Cooling Hot Cameras with EXAIR Super Air Amplifiers

Quality Control Camera

Sometimes, the design of an application is a perfect fit for the application purpose until parameters change.  For instance, if ambient temperatures creep a little higher than normal, or workflow increases and machine cycle times are longer than they were planned to be initially, unwanted downtime can become a problematic reality.

Ambient temperatures are sometimes an uncontrollable variable, and increased workflow is a blessing all businesses hope to have.  But, when these, or other, variables change and a process disturbance starts to affect productivity, a viable solution becomes a necessity.

Solving industry problems is the backbone of EXAIR products.  Whether the need is cooling, cleaning, coating, conveying, or conserving (compressed air), there is a good chance we can offer a viable solution.

For example, a global fabrics manufacturer contacted me to discuss a problem with their quality control system.  As they make their proprietary fabrics, they are inspected through a semi-enclosed camera system to ensure the product form is to spec.  As summer temperatures have increased for their U.S. operations, and as demand for their fabrics has increased, the fabric output and the heat within the facility has noticeably increased.  With increased output comes increased use of the quality control camera system, and with increased heat comes the additional heat load upon the cameras components.

This customer was getting by using some air flow generated by a blower to cool the cameras, but blowers heat the output air flow. Ultimately the blowers added too much heat to the higher ambient temperatures and the cameras were failing.

Given the setup of the quality control system, which used (6) cameras atop a semi-enclosed QC station, Super Air Amplifiers were found to present the best solution.  The Air Amplifiers can use large volumes of ambient air to convectively remove the heat building up upon the cameras.  Super Air Knives could also be used, but Super Air Amplifiers were chosen based on airflow pattern (conical vs. laminar airflow).  The Super Air Amplifiers were able to replace the existing, underperforming and problematic blowers to improve production capacity and workflow in this application.

If you have an application in need of increased uptime and think EXAIR products or engineers may be able to help, give us a call.

Lee Evans
Application Engineer
LeeEvans@EXAIR
@EXAIR_LE

Ordering Off-The-Menu, And Other Tales Of Customer Service

In the quaint little beach town where I used to live there was a diner that met – in fact, most would say exceeded – the town’s standard for quaintness. It was one of those places where, if you ordered the same thing twice in a row, it became your “regular order,” and the server would yell it back to the kitchen as soon as you walked through the door. They were also famous, to the locals anyway, for having about as many dishes that weren’t on the menu as they actually had ON the menu.

My favorite among these was their egg salad sandwich; an exquisite helping of comfort food that was once recommended by the kindly wait staff upon recognizing my compromised state in the wee hours of that particular morning. It was a condition I had brought upon myself at a local tavern…a place that, between you and me, was NOT always known for its quaintness. I’ve left the intemperate indiscretions of my youth long behind me (for the most part), but I still enjoy a good egg salad sandwich from time to time.

I got to thinking about that for a couple of reasons today…first and foremost, we were treated to a grill out this week at EXAIR – a wonderful gesture of appreciation from management, and another reminder of why I’m tickled pink to be here. Good food will both trigger, and create, fond memories. And free food tastes best.

I also thought of a call I got this morning, from an Air Amplifier user who wanted more technical data than we publish in our catalog. Now, we’re not trying to be eclectic or quaint, like my old favorite diner, and keep a special secret “stash” of knowledge for an inner cadre…it’s just that we’ve only got so much room in the catalog. Anything else means a call in to us.

Catalog 27

If you don’t have our new Catalog #27, you should get one. Click here.

Of course, in the same vein as my old favorite diner, we do indeed want to make you feel welcome and at ease when you need assistance. That’s why we offer phone support, e-mail assistance, Live Chat – feel free to contact us in any manner that you choose. You’ll get expert support and immediate attention from the most highly trained and experienced Application Engineers in the business. Try us. Depending on where you are, I may even be able to tell you where you can get the best egg salad sandwich ever.

