offering on this machine.

For 31 years now, EXAIR Corporation has established and maintained a formidable reputation for being easy to do business with. In Application Engineering, we support this by committing to making sure you get the most out of our products. If you have an application, or an idea, you’d like to discuss, give us a call. We can’t wait to find out how we can help.

Russ Bowman
Application Engineer
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Super Air Amplifier Provides Needed Ventilation

Behold: The Power of the Microwave!!!

Behold: The Power of the Microwave!!!

Over the weekend, my wife and I were doing some “re-organizing” upstairs (actually throwing away some old toys and clothes), when our son decided to make a snack. I heard the pantry door close so I asked, “hey bud, what are you doing down there?”  He promptly replied, “I’m just making a snack dad. How long do you normally microwave my soup?” While we questioned making soup at 9:00 AM for a snack, I reluctantly replied 2 minutes and heard the microwave begin. Slowly, a strange (awful) odor started to fill the house so I went downstairs to investigate. To my horror, I opened the microwave door to discover that he wasn’t making a snack for him, he was actually heating up a can of dog food, so his partner in crime (our dog), “could have a warm meal like us”.  I immediately took the snack to the garbage outside and attempted to remove the stench from the house. I opened a couple windows and turned on the stove exhaust but this was still not working. That’s when I started thinking it sure would be nice to have a Super Air Amplifier handy, to help evacuate some of the odor and make the house livable again.

Using a small amount of compressed air, the Super Air Amplifier entrains a large volume of surrounding air and pulls this air through the unit, resulting in a high velocity, high volume of air on the exhaust side. The intake, or vacuum, side of the Super Air Amplifier pulls in 25 parts of surrounding air for every one part of compressed air. This high volume of ambient air being moved makes the Super Air Amplifier ideal for venting and exhaust applications.

Additionally, the vacuum and exhaust ends can be ducted, which makes this a good product for moving air from one place to another or from inside to outside. They are used in many applications for assisting air circulation and available in styles which are placed in ovens (and other high temp areas), corrosive environments, and remote locations. With the large volumes of air being moved, they are also an ideal choice where cooling and drying is required.

Our Air Amplifiers entrain enormous amounts of "free" air, at ratios of up to 25:1!

The Super Air Amplifier entrains large amounts of surrounding air, at ratios of up to 25:1.

Air Amplifiers are some of the most efficient products in the extensive EXAIR line of compressed air products. They use a patented internal shim to minimize air consumption and increase air volume on the output side. The operate exceptionally quiet, are OSHA safe and CE compliant.

If you have a ventilation or fume exhausting application, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Day 619 /365 – Radiation Burns, Jason Rogers  Link

Force And Flow…Which One Is The Right Tool For The Job?

If you’re even a casual, occasional reader of the EXAIR Blog, you know we write an awful lot about efficiency…namely, the ability of engineered products to conserve compressed air, while optimizing its effectiveness. Oftentimes, these blogs are inspired by a conversation we’ve had with a user of simple and inexpensive (but wasteful and unsafe) blow off devices, such as open-end tubing, or drilled pipes. The first thing the caller wants to talk about is the force produced by one of our products…will it be the same as what’s being currently used?

The quick answer is no. In fact, if you’re looking for maximum force, there’s no better way to get it than simply blowing compressed air out the end of an open pipe. This has to do with nothing more complicated that grade school science – converting the potential energy (due to the compression of the air) to kinetic energy (what happens when it’s put into motion.) See, with an open-end blow off, almost all of the potential energy is converted to force. Plain old brute force. And it works GREAT for blowing stuff around…the larger the opening, and the higher the supply pressure; the more air will flow, and faster. Thing is, to produce a good blow off, you don’t need maximum force.

EXAIR’s Intelligent Compressed Air Products are engineered to use some of that potential energy of the compressed air to entrain large amounts of “free” air from the surrounding environment. That’s the purpose of the jets recessed between the fins of our Super Air Nozzles, and the Coanda profile of our Air Knives, Air Wipes, & Air Amplifiers.

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

These designs reduce the amount of compressed air that is used, which reduces the load on your air compressor, which makes everyone happy (OK, maybe not that happy, but pretty happy still.) They also mean that your blow offs will be quieter, and safer.

