Drilled Holes In A Pipe – Stop Violating OSHA Standards!

The photos below show one of the most common OSHA violations we see at EXAIR.  A  1-1/4” pipe with 5mm holes drilled every 1.5”.  Drilled pipe is a common practice in many facilities for two reasons – One, it is quick and two, is it easy.  The problem with this type of setup is the safety concern if the drilled hole is dead-ended against skin.  A pressure above 30 PSI can force compressed air into the bloodstream, creating the risk for an embolism – a condition which can be fatal. EXAIR’s engineered Super Air Nozzles can save the day.

IMG_4666

5mm holes drilled into a 1-1/4″ pipe (Top)

IMG_4668

5mm holes drilled into a 1-1/4″ pipe (Left)

IMG_4667

5mm holes drilled into a 1-1/4″ pipe (Right)

 

All EXAIR products conform to OSHA standard CFR 1910.424(b), a standard that regulates dead-end pressure level maximums for compressed air products.  The designs of all EXAIR products are developed in such a way that if dead-ended against human skin they will never exceed the maximum pressure mandated by OSHA (30 PSI). In the above case, our Pico Super Air Nozzles are the right solution. With its recent nomination of the 1109-PEEK for the Plant Engineering Product of the Year Award in the Compressed Air Category, I got to thinking about the product.  There are the obvious, material-specific benefits such as the chemical resistivity of PEEK plastic, the high temperature range (160°C/320°F), and the friendly, non-marring qualities when in direct contact with other materials. But, there is also another side to the 1109-PEEK nozzle (and every other EXAIR product), and that is the added safety with every installation.

EXAIR can also supply a quick and easy solution to keep you OSHA safe and conserve air at the same time. With EXAIR’s unmatched variety of sizes and material, we have an in STOCK solution for your drilled pipes. With threads sizes ranging from M4 x 0.5 through 1-1/4 NPT on the shelf, we ship orders same day in most cases. That is the quick part of the equation.

The correction for such a condition can be the easy installation of a Super Air Knife, or Super Air Nozzles (below) – This illustrates the easy part of the equation.

IMG_4672

1109-PEEK nozzles installed into 1-1/4″ pipe

IMG_4669

Closer view of 1109-PEEK nozzles

IMG_4670

Close-up of 1109-PEEK nozzles

IMG_4671

1109-PEEK nozzles lookin good… and SAFE!!

The 1109-PEEK nozzles installed above provide the needed safety to this drilled pipe. The same nozzle is also available in 316 stainless steel. If you have an application with a similar need in your facility, contact an EXAIR Application Engineer to discuss technical details and specific recommendations.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

We Like Safety, Yes We Do

If you’re even just a casual reader of our blogs, you likely know that EXAIR Corporation is focused on efficiency and safety. Our Design Engineers (starting with our founder & CEO) have always, and continue to be, determined to produce the most efficient, quietest, and safest compressed air products you can find. Our Production Team not only manufactures these products in strict compliance to these designs, but they do so with keen attention to safety in every evolution of every operation, from machining and assembly to packaging and quality control, and all points in between. Getting hurt on the job here is the last thing someone has to worry about, because safety is the first thing everybody is thinking about. And I really, really like that.

I had the pleasure of helping a caller recently who was focused on that exact same thing: workplace safety. They operate a brake press, and, in continuing efforts to improve safety, had been using tongs to place parts into, and retrieve them from, the press platen. Some of the parts weigh about 1-1/2 pounds, and the tongs were, necessarily, a two-hand operation. As you can imagine, this was a laborious and tiresome process, involving hundreds of operations over the course of the day. The main concern was still safety, of course, but they were also looking for a lighter-weight, more ergonomic solution, so we started talking about a simple pick-and-place device, using an E-Vac Vacuum Generator and a Vacuum Cup.

Again, the largest part weighed only 1-1/2 pounds, and was about 8” in diameter. This was easily handled by a Model 900753 Small Round 1-1/2” Diameter Vacuum Cup. Given the light weight of the parts, and the compact (by design) nature of their device, they were able to use our smallest Model 810002M In-Line E-Vac High Vacuum Generator, which uses only 2.3 SCFM @80psig.

With (14) Models to choose from (seven sizes, all available in "High Vacuum" for non-porous products and "Low Vacuum" for lifting objects with a porous surface,) we've got the solution to your pick-and-place application.

With (14) Models to choose from (seven sizes, all available in “High Vacuum” for non-porous products and “Low Vacuum” for lifting objects with a porous surface,) we’ve got the solution to your pick-and-place application.

By incorporating a simple thumb-trigger air gun and an arrangement of short pipe nipples, fittings, and elbows, they were able to quickly assemble a lightweight, ergonomic pick-and-place tool to replace the cumbersome tongs…and still keep the operators’ hands safely away from the press platen. Add in the fact that it’s now a one-handed operation, it’s a win-win-win. And I really, really, like that too.

If you’d like to find out how a pick-and-place system using EXAIR E-Vacs and Vacuum Cups can make life easier in your machine room, fab shop, or even shipping & receiving, give me a call.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Find us on the Web
Follow me on Twitter
Like us on Facebook

Vac-u-Gun Improves Valve Cover Machining Operation

A machine shop called looking for a way to vacuum the scrap aluminum chips from their valve cover machining process. They were considering using a Line Vac Air Operated Conveyor to remove the chips, but preferred something hand held, so I recommended our Model # 6192, Vac-u-Gun Collection System.

Vac-u-Gun 6192

Model # 6192 Collection System includes Vac-u-Gun, reusable collection bag, extension wands and tools.

 

The Vac-u-Gun incorporates a nozzle insert where the orientation can be changed, allowing the unit to be used as a vacuum or a blow gun. Using the unit in vacuum mode would allow them to remove the chips and deposit them in the reusable collection bag (included with the system), rather than blow them in an undesired location in the shop. They could then change the direction of the insert and convert the unit to an air gun and blow off any residual cutting oils from the valve cover, reducing their overall process time. Also adding to their plant’s safety as the unit is OSHA compliant per Standard 1910.242(b) for 30 psi dead end pressure (cannot be dead ended) and allowable noise exposure per Standard 29 CFR 1910.95(a).

Vac-u-Gun orientation

Change from vacuum mode to blow mode in seconds!

 

This is another solution that EXAIR had on hand ready to ship same day to fit the customer’s needs.  If you have a similar application where operators are blowing debris into unwanted areas, please give us a call at 1-800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

The Best Company Policy Is Right Here At EXAIR

All companies have policies. Some have a LOT. Others may not have enough. Some emphasize documenting every single action. Others write down the basics, and rely on “unwritten mutual understandings” for the rest…

We don't call it "yelling;" we call it "stuff you should already know."

We don’t call it “yelling;” we call it “stuff you should already know.”

At EXAIR, we have one core policy: to be easy to do business with. This has served the company well for thirty one years now, and I don’t expect it to be supplanted with anything else, anytime soon. Now, it may seem vague or ambiguous, but we’re quite specific, and diligent, in our methods of adhering to this one core policy:

Easy to find technical information: We offer complete specifications, performance data, dimensions, and application information for any EXAIR compressed air product on our website, and in our catalog. If you have specific questions, a team of the most knowledgeable and experienced Application Engineers in the business are standing by.

Easy to contact technical support: You can reach an Application Engineer immediately by phone or Live Chat. Emails to techelp@exair.com are also given prompt attention. We have a number of tools at our disposal, including a comprehensive test facility that we call the Efficiency Lab…if you have an operational question that we haven’t answered yet, we’ll find the answer in short order.

Easy to get products: If it’s got a part # in our catalog, it’s in stock, and available for same day shipment. Exceptions are some of our longer Air Knife products, which may take one day to ship. We can even manufacture custom length Air Knives, and ship them in only three days. Just so you know, we’re finishing up our 19th consecutive year with a 99.9% on-time shipment record.

Easy to solve applications: This is where the rubber hits the road, once we’ve made it easy to select and obtain your EXAIR product. Those same Application Engineers are ready to assist with any questions you may have about installation, operation, “tips and tricks,” etc. We’ve got an Application Database (registration required for access) that details over 1,000 successful uses of our products. Odds are, one of them is close enough to your situation to help shed some light.

Easy to solve applications, part 2: If, for any reason, the EXAIR product you buy doesn’t work out for you, we offer a 30 Day Unconditional Guarantee on all catalog products. Whether you want to get the next larger or next smaller product, a different one, or go another direction altogether, you’re not stuck with your first purchase…we’ll arrange return for full credit.

Easy to help us help the next person…and yourself: We’re keenly interested in knowing how our products work in specific applications. If you’ve put an EXAIR product to the test, and found that it’s saving you time or money, cutting your air consumption or noise levels, increasing production or safety, or any other quantifiable benefit, you may qualify for participation in a Case Study. Not only will that allow us to better apply our products, we’ve got something for you if you provide a case study for EXAIR.

If you’ve got an application that an EXAIR Intelligent Compressed Air Product may be the solution to, give me a call and find out how easy we can make it work for you.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Find us on the Web
Follow me on Twitter
Like us on Facebook

 

Max the Brown Tabby and Burt the Grey Kitten: Cat Argument 3 photo courtesy of Found Animals FoundationCreative Commons License.

Mini Cooler Provides Sewing Needle Cooling

I recently worked with a surf casting bag manufacturer who was experiencing needle breaks during their sewing operation. (The term surf casting refers to surf fishing from the beach, typically in saltwater.)

The bags, made to hold tackle and gear, are manufactured out of a sail cloth material and are double stitched for added strength. During the operation, the sewing needles would begin to heat up, weaken and break, resulting in damaged product. The customer was considering using a Vortex Tube to blow cold air across the needle and while the Vortex Tube would work well in this application, I recommended using our Mini Cooler. The Mini Cooler is engineered to provide a focused stream of 20°F cold air (based on 70°F supply) while utilizing only 8 SCFM @ 100 PSIG. The Model # 3808 Mini Cooler System includes a swivel magnet base and single point hose kit, allowing for easy mounting and delivery of the cold air direct to the tool. Another advantage is that the Mini Cooler offers a shielded and muffled hot tube, which makes it better for operations where operators may come into contact with the tube.   The perfect solution for a needle cooling application due to the fact it can easily be positioned and always puts out the 20°F air!

Mini Spot Cooler

Provides a focused stream of 20°F cold air with no moving parts.

EXAIR provides a wide variety of spot cooling products including Vortex Tubes, Adjustable Spot Cooler, Mini Cooler and our Cold Gun Systems. With help selecting the best products for your application, please call us at 1-800-903-9247.

 

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Video Blog: What Can Air Wipes Do For You

Below is a short video showing the cleaning power of a Standard Air Wipe. EXAIR has a variety of sizes from 1/2″ to 11″, and the air wipes are available in aluminum or stainless steel. Air Wipes are often used in the manufacturing processes for pipe, tubes, extruded profiles, wire and cable.

For help with your Air Wipe application, please do not hesitate to contact an application engineer at 1-800-903-9247.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

 

Professor Penurious, Mystery Solver!

ZOINKS! What have Professor Penurious and the gang gotten into this time? Enjoy viewing this video – we sure do enjoy making them…And recognizing that some day the Oscar committee will be calling.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Find us on the Web
Follow me on Twitter 
Like us on Facebook

Follow

Get every new post delivered to your Inbox.

Join 12,891 other followers

%d bloggers like this: