Truck Headlight Assembly Relies on EXAIR Static Eliminators

This week I was contacted by an automation company who was contracted to assemble new truck headlights. The 2 parts in the process are the lens and the body and they are brought into a machine on 2 separate lines running parallel to each other. A robot arm picks up the lens and holds it in place against the body while a thin layer of glue is placed around the edge. The finished product is then sent down line where it travels under an inspection light to check for any captured debris and to ensure a proper seal. It was at this point they noticed residual internal dust on both pieces which caused an inspection fail and created a large amount of rework and/or scrap, so they called EXAIR for help.

The customer set up an online meeting where they were able to show an illustration of the process. Since these parts are plastic, their potential for holding a static charge increases. These lenses are also recently removed from the mold which may also be causing a static charge as they are separated from the mold. At the time of the call the lenses were brought in 2 at a time, face down over an opening in the bottom of the table where they use compressed air to blow them clean. The customer had not considered that static may be holding the dust on the surface of the lenses and that a static elimination process could provide a solution. The opening under the lenses was approximately 12″ (300mm) long x 6″ (150mm) wide so I recommended using our Model # 111012, 12″ Super Ion Air Knife and mounting the unit under the opening, directing the airflow blow out the inside of the lens. The Super Ion Air Knife produces a high velocity, laminar sheet of ionized airflow across the entire length of the knife capable of dissipating 5kV in .018 seconds when 6″ away and operating at 80 PSIG supply pressure.

Super Ion Air Knife
Super Ion Air Knife available up to 108″ in one-piece construction.

For the body application, the parts were again brought in 2 at a time, face down but there were (2) smaller openings, approximately 4″ (150mm) x 4″ (150mm) so I recommended using (2) of our Model # 7194-9362, Stay Set Ion Air Jets and mounting one unit at each opening. blowing back up inside the body.  The Stay Set Ion Air Jet produces a more focused ionized airflow and allows you to bend the hose to deliver the airflow to the critical area.

Stay Set Ion Air Jet easily directs ionized airflow and holds position.

Since both processes are being performed in close proximity, on one machine, they were able to use our Model # 7940 Power Supply (115V, 50/60Hz) with 4 outlets to operate all 3 ionizers, simplifying the setup and installation.

If you are experiencing a static issue in your facility, give us a call, we are here to help.

Justin Nicholl
Application Engineer


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