Perhaps your application calls for higher force. If that’s the case, EXAIR’s Air Knives, Air Amplifiers, and Air Wipes can be fitted with thicker shims for additional flow and force. So can our Flat Super Air Nozzles. And our largest High Force Super Air Nozzles are capable of generating up to 23lbs (10.4KG) of force.

Perhaps, though, your application calls for the highest force that can only be achieved with an open-end blow off. If that’s the case, you can still meet OSHA compliance through the use of extra protective equipment, pressure relief valves, guarding devices, etc. But the costs of those measures can make the cost of engineered products pale in comparison, so I highly recommend you make sure of what you need.

If we can be of any assistance with that, give us a call.  We can discuss your application, and get you the right tool for the job.

Russ Bowman
Application Engineer
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Calculating Force and Pressure For Air Nozzles

I assisted with an application where logs were being shaved to make thin laminate.  Because the logs were non-concentric or entirely smooth, the beginning of the sheet was riddled with scrapes and defects until it was about 8 foot (2.4 meters) long.  This was a very quick process, and once good product was coming from a shaved log, the machine would divert the material from the scrap bin to the production feed line with a nip roll.  At the speeds that the material was traveling, they needed to kept pressure on the leading edge of the sheet so that it would not “curl” up before the nip roll closed and grabbed the sheet. The drive rolls were pushing the laminate product toward the nip roll and they needed to keep the curl pushed flat along a plate and wondered if we had a product that could accomplish this.

We suggested a series of 2” flat air nozzles, model 1122, to keep the product pressed down on the plate with the force from the airflow.  In their trial runs, they tried to find the correct amount of air pressure to keep the product flat.  Once they found the pressure required, they noticed that the thin and delicate laminate was getting damaged.  Of course, it was just at the beginning length when it was being held in place as it slid into the nip roll, approximately 3 feet (0.9 meters).  Like any company, they did not want to waste any more product and wondered if we had anything else that we could recommend.

Thus a question was presented, and a solution was needed.  In thinking about this, it took me to my Michigan days where snow was abundant.  When walking on snow, you would fall through, but if you had snow shoes, you could stay on top of the snow.  This brought me to the factors of Pressure and Force.  Like with the laminate, if a smaller area does damage to the product (boots through the snow), can we expand the area to keep it from being damaged (snow shoes on top of the snow).

Snow Shoes

Snow Shoes

With the application, we needed to apply the same force on the material.  The equation for force is F = P *A (Equation 1), where F – Force, P – Pressure, and A – Area.

We can do an equality statement from Equation 1 which shows F = P1 * A1 = P2 * A2 (Equation 2).  The amount of pressure required from other EXAIR products can be determined, i.e. if I can double the surface area, then I can reduce the pressure by ½.  For model 1122, we can determine the pressure that was generated from Equation 1 and from the catalog data:

Imperial Units of Model 1122                                                      S.I. Units of Model 1122

F = 1.4 lbf (catalog)                                                                       F = 0.624 Kg (catalog)

A1 = Length X Width                                                                    A1 = Length X Width

= 5 inches X 2 inches (catalog)                                                   = 12.7 cm X 5.1 cm (catalog)

= 10 in^2                                                                                         = 64.8 cm^2

P1 = F/A1 (Rearranging Equation 1)                                         P1 = F/A1 (Rearranging Equation 1)

= 1.4 lbf/10 in^2                                                                            = 0.624 Kg/64.8 cm^2

= 0.14 PSI (pounds per in^2)                                                     = 0.0096 Kg/cm^2

Super Air Amplifier

Super Air Amplifier

Now that we have all the information from model 1122, we can determine the pressure required for a different product to keep the force the same.  With the 2” Super Air Amplifier, model 120022, it has a much larger footprint than the 2” flat air nozzle, model 1122.  So, with Equation 2, we can determine the amount of pressure required.  We will use model 1122 for our P1 and A1, and we will use model 120022 for P2 and A2.  From the catalog data for model 120022, we get a target area as follows:

 

Imperial Units for Model 120022                                               S.I. Units for Model 120022

A2 = pi * (diameter/2)^2                                                              A2 = pi * (diameter/2)^2

= 3.14 * (5.15 in/2)^2                                                                    = 3.14 * (13.1 cm/2)^2

= 20.8 in^2                                                                                      = 134.7 cm^2

 

When we apply the information to Equation 2, we get the following information:

 

Imperial Units                                                                                  S.I. Units

P2 = P1 * A1 / A2                                                                              P2 = P1 * A1 / A2

=(0.14 PSI * 10 in^2) / 20.8 In^2                                               =(0.0096 Kg/cm^2 * 64.8cm^2) / 134.7 cm^2

= 0.067 PSI                                                                                       =0.0046 Kg/cm^2

 

Now that the area was increased like the snow shoes above, the pressure was reduced and no additional waste was incurred.  Sometimes you have to think outside the igloo.  As with any application or product, you can always contact us at EXAIR for help.

 

John Ball
Application Engineer
johnball@exair.com
twitter.com/exair_jb

 

Image courtesy of VasenkaPhotography. Creative Comment License

Super Air Amplifier Removes Fumes In Plastics Machining

I recently took a call from a customer who was using our Model # 120022, 2″ Super Air Amplifier to remove an odor that is produced from trimming their plastic pump impellers. The impellers are made of carbon fiber reinforced plastic and when they turn the larger impellers the Super Air Amplifier “works great”. The fumes are captured by the amplifier and exhausted through 10′ of duct attached to the positive pressure side of the amplifier. However, as they increase the speed to trim the smaller sizes, the amount of fumes would increase and remain in the area, so they called EXAIR for help.

Using the Coanda profile, the Super Air Amplifier utilizes a small amount of compressed air to induce a large amount of surrounding ambient air and directs it into the primary airstream. The surrounding ambient air is pulled into the Super Air Amplifier from the large diameter (vacuum side) to the small diameter (positive pressure side). The result is a large volume of outlet airflow, making them the ideal choice for this type of application. While the units are shipped with a .003″ shim installed, we offer both a .006″ or a .009″ shim (available in a Shim Set) that allows you to increase the gap, resulting in more volume of vacuum and positive pressure flow, and force.

Super Air Amplifer w- shims

Super Air Amplifier and Shim Set

I recommended the customer order the Shim Set, allowing them to increase the gap to induce a larger amount of air to evacuate the area. They are now using one unit, capable of handling both jobs.

If you have a similar application or need help with your existing Air Amplifier, give us a call!

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

More Power? I DO Think So…

We occasionally get calls from folks who are looking for “more power” – and it always brings that classic 1990’s sitcom “Home Improvement’s” Tim “the Tool Man” Taylor to mind. Well, not so much Tim’s “more power” mantra, but the ubiquitous response from his long-suffering sidekick, Al Borland:

Al knows it.  George Foreman knows it. Lisa knows it.  Even Tim knows it, this time.

Sometimes, they’re looking for a product to replace what they’re currently using…something they’re not getting desirable results from. Other times, they have an EXAIR product in place, and it’s just not getting the job done.

Our first response is, of course, to make sure they’re getting a sufficient supply of air to their product, no matter whether it’s ours or not. If you’re familiar at all with our blogs, you know we write about this frequently:

The Importance of Proper Compressed Air Supply Lines

Video Blog: Proper Supply Plumbing for Compressed Air Products

Improper Installation and Associated Problems

3 Common Mistakes in Your Compressed Air System

Once we’ve made sure that the product is indeed receiving appropriate air supply, we can look at adding to the flow rate and force of the air stream. We’ve made it easy to do that with a variety of blow off products by designing them with a replaceable shim.

All of our Air Knife products (Super, Standard, and Full Flow) will ship with a 0.002” thick shim installed. These will perform superbly in a wide variety of general industrial blow off applications. If this doesn’t provide the force needed for your application, we carry Shim Sets for any Air Knife that will allow you to double, triple, or even quadruple the air flow for amplified thrust. Some common examples are stubborn debris in tight spaces (like the fins of a fin-and-tube heat exchanger) or removing oil from a corrugated surface.

From left to right: Super, Standard, and Full Flow Air Knives.

