The other day, I was talking to a customer who is providing a testing service for a manufacturer of shocks and struts. The test is one of cycle testing to failure for a shock absorber. The problem is that due to the nature of the testing cell, very little heat is removed from the shock absorber assembly. The customer wanted to simulate the airflows that would normally move past the shock absorber when installed and moving inside a vehicle. Currently, the problem is that the rubber grommets at each end of the shock are getting too hot and failing.
This is where the blowing comes in. Since Air Amplifiers are perfectly suited for creating such airflows, I recommended that the customer use our model 120022. This is a 2″ diameter output Super Air Amplifier and can produce anything from a small breeze to a high velocity blast up to about 350 SCFM. With use of a pressure regulator, the customer was able to dial in the performance of the Super Air Amplifier such that the airflow mimicked that of normal air streams moving past a vehicle while in motion.
The result was that the customer was able to completely eliminate premature failure of the rubber grommets due to over-heating in the unnatural environment of the test cell.
I have had this application before with other testing companies who were testing everything from steering components, suspension components and even braking systems.
Yes, its true, folks. They even have compressed air at the North Pole. How do I know this, you ask? Because Mr. Santa Claus himself called me last week with a big problem on his hands. His elves have been furiously working away, getting all the toys made that are to be delivered tomorrow morning to good girls and boys around the world. However, in their haste, they neglected to clean up after themselves. So, Santa’s workshop is covered in little bits and pieces of plastic, wood, and even some metal shavings. Mrs. Claus, who likes to keep a clean house, let it slide for a while. But, now, it is simply unacceptable. She requested a quick, easy way to clean up the mess so the workshop is all ready to go for next year’s batch of toys.
So, when Santa called me in his predicament, I quickly recommended our model 6293 Deluxe Chip Vac System. It runs only on compressed air, which they have plenty of, since they use it to make some of the toys. The Deluxe system comes with the hose, and all sorts of tools to connect to the end of it, just like your standard vacuum cleaner at home. So, they can clean up both small and big chips, from open spaces and little nooks and crannies on the machines. It even comes with a drum dolly, so the drum can be easily pulled around the workshop on wheels as it gets fuller and heavier.
I haven’t heard back from him yet, because I am sure he won’t even get to the cleaning until January. But, I am certain he will be pleased with the results. He may even decide to incorporate some of our other products into the toy making process, such as Vortex Tubes and Super Air Knives. But, that is a whole other discussion.
Happy Holidays, everyone!
Our new product line of vacuum generators, the E-Vac, is gaining interest from our customers and allowing us to provide solutions for many different applications.
One of our customers wanted to place a solenoid valve on the exhaust of the E-Vac because she needed to create a positve purge on the vacuum port of the E-Vac which would eject the part which was initially picked up out of a die. With a closed valve on the exhaust of the E-Vac, the air is forced through the vacuum port.
I did not know how the vacuum levels would be affected with any back pressure through the open solenoid, and needed to run some tests. It wasn’t just out of the kindness of my heart (some would tell you it would be hard to find) that I ran the tests, and not just because it is the holiday season; It is how we are trained to react to questions we may not have an immediate answer to.
Fortunately we are fully staffed which allows any one of us (the Application Engineers) to step away and run some test which could be helpful to our customer. Most of this results in information which will be helpful to another customer in the future. We can also provide product on a 30 day unconditional trial if we feel it is best for the testing to be done in a real world situation – either way we can provide valuable information.
We have all been given them but have you ever wondered where they came from? I came into contact with a Christmas Fruit Cake bakery having a problem with burned up shop vacuums.
At the end of a product run, there is residual product (fruits and liquid) left in the product bin that has to be vacuumed out. They have been using commercial vacuums which would burn up within a couple of months. They saw one of our ads depicting a guy throwing away burned up shop vacuums and related with the picture.
They contacted me for technical assistance. We went over the design features, specifically the fact that the Drum Vac has no moving parts so nothing to wear out or burn up. Powered with compressed air, it is also safer in a wet environment. I suggested the Model 6296 Deluxe Drum Vac because it could do double duty. They could use it to vacuum up their sump as well as spills on the floor.
They purchased 6296 Deluxe Drum Vac and were elated with the performance. It is one of the more sought after pieces of equipment on their shop floor.
I had a customer call in the other day who manufactures and packages cotton balls used in the medical and cosmetics industries. The customer has to interface two machines; a cotton ball manufacturing machine and a form, fill & seal machine where the balls are packaged. The customer has looked into ways in which to move the machines close enough that the balls of cotton could just drop from one to the other. They have even looked into small bucket conveyors. But none of the choices seemed to be as clear cut and inexpensive to execute as using a Light Duty Line Vac. Also, by using the Light Duty Line Vac, they could locate their machines relative to one another in places where they made more sense from a floor space point of view. They were originally looking to install the cotton ball machine up 72 inches in the air so the balls could drop right into the packaging machine. Again, all of the alternate choices had serious drawbacks due to price or difficulty to execute.
The customer ended up going with Model 132300 (3″ Light Duty Line Vac Kit) and a 20 ft. length of hose to accomodate the movement of the material from one machine to the next.
The Light Duty Line Vac option was clearly the more economical option that made the most sense to the customer. The Light Duty Line Vac solution was easily less than ½ the cost of the other solutions that the customer had considered. The Light Duty Line Vac works flawlessly to convey the 2000 cotton balls/minute required.
This past week, I spoke to someone at an Engineering consulting company who makes turnkey automation systems for various industries. He was looking to incorporate one of our Line Vacs into a system that conveys small discs that had been punched out of cardboard sheets. The discs needed to be carried from the collection bin they drop into after being punched out, a few feet away to a funnel assembly. This funnel has a small rectangular opening at the outlet, where the discs pass through single file, to then be counted by a laser counting system.
I recommended our model 6084 2″ Aluminum Line Vac. It will support all the various disc sizes that need to be moved. It will be mounted on the bottom of the collection bin so that it will be gravity fed, and no discs will be missed. I also recommended using a pressure regulator to fine-tune the inlet pressure so that the feed rate from the Line Vac into the funnel doesn’t create a backlog or overload the laser counting system and further contribute to jam-ups and miscounts.
This is what our products do all day long… Problem one is a home-made blow off consisting of four open tubes, each with a 1/4″ inside diamter. Each tube running at 80 PSIG consumes around 35 SCFM and runs upwards of 85 decibels. Problem two is even with all this air blowing around an iron sprinkler pipe, the rinse water is not being removed well enough for a good finish. This pipe gets coated with a UV cured lacquer as the last finishing step and the water prevents a good finish. The maximum diameter of the sprinkler pipe is 2″ which is a good fit for our 3″ Super Air Wipe. Problem one, high air consumption, is brought down from 140 SCFM to 39.8 SCFM at 80 PSIG. Problem two, uneven removal of water and high decibels, is remedied by providing a complete 360 degree blow off at 79 decibels. Ultimately, the bad finish upon the sprinkler pipe is no longer a problem area of the process, the customer has saved air, and the environmental noise levels are reduced. EXAIR expects nothing less, why should you?