EXAIR is always focused on releasing new products and improving on existing product lines, and 2018 has been no different! Earlier on this year we introduced the New Super Air Scraper as an accessory to… More
Deep Hole Vac-u-Gun – Blow Chips Loose and Vacuum Them Away in One Step!
Last week, we looked at the Vac-u-Gun, and you can take a look at that blog here.
This week I wanted to present the Deep Hole Vac-u-Gun, a special iteration of the Vac-u-Gun, designed to provide a solution to the troublesome process of cleaning cavities and drilled holes.
The Deep Hole Vac-u-Gun is a low cost solution to quickly remove chips and debris from grooves and drilled holes where blow gun could create potentially hazardous flying debris. The Deep Hole Vac-u-Gun is simply positioned over the hole, and the trigger squeezed and then a small blow tube delivers a a stream of air to dislodge and lift the chips while the large suction tube vacuum them away. The operator is protected form flying debris since all chips and debris is contained within the clear suction tube. The device is capable of cleaning holes up to 1-1/4″ (32mm) diameter and 18″ (457mm) deep!
How does the Deep Hole Vac-u-Gun work?
Compressed air, normally 80-100 PSIG (5.5 – 6.9 bar), flows through the inlet (1) into an annular plenum chamber (2) when the trigger is pressed. A small amount of air is injected into the blow tube (3) to provide agitation and lift to the chips or debris. The larger airflow is injected into the the throat of the gun through directed nozzles (4). The jets of air create the vacuum at the intake (5) which draws the material in and accelerates it through the unit. The chips, debris or other particulates can then be exhausted into a filter bag or hose attached to the Deep Hole Vac-u-Gun System.
We have found many applications where the Deep Hole Vac-u-Gun is beneficial- including removing chips and debris in:
Holes in fixtures, drilled plastics, T-slots’groove cleaning , coolant evacuation from parts, woodworking, tapped holes, cavity evacuation, and many more!
There are many advantages to the Deep Hole Vac-u-Gun, and some are:
Low cost, no moving parts/maintenance free, durable die cast construction, eliminates shock hazard – no electricity, meets OSHA pressure requirements, safe operation – no flying chips, lightweight and portable, and quiet.
The Deep Hole Vac-u-Gun uses less compressed air than ordinary blow guns, and the amplified output flow is 12 times the air consumption rate.
Note that the Deep Hole Vac-u-Gun should not be operated without a filter bag or vacuum hose attached to the exhaust.
There are three (3) Deep Hole Vac-u-Gun System options-
The Model 6094 is the Deep Hole Vac-u-Gun only.
The Model 6194 comes with a reusable bag and clamp for debris collection.
The Model 6394 comes with the reusable bag and a 10′ (3m) section of vacuum hose for transferring the debris to a collection point.
If you have questions about the Deep Hole Vac-u-Gun or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.
Brian Bergmann
Application Engineer
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Twitter: @EXAIR_BB
Back Blow Nozzles Clean Inside Metal Tubes
A manufacturing plant EXAIR worked with made cast aluminum tubes for the automotive industry. After the parts were cast, a machining operation would clean the ends. This left coolant and metal shavings inside the tube. Before going to assembly, they had to clean the part. They created a two-tube fixture (reference picture above) to fit the 25mm tubes in place.
Two home-made nozzles were used to fit inside the tubes to blow compressed air. The nozzles were attached to the ends of two 17mm pipes which supplied the compressed air. A cylinder was used to push the nozzles from the top of the aluminum tube to the bottom then back up again. The liquid emulsion and debris would be pushed downward into a collection drum. When they started operating their system, the inside of the tubes still had contamination inside. They wanted to improve their process, so they looked for an expert in nozzle designs, EXAIR.
EXAIR designed and manufactures a nozzle for just this type of operation, the Back Blow Air Nozzles. We offer three different sizes to fit inside a wide variety of diameters from ¼” (6.3mm) to 16” (406mm). They are designed to clean tubing, pipes, hoses, and channels. The 360o rear airflow pattern can “wipe” the entire internal surface from coolant, chips, and debris. For the application above, I recommended the model 1006SS Back Blow Air Nozzle. This 316SS robust design would fit inside the tubes above. The range for this Back Blow Air Nozzle is from 7/8” (22mm) to 4” (102mm) diameters. The customer did have to modify the function of the equipment by placing the cylinder and the rods under the aluminum tubes. The reverse airflow would still push the contamination into the collection drum that was placed underneath the tubes.
After installing the model 1006SS onto the rods, the cleaning operation became more efficient. Not only was the entire internal diameter getting clean, they were able to turn off the compressed air until they reached the top of the tube. With the model 1006SS, they only needed one pass to clean. This cut the air consumption in half, saving them much money by using less compressed air. In addition, they were able to speed up their operation by 20%. Cleaner tubes, less time, cost savings; they were happy that they contacted EXAIR for our expertise.
If you need to clean the inside of tubes, hoses, pipes, etc., EXAIR has the perfect nozzle for you, the Back Blow Air Nozzles. EXAIR can also offer these nozzles on our VariBlast, Soft Grip and Heavy Duty Air Guns for manual operations. They come with Chip Shields and extensions that can reach as far as 72” (1829mm). Or like the customer above, automate the system to get a great non-contact cleaning.
If you require any more details, you can contact an Application Engineer at EXAIR. We will be happy to help.
John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb
Mounting Options for EXAIR’s Super Air Knife
The key towards a successful Super Air Knife application is making sure it’s installed properly. Using the chart on the installation & maintenance guide to ensure your plumbing is properly sized is the first step. This ensures that an adequate volume of compressed air is able to reach the knife, without causing an unnecessary pressure drop.
Once you’ve planned out the distribution of compressed air to the Super Air Knife you must consider how to mount it in your application. Across the bottom of the knife are ¼-20 tapped holes spaced out evenly every 2” along the knife. A 30” Model 110030 will have (15) holes, a 60” 110060 (30), and so on. These holes are tapped through to allow you to mount the knife to best suit the application.
If you’d rather have a more “out of the box” solution, EXAIR offers our Universal Mounting System. It gives you the ability to mount onto a conveyor rail or machine frame and provide precise positioning for all of EXAIR’s Super Air Knives, Standard Air Knives, Full-Flow Air Knives, as well as the Standard and Super Ion Air Knives. Each system comes with (2) 1/2-13 x 5” long bolts, 2’ long stainless steel rod, mounting hardware, angle bracket, and adjustable swivel clamps. Check out the video below for a demonstration of the adjustability you can achieve with the Model 9060 Universal Mounting System.
Another critical factor to consider is the mounting position of the knife. If the material is moving along a conveyor, the knife should be positioned as closely as possible with the airflow oriented against the direction of travel of the material. By doing so, we increase the amount of time that the material is in contact with the airflow. We call this term counter-flow. Maximizing the time in contact with the laminar airflow from the Super Air Knife gives us the best chance at a successful result. Whether we’re talking about cooling, drying, or cleaning, the longer that the material is in contact with the laminar airflow the better the results will be.
In this photo, the Super Air Knife is positioned upside down at an angle above a conveyor belt, against the direction of travel. We recommend installing the Super Air Knife in this orientation as it allows the airflow to get closest to the material being blown off. They’ve used their own brackets to allow the knife to be adjusted when blowing residual dust off of a conveyor for a mining application. The dust on the belt would build up over time and was difficult to remove. By installing a Super Air Knife, they’re able to continuously remove the dust from the conveyor belt before it becomes a problem.
If you have an application that would be better served with one of EXAIR’s Super Air Knives, give us a call. An Application Engineer is ready to assist you in selecting the proper material, length, and mounting method.
Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD
Where Can’t I Use An EXAIR Super Air Knife?
Considering the material options available, there are very few places you CAN’T use a Super Air Knife. Most often, we find those to be due to extreme elevated temperature, like this one:
A caller from a glass manufacturing company wanted to replace a drilled pipe in a cooling application. Thing is, glass makers deal with their product in molten form, which is HOT…the ambient temperature that this drilled pipe is exposed to reaches 800°C, or 1,472°F. Because of the temperature, and corrosive atmospheric elements (SO2 is also present, as if the heat wasn’t bad enough,) they have to replace the drilled pipe every so often, and wanted to explore other solutions.
Now, this was a rare case where a Super Air Knife would not have necessarily offered an improvement over a drilled pipe:
- The air flow from the drilled pipe is primarily straight from their compressed air system. Since the Super Air Knife entrains air from the surrounding environment at a rate of 40:1, the resultant flow would be very close to the 800°C ambient temperature…and not as effective at cooling as the much cooler compressed air supply temperature. It wouldn’t have helped to reduce consumption if it simply didn’t work.
- Another great thing about the Super Air Knife is that it’s dramatically quieter than any other method of compressed air blowing. Of course, if you find yourself in a 800°C sulfur dioxide environment, hearing protection is the least of your concerns.
When supplied at 80psig, the EXAIR Super Air Knife produces a hard hitting, powerful curtain of air, with a sound level of only 69dBA. - EXAIR Super Air Knives (and all of our Intelligent Compressed Air Products) are compliant with OSHA Standard 1910.242(b) which limits the outlet pressure of a compressed air blowing device used for cleaning to 30psi…this protects personnel from high velocity debris and air embolisms. Again, not a concern in an unoccupied (and uninhabitable) space.
