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Happy Thanksgiving from all of us at EXAIR Corporation!
EXAIR is closed for the holiday on Thursday and Friday, November 27th and 28th, 2014.
Quick Disconnects are a quick and easy solution to hook up devices to your compressed air system. These units can be found in quite a few factories and are more often than not being used incorrectly. I know that on the air compressor in my garage, the only way to hook anything up to it was to use 1/4″ quick disconnects. Chances are they are even a few of them within your facility, assuming you have compressed air available.
When you really look at a quick disconnect though you start to see why it shouldn’t be used to install every compressed air driven device there is. You can see in the pictures below that a 1/4″ quick disconnect that goes to a 3/8″ NPT adapter has a .192″ opening at the small end. A 3/8″ Schedule 40 iron pipe will actually carry a .493″ inner diameter. If you were to use this quick disconnect on something like a 2″ Heavy Duty Line Vac, you will starve it for air due to the limited ability of the small diameter to carry enough air volume. This, in turn, will limit the performance of the Line Vac. This is because the through hole on the quick disconnect cannot pass enough air to feed through to the Line Vac.
On the 1/4″ quick disconnect to a 3/8″ NPT this may not be as large as a problem as the next picture. Below you can see a 1/2″ quick disconnect that is going up to a 3/4″ NPT. a 3/4″NPT Schedule 40 iron pipe is actually a .824″ inner diameter. The quick disconnect at most has a .401″ inner diameter.
Even though you are providing the correct thread size for your connection (a 3/8 MNPT and a 3/4 FNPT respectively in our example) the quick disconnect’s small inside diameter could be too much of a restriction for the volume demanded by an end use product. Due to this restriction point you will see pressure drops in your system when using a device with a properly sized inlet for its demand of compressed air being fed with an improperly sized quick disconnect. This is one of the main reasons one of our first questions in troubleshooting an EXAIR products performance with a customer is whether or not they are using quick disconnects.
In case you missed our blog on EXAIR having 4 finalists for Product of the Year 2014 from Plant Engineering there is a link here. Today however, I would like to focus on just one of those products, the Model 1104-PEEK, 3/8″ FNPT Peek Plastic Super Air Nozzle.
The 1104-PEEK is constructed out of PEEK Thermoplastic which is designed to be chemical resistant, non-marring, and carries a high temperature rating. The chemical resistance of PEEK plastic will help greatly in locations such as plating operations, chemical etching or cleaning metals, painting, or glass etching. The low friction characteristic of PEEK plastic makes it ideal when trying to blow off delicate surfaces which may be scratched by metallic blow off nozzles such as, painted surfaces, glass, plastics, or even polished metals. The PEEK thermoplastic is rated for environments up to 320°F (160°C). This can be ideal for paint or coating curing ovens. This could also come in handy around the exit of a furnace where there may be caustic fumes mixed with elevated temperatures.
When you combine all of the benefits from PEEK plastic with the engineered solutions from EXAIR, you will get an efficient, safe, engineered solution to your blow off application that will work in a caustic or hot environment, yet not mar a delicate surface.
If you have an 1104-PEEK already in your application, or are using another EXAIR product, please go and vote for us in the Plant Engineering Product of the Year awards. We greatly appreciate all who are willing to vote for any of our products and are proud to continue bringing you the best products we can offer that fit your every compressed air need.
One of the most repeatable aspects of EXAIR products is the ability to make sustainable, measurable improvements to an application. Whether the application need is for spot cooling to improve process speeds, static elimination to eliminate defects, or debris blow off to improve quality, EXAIR products fit the bill time and time again.
In the photo above the hub is used as a quality checking device after a machining process. The hub remains stationary while a machined part is brought into the application via robot. During the mating of the machined part to the hub, to check proper fit and tolerance, small chips were becoming trapped between the hub measurement sensors and the machined part.
To eliminate this disturbance a 3” Super Air Wipe was installed to keep the OD of the measuring hub clean and free of debris. Since installing the Super Air Wipe, debris and damage related measurement errors have been reduced to zero.
These tighter quality control capabilities have increased the efficiency of the application and reduced the need to rework existing product.
If you have a similar application, or one for which you think an EXAIR solution may be viable, contact an EXAIR Application Engineer.
I watch an awful lot of television. I always have. I grew up in the 1970’s, and I can STILL remember the sixth sense that my friends and I seemed to possess, regarding the imminent air time of our favorite shows. We could be engaged in the most epic Friday evening whiffle ball game EVER, but a few minutes before 8pm, we all became acutely aware that The Incredible Hulk was about to come on, followed by The Dukes Of Hazzard. Throughout the week, our games might be called on account of weather or darkness, but on Fridays, they’d be called on account of Lou Ferrigno (The Hulk) and Catherine Bach (Daisy Duke.) It’s entirely likely that this was triggered by the subtle reinforcement of having viewed a short advertisement earlier in the week, shown multiple times, just to make sure it stuck:
For the record, we didn’t watch Dallas an awful lot. We got sent to bed right about then. In retrospect, I’m glad.