Russ Bowman
Application Engineer
RussBowman@EXAIR.com
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Adjustable Air Amplifier Removes Heat, Protects Thermocouple

I was working with a customer recently who had a fairly interesting application that I’d like to share with you. The customer operates a steel furnace and they have an automatic, liquid steel temperature probe that does not have sufficient time to cool down before they take another temperature measurement which should be a minimum of 5 minutes.

thermocouple

The probe consists of a 6 foot long, ¾” pipe, attached to the end of a 12 foot long beam. The beam lowers the pipe with the probe attached into the steel bath to take the temperature (see sketch below). The pipe is covered with a consumable, cardboard type of tube (pictured above) which is the thermocouple.  A contact block with wiring inside the pipe connects to the thermocouple. This contact block becomes heat damaged because the pipe does not have enough time to cool between temperature measurements.

steel temperature

The customer was originally thinking about using a Super Air Knife to cool the probe and pipe between temperature measurements. After discussing options, the customer took our advice and went with (2) of our 2” Stainless Steel Adjustable Air Amplifiers (model 6042) instead. The Air Amplifiers are able to be mounted at the “parked” position of the pipe / probe and actuated to blow down the pipe and thermocouple length-wise during this time.

The high velocity airflow was able to carry enough heat out of the assembly between temperature measurements that the contact block was no longer becoming overheated and damaged as it was before. We decided to suggest this option to the customer because the air usage for this option was less than that of a 60” long Air Knife and the Stainless Adjustable Air Amplifier has temperature rating of 400°F which was easily able to withstand the heat in the application.

Neal Raker, Application Engineer
nealraker@exair.com

 

 

Everybody Wants Options II

Justin Nicholl, I hear you loud and clear about how Everybody Wants Options. I would go so far as to say a lot of people NEED options. This was evident in an application that I had the pleasure of assisting a caller with recently. They make plastic parts for the automotive industry, and manually remove them from a conveyor line, where the operators experience a nuisance static shock. This static charge also presents a problem when the parts are packaged for shipping, so there are two great reasons for getting rid of it right there.

On to the options: they weren’t sure if they wanted to mount something over the conveyor (like a Super Ion Air Knife or Ion Air Cannon,) or if they wanted to have manual, precise control (as with an Ion Air Gun.) I recommended that they try the Ion Air Gun…for ease of setup, it can’t be beat: you can literally go from opening the box to blowing ionized air in a matter of minutes, provided you’ve got a compressed air line and an electrical outlet within reach. If it is indeed successful in eliminating the static charge (and this is a VERY common & successful application,) then the only question is: Will the operator want to have another hand free? If so, they can return the Ion Air Gun for full credit per our 30 Day Unconditional Guarantee, and get either the Super Ion Air Knife or Ion Air Cannon; whichever they choose. In fact, it’s very likely that using the Ion Air Gun for a little while will better inform their decision.

EXAIR Static Eliminators: Mount in place, or hold in your hand.

EXAIR Static Eliminators: Mount in place, or hold in your hand.

EXAIR product lines, across the board, are rife with options. I wrote a while back about a purchasing agent who got a request for “the largest, most powerful air gun they’ve got” and ordered a 6′ Super Blast Safety Air Gun (with a 1-1/4” NPT connection, 6 foot extension, and a whopping 23lbs of force) when they just wanted to blow off some chips from their machine tools. Again, we used the 30 Day Unconditional Guarantee to get them a 6″ Heavy Duty Safety Air Gun (3/8” NPT connection, 6 inch extension, and a very usable 13oz of force.)