Again, that’s a rare case…a very specific exception to a broadly inclusive rule, in light of the options EXAIR offers. Consider:
- Aluminum Super Air Knives are durable, lightweight, and suitable for most any installation in a typical industrial/commercial environment. They’re good to 180°F (82°C) and are fitted with stainless steel fasteners to eliminate corrosion in damp environments. The polyester shim can be replaced with a custom stainless steel shim, increasing the temperature rating to 400°F (204°C) if needed.
- Type 303 Stainless Steel Super Air Knives offer higher tensile strength, and are good to 800°F (427°C.) They are popular in applications with factors like high heat, corrosive environments, frequent spray down cleaning, outdoor installations, etc.
- Type 316 Stainless Steel Super Air Knives are often specified in food and pharmaceutical applications, due to their even higher resistance to chemical attack and pitting. They’re also rated to 800°F (427°C) and have the same high tensile strength as the Type 303 Stainless Steel models.
- Some situations call for better corrosion resistance than these high grades of austenitic stainless steels – and that’s where EXAIR’s PVDF Super Air Knife comes in. Fitted with PTFE shims and Hastelloy© C-276 hardware, they are especially well suited for processes involving the harshest of corrosive agents, such as electroplating, solar cell manufacturing, and lithium ion battery production, just to mention a few. They would, in fact, be ideal for the SO2 environment at the glass factory, if it weren’t for the temperature…they’re rated to 275°F (135°C.)
Performance is identical, regardless of construction materials, and all EXAIR Super Air Knives come in lengths from 3″ to 108″ (except PVDF…those go up to 54″ lengths) and ship quickly from our well maintained inventory. Aluminum and Stainless Steel models can be coupled together for even longer flow lengths. Plumbing Kits and Universal Air Knife Mounting Systems make for easy and quick installation, and all Super Air Knife Kits come with an Automatic Drain Filter Separator, a Pressure Regulator, and a Shim Set for reliability, clean air flow, and total performance control.
If you need a reliable, cost effective, safe, quiet, and efficient curtain of air, EXAIR’s Super Air Knives are what you’re looking for. If you’d like to discuss a particular application and/or product selection, give me a call.
Russ Bowman
Application Engineer
EXAIR Corporation
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No Drip, External Mix, Atomizing Spray Nozzle Overview
EXAIR’s Atomizing Spray Nozzles are used to clean, coat, or cool parts and they also lend themselves very well to humidification and dust control. They are constructed from rugged and durable 303 SS to provide corrosion resistance and they can operate in temperatures up to 400°F (204°C). All EXAIR Atomizing Spray Nozzles are also CE compliant.
Atomizing Nozzles are separated into 5 categories – Internal Mix, External Mix and Siphon Fed, Deflected Flat Fan, and Internal Mix 360° Hollow Circular Pattern. They are available in 1/8″, 1/4″ & 1/2″ NPT to make it easy to provide the coverage and flow rate you need for nearly any application. For today’s focus, we will discuss the No Drip External Mix Atomizing Nozzles.
External Mix Atomizing Nozzles have the highest flow rates and are ideally suited where precise liquid flow is required and both the air and liquid are pressurized. Also the External Mix Atomizing Spray Nozzles can easily atomize liquids with a viscosity above 300 cP (Centipoise).
Centipoise is defined as a dynamic viscosity measurement unit. A Centipoise (cP) is a non-SI (non-System International) measurement unit of dynamic viscosity in the centimeter gram second (CGS) system of units.
Our patented No Drip feature positively stops the liquid flow when the supply air pressure drops below 20 PSIG for 1/8″ NPT Nozzles or 30″ PSIG for the 1/4″ or 1/2″ NPT. By incorporating this feature into the design, it eliminates the need for any additional valves or supply lines. They are available in flow rates that range from less than 2 GPH (7.57 LPH) for our Model EF9010SS 1/8 NPT No Drip External Mix Narrow Angle Flat Fan Pattern and up to 303 GPH (1,147 LPH) for the Model EF6010SS 1/2 NPT No Drip External Mix Narrow Angle Flat Fan Pattern.
When making a selection, below are some points to consider:
- Volume of liquid required?
- What is the viscosity of the liquid?
- What type of spray pattern fits the application?
If you would like to discuss External Mix No Drip Air Nozzles or any of EXAIR’s safe, quiet & efficient compressed air products, I would enjoy hearing from you…give us a call.
Steve Harrison
Application Engineer
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The Adjustable Spot Cooler – Cold Air to -30°F (-34°C) From Your Compressed Air Supply
The Adjustable Spot Cooler is a low cost, reliable , maintenance free way to provide spot cooling to a myriad of industrial applications. Simply turn the knob, and the temperature can be changed to suit the needs of the process. The Adjustable Spot Cooler delivers precise temperature settings from -30°F (-34°C) to room temperature.