In the present age of Digital TV and programmable DVR’s, I honestly don’t watch too many shows when they’re actually being aired. And with the fast forward function, I don’t catch too many commercials, except when (much to my wife and sons’ chagrin) I back up to see if I might be interested in. And yes, it’s usually food or vehicle-related. I’m usually in the mood for a cheeseburger, and…don’t tell her…but I may be purchasing a pickup truck very soon.
But I digress. I got to thinking about the effectiveness of commercials when I had the pleasure of discussing a blow off application with a caller recently. He was looking for a way to keep the lens of laser sensors clean…there are three sensors located inside his machine, and they are used to check & control the exact positioning of precision machined parts. As good as they are at doing so, just a little bit of coolant spray on the lens will have a pretty bad effect on their operation. When he started describing the sensor to me, I knew exactly what he was looking for, because I’d seen something just like it in a “commercial”…
OK, a Press Release, actually. Now, this is the Model HP1126SS 1” High Power 316SS Flat Super Air Nozzle, which was needed for the aggressive, high temperature environment in which this photo was taken. He didn’t need all that, so he went with the Model 1126 1” Zinc Aluminum Flat Super Air Nozzle, which has more than enough force & flow to blow off a little coolant mist, and is perfectly suitable for use around water-based solutions.
When I showed it to him, he agreed that it was exactly what he was looking for. I feel bad that I neglected to tell our Marketing folks how easy they made it for me to solve this application until now…but they totally rocked it. Thanks!
Our Application Engineers work with them to publish Press Releases, Newsletters, Case Studies, Application Database entries, and more, on a regular basis. I encourage you to check out our Media Center and Knowledge Base (registration required, but it’s free and easy) to get an idea of the full range of our abilities to solve your compressed air product applications. We can start there, and if you ever have any questions, give us a call. We’re eager to help.
Winter is fast approaching us here in Cincinnati, which can mean just about anything, temperature and weather wise. For instance, 2 years ago we had a very mild winter, with warmer than usual temperatures and very little snow. I can remember golfing in December, January and even in to February, which was awesome! But last year however was much different. We experienced a very harsh winter with extreme low temperatures (several -0°F days) and a steady amount of snowfall – I know I felt like I was shoveling the driveway and sidewalk about every 2 days! The weather was so bad that local schools ran out of snow days.
The lower temperatures mean turning up the heat on the thermostat, which is going to dry out the air. As a result of the dry air, a common problem is ESD (ElectroStatic Discharge) or static electricity. All of us at some point have probably brushed our feet on the carpet to build up a charge, then “reached out and touched someone” to give them a little jolt. While this may seem slightly humorous, the truth is, static electricity can be quite problematic.
Some common static issues:
Ion Air Knives – Provides a laminar sheet of high velocity, ionized airflow. Available up to 108” single-piece lengths.
Ionizing Bars – Capable of eliminating surface static within 2” of the bar.
Super Ion Air Wipe – 360° uniform ionized airflow, ideal for ionizing extruded shapes, hose, pipe, cable etc.
Ion Air Cannon – Concentrated ionized airflow, effective up to 15 feet.
Ion Air Gun – Static eliminating, hand-held air gun, allowing easy operation.
Ion Air Jet – Static eliminating spot cleaner, available in permanent or flexible mounting.
Ionizing Point – Single point ionizer, delivering a high concentration of positive and negative ions.
We also offer our Model # 7905 Digital Static Meter, allowing you to pinpoint the source of the static. Capable of reading up to +/- 20 kV with 5% accuracy (+/-) when measured at a distance of 1”.
If you are experiencing a static issue with your process, please contact an application engineer for assistance.
Many times we will be contacted by clients who provide vision inspection systems for a variety of industries. These companies are involved in applications to inspect everything from part conformance to product counting to processes to filling applications.
In the first photo above a customer had their vision inspection system set to inspect the filling of a powder material into its container. The problem is that the fine, dusty nature of the product would cause a small cloud to form near the filling point which would end up settling onto the lens area. Over time, so much build up would occur that the vision inspection system was rendered useless.
The customer had a small air jet set up as shown in the photo on the left, above. The problem with their air jet was that it did not provide full coverage across the width of the lens and allowed dust to still settle there. You can see it in the photo. After the customer contacted us and described the situation and the size of their lens, we recommended model 1122 2” Flat Super Air Nozzle with the thinnest shim available which is .005” thick. The 2″ Flat Super Air Nozzle was able to provide an airflow that covered the full diameter of the lens and blast any debris away. In the end, they removed the homemade small air jet assembly and simply blew air across the lens with EXAIR’s nozzle. See photo on the right above.
Vision inspection cameras, lasers, and sensors are found in a variety of dusty and messy environments. Inspection systems on filling lines, sawing applications, weighing machines and grinding applications are just some of the notoriously problematic processes. If you are involved in a process that has trouble keeping the vision inspection lenses clean, the 2” Flat Super Air Nozzle is a great way to mount an engineered solution that won’t run you out of house and home on your compressed air usage. And best of all, it actually does a good job. If your application is slightly bigger, smaller, dirtier etc., EXAIR’s unmatched selection of nozzle and blowoff products can likely provide a solution.
Neal Raker, Application Engineer