 

Like the Air Knives, our Air Wipes (Super and Standard) are built with 0.002” thick shims, which can be easily replaced for additional flow and force. Like when the Air Wipe is getting all the coolant off an extruded & machined part, but some stubborn, hair-like fibers need a little more “oomph” to remove.

 

Super (left) and Standard (right) Air Wipes come in sizes from 1/2" to 11".

Super (left) and Standard (right) Air Wipes come in sizes from 1/2″ to 11″.

Yes, those were real calls I took. Yes, they had sufficient air flow. Yes, the extra shims worked like a champ.

Similar to our Air Knife products, our Flat Super Air Nozzles also incorporate a replaceable shim. In fact, you have your choice of standard Models with a 0.015” thick shim installed, or High Power Models with a 0.025” thick shim. Shim Sets with a variety of thicknesses from 0.005” to 0.030” are available for either of these.

Our Super Air Amplifiers and High Velocity Air Jets incorporate patented shims that make for the highest amplification flows available, anywhere. These are available, from stock, in Shim Sets or individually.

High Velocity Air Jets and Super Air Amplifiers use patented shims for optimum performance and efficiency.

High Velocity Air Jets and Super Air Amplifiers use patented shims for optimum performance and efficiency.

If you have an air blowing application that you’d like to get a little (or a lot) more out of, give us a call. Prepare for a discussion on proper air supply first (of course,) but we’ll be more than happy to help in any way that we can.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
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Special Air Amplifier? Not A Problem!

This week I worked with two customers that wanted to boost their air flow with an Air Amplifier. One customer ended up going with a Special Air Amplifier. The second customer I ended up pointing to a different product line entirely. Keep reading to find out why.

The first customer needed to boost the exhaust flow through six inch duct.  The six inch duct was an open vent that allowed fumes to slowly escape from a vessel. During normal operation the vessel, was unmanned, so the fumes only need a path to escape, but could linger. The company wanted to do some maintenance work in the area while the machine was in operation. The vent met the necessary requirements for the air flow of the machinery, but left maintenance workers exposed to a variety of fumes while working in the vessel, if the unit was in operation.

The customer was interested in the model 6034 Stainless Steel Air Amplifier. With 0.002″ air gap and 80 PSIG of inlet pressure, the unit will flow 1,200 SCFM of compressed air at the outlet of the Air Amplifier, but the 6034 can be adjusted to much higher flows from there.  The Air Amplifier would easily be able to exhaust the fumes from the area to maintain a safe and comfortable working environment. The problem was mounting the 6034 Adjustable Air Amplifier. The 6034 is designed to be used in free air with the discharge side of the air amplifier connecting to a duct. The suction side of the Air Amplifier is as open as possible to entrain air, but my customer needed to connect the Air Amplifier to the outlet of the vent. We worked with the customer on designing an Air Amplifier to fit the 6″ Flange that they used to connect sections of their duct similar to the Air Amplifier pictured below.

special air amplifier

This special stainless steel flange-mount Air Amplifier was designed for exhausting hot flue gases from a furnace.

My other customer called to move the air inside a heated drying tunnel. The customer uses a process air heater to heat a large drying tunnel. Unfortunately, the air heater created hot air at the entrance of the drying tunnel. By the time the air reached the end of the drying tunnel the temperature was significantly higher at the top of the tunnel as opposed to the bottom from natural convection. To counter this effect the customer wanted to move air from the process heater half way down the tunnel and release the air. In this application, the customer wanted to duct both the inlet and the outlet of an Air Amplifier. The Air Amplifier is not well suited for ducting and you limit the amount of air that the Air Amplifier can entrain by connecting it to a duct.

For this customer, I recommended he use a Line Vac. The Line Vac typically conveys materials, but it will also move a good amount of air.  The customer was going to use heated compressed air and wanted to convey the air from the process heater to the other side of the drying tunnel. Another key benefit to the Line Vac is the discharge and suction side of the units are both the same size.  This makes it extremely easy to install for the customer and is off the shelf, ready to ship.

Two similar applications on the surface that result in different product recommendation. Not every application for an air mover is this complicated, but if you want to talk through your application EXAIR’s application engineer’s will be happy to help.

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com

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