1218-6 1310-6 blog

Another user recently tried a Stainless Steel Line Vac – the product they needed to convey was too abrasive for an aluminum Line Vac – but they just weren’t getting the conveyance rate they wanted. No problem…the Model 150200 2” Heavy Duty Line Vac is made of an abrasion resistant hardened alloy, and boosts conveyance performance dramatically. The dimensions were the same, so the new one dropped right in, saving them from exploring the option of re-plumbing their lines.

all lv blog

Regardless of your compressed air product needs, EXAIR is the most likely solution:

*Super Air Knives are available in lengths from 3” to 108”. They come in aluminum, 303 or 316 grade Stainless Steel, and PVDF plastic (with Hastelloy-C fasteners and Teflon shims for the most aggressive installations.) This is, by far, the most options you’ll find in the industry. And they’re all in stock…waiting until next week doesn’t have to be an option.

*Cabinet Cooler Systems come in capacities from 550 BTU/hr to 5,600 BTU/hr. Whether your enclosure needs NEMA 12 (oil tight, dust tight, indoor duty), NEMA 4 (splash resistant) or NEMA 4X (corrosion resistant,) we’ve got it. And yes, they’re in stock.

*If you need to move a lot of air, or draw a vacuum, our Adjustable Air Amplifiers and Adjustable E-Vacs, respectively, offer you infinite options in range of performance with the simple twist of a locking ring.

You want options? We’ve got them. You want help narrowing them down? Call us.

Russ Bowman
Application Engineer
www.exair.com
twitter.com/exair_rb
facebook.com/exair

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The Thing About 100 MPH Fastballs

A few weeks ago, I wrote about an awesome Sunday afternoon at the ballpark. Today, dear reader, I want to write about something completely different: An awesome Tuesday evening at the ballpark. My youngest son and I went with his Knothole Baseball team with tickets purchased through The Kid Glove Way, a charitabler organization that has partnered with the Cincinnati Reds since 1949 to ensure that local youth have equipment to play baseball & softball, regardless of their financial situation.

redlegs

The weather was perfect, and my Reds got off to a great start: Leadoff batter Billy Hamilton hit one into the left field corner for a triple. Now, this would have been a double for most any other player – proven out by Reds’ sluggers Todd Frazier and Brandon Phillips, who both hit balls in almost the exact same location as the night progressed, and both ended up on second base. But not Hamilton…he’s FAST – the fastest runner in Major League Baseball by most accounts. If you have the opportunity to see this guy run in person (he IS coming right along as a hitter, so the odds are increasing), I highly recommend it…television doesn’t do his speed justice.

The rest of the game dragged on in a pitcher’s duel…not the most exciting spectacle in the wide world of sports…but the crowd took notice when Reds’ closer Aroldis Chapman started warming up in the bullpen. “The Cuban Missile” caught a line drive in the eye during Spring Training, which fractured his skull…thing about a 100 mph fastball; it goes the other way just as hard if the batter turns on it well. It was cool to be there for his second game back after recovering from that serious of an injury.

So there we were, top of the ninth inning, score tied 1-1, and Chapman strikes out the first two batters. The Padres’ Chase Headley came to the plate, took a ball, fouled one off, and drove the next pitch over the left field fence. Thing about 100 mph fastballs…

The Reds’ offense came up short in the bottom of the ninth, and they lost. It was still an awesome night at the ballpark with my son, though.

The thing about 100 mph fastballs reminded me of the thing about open ended compressed air blow offs: there’s no way to generate an air flow with a higher force, but that’s not always a good thing. They’re loud, unsafe, inefficient, and wasteful of your compressed air. Conversely, EXAIR’s Intelligent Compressed Air Products, such as our Super Air Nozzles, Super Air Knives and Super Air Amplifiers, are all specifically designed to use MUCH less compressed air, meet OSHA standards for dead end pressure and permissible noise exposure  and still produce a highly effective air flow for blow off, cooling, drying, etc. Sure; the air flow from these products doesn’t have the force of what you get from an open pipe, but the fact that these engineered products entrain so much “free” air from the surrounding environment into a laminar (as opposed to the open pipes’ turbulence), high velocity flow, make them an ideal choice for most any air blowing application. Not to mention, they’re also much quieter, and ensure compliance with OSHA directives concerning the use of compressed air for cleaning purposes.

The Reds will be in and out-of-town for the rest of the season, trying to solve the different equations for beating different opponents. We’re here every day, looking to help you solve your unique compressed air applications. Batter up!

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Web: www.exair.com
Twitter: twitter.com/exair_rb
Facebook: www.facebook.com/exair

Outside Your Comfort Zone?

Over the past several months I have found myself more and more outside of my comfort zone throughout the day.  This feeling has been declining over the past few months, however, as the situations which cause discomfort seem to come up more and more every day so my comfort zone is constantly expanding. I like comfort zones, but also understand that being outside of them helps me to learn and gain new experience. I bring this up because I had a customer come in yesterday so they could be shown a demonstration of an EXAIR Super Air Knife.

Now, customers coming in is not a problem at all, I spoke with him last week and we discussed the application.  This time, it was outside of his comfort zone so he wanted to come in.  Well, when I got the call I had a visitor I grabbed a single business card and walk out to find that there were four gentlemen waiting to see me, not just one.  Still, not a problem. I showed them to our fully stocked demo room and we proceeded to discuss their application.  They were hoping to make the environment their employees work in a little cleaner.  They had new down draft work benches which had three sides on it, similar to the picture below.

downdraft The problem the team was having is that all their operators were using hand-held grinders to deburr parts as they were manufactured.   The downdraft table was added to help prevent the dust and debris from getting all over the operators, however it wasn’t working good enough.  So they started looking and found EXAIR Super Air Knives.  They didn’t believe that a Super Air Knife would move enough air and still be quiet enough to have an operator sitting at the station, so they drove down to our facility and I showed them all the benefits that a Super Air Knife has.  This was all based off a 6″ Aluminum Super Air Knife I had handy.  I then swapped the stock .002″ thick shim out with a .001″ thick shim.  They were amazed at how quiet the Super Air Knife was (with either shim) and how the flow of air was enough to disturb and direct dust but not over powering and blowing parts off the table. LSAN I could definitely see that they were impressed by the simplicity of working with the Super Air Knife and the performance it achieved. But alas, they were still trying to figure out how a 48″ would work, so I went straight out and got a 110048 off the shelf and hooked it up for them.  That was all that they needed in order to really get the wheels in their heads spinning into overdrive.   They all left with my contact information and catalogs in tow but I didn’t hear them stop talking about the possibilities until they were in the car.

The fact of the matter is that they were outside of their comfort zone and had no concept of how you could make compressed air blow in a laminar sheet to help contain dust in a down draft work bench.  Once they saw how easy the Super Air Knife was to hook up and mount they were instantly back into their comfort zone of making their employees happy and safe. If you have some applications using compressed air and you are well out of your zone, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Office Rule #1

Today I was smacked in the face with the reminder of many applications I have helped customers with over the years.  As I walked through the door into our lunch room I was hit in the face with a very strong odor. This is why Office Rule #1 is, “DO NOT microwave fish in a common area microwave.” The odor was microwaved fish.  Now it doesn’t matter who cooked the fish, all that mattered was it had not only worked its’ way through the kitchen but also the entire office and then it was being vented into our manufacturing area.   Needless to say, the force was strong with this one.   That is when I was reminded of the fume evacuation applications I have done through the years.

fume

Air Amplifier Removing Welding Fumes

If only we had a windows that opened, we could have used an EXAIR Super Air Amplifier to quickly and efficiently evacuated the air out of the kitchen area. I have helped many of my customers evacuate fumes from anything from a mining shafts to welding fumes. Using a small amount of compressed air the Super Air Amplifiers move large volumes of air. Super Air Amplifiers are also effective for moving large volumes of air for cooling and blow off applications.

Have a cooling, blowoff, or evacuation application? Call our application engineers and they will help you select the appropriate model air amplifier.

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363
exair_jp

 

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