The Adjustable Spot Cooler utilizes the Vortex Tube technology that converts compressed air into a cold air stream. To learn more about EXAIR vortex tubes, click here.
- It can produce temperatures form -30°F to +70°F (-34°C tp +21°C)
- Parts included for flow rates of 15, 25 and 30 SCFM (425, 708, 850 SLPM.) The unit comes from the factory set at 25 SCFM (708 SLPM)
- It can produce refrigeration up to 2,000 BTU/hr (504 Kcal/hr.)
A swivel magnetic base allows for easy mounting and portability, you can move it from machine to machine as needed. The flexible cold air outlet tubing holds its position and is easy to aim. Most importantly, there are no moving parts or CFC’s, ensuring maintenance free operation.
The Adjustable Spot Cooler incorporates a vortex tube to convert a supply of compressed air (1) into two low pressure streams, one hot and one cold. With the turn of a knob, the temperature control valve (2) allows some hot air to flow through a muffling sleeve and out the hot air exhaust (3). The opposite end provides a cold air stream (4) that is muffled and discharged through the flexible hose, which directs it to the point of use. The swivel magnetic base (5) provides easy mounting and portability.
The Adjustable Spot Cooler can produce a wide range of air flows and temperatures as determined by the temperature control valve knob setting and the generator installed. The generator controls the total SCFM (SLPM) of compressed air consumption, and is easy to change. From the factory, the 25 SCFM (708 SLPM) generator is installed, producing up to 1,700 BTU/hr (429 Kcal/hr) of cooling. For less cooling, the 15 SCFM (425 SLPM) generator can be installed, providing up to 1,000 BTU/hr (252 Kcal/hr) of cooling. And for more cooling, the 30 SCFM (850 SLPM) generator can be installed, providing up to 2,000 BTU/hr (504 Kcal/hr) of cooling.
Two (2) Systems are available as shown below, and include the 15 and 30 SCFM (425 and 850 SLPM) generators, a filter separator, and either a single or dual point hose kit.
Adjustable Spot Cooler Systems
If you have questions about the Adjustable Spot Cooler or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.
Brian Bergmann
Application Engineer
Send me an email
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Twitter: @EXAIR_BB
Shot Blasting Media and Dust Problems Solved with EXAIR’s HEPA Vac
Have you ever heard an electric vacuum toward the end of its life? It gets an irritating high-pitch noise caused by the bearings going out. A customer was hearing this annoying sound after only two months of use. Their application was shot blasting metal parts. The shot blast media was very dusty and carried everywhere around the room. After use, they would use a shop vac to clean the machine and around the area. When they started to hear that “moan” from their electric vacuum, they knew that they would have to purchase another unit. Additionally, they noticed a lot of dust migrating into the work environment from the shop vac, creating a breathing hazard for the operators. After their second electric vacuum failed, they started looking for a better choice.
When they contacted EXAIR about these issues, EXAIR had a great solution for them. I recommended our model 6399, 55-gallon Premium Heavy Duty HEPA Vac System. This system comes with a drum, drum dolly, heavy duty accessories, HEPA Filter, and a robust vacuum system. The heavy-duty accessories are easy to use to vacuum in tight spaces. The HEPA filter inside the drum has an efficiency of 99.97% at 0.3 micron. So, the dust will remain in the drum and not migrate back into the ambient air. The HEPA filter media is pleated to give a large surface area of 36.7 ft2 (3.4 m2). Packed inside a supported cylindrical, it will allow for great amount of debris before changing. With the shop vac above, the surface area of the filter was very small causing the filter to plug and under-perform. The EXAIR Heavy Duty vacuum generator is made from a hardened-alloy steel construction which is very resistant to wear. It does not have any moving parts or bearings to wear. For this application, the generator is perfect for the shot blast media. The Heavy Duty HEPA Vac only requires compressed air to operate, not an electric motor which can fail from dusty environments. The Heavy Duty HEPA Vac System only has a decibel level of 82 dBA which makes it very quiet compared to shop vacs. With clean compressed air as the engine for the vacuum, this system can last for years; not months.
When the company above started to use the Heavy Duty HEPA Vac, the first thing that they noticed was how quiet it operated. That constant loud noise from their electric vacuum was gone, making it a better working environment for the operators. They also noticed that the dust was not getting back into the environment, reducing the dust nuisance. If you find that your electric vacuums are breaking down or you would like to reduce the noise levels, EXAIR has a large line of Industrial Housekeeping Products. You can contact an Application Engineer to see if we have the right vacuum product for you.
John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb
