Video Blog: EXAIR Swivel Fittings

A brief video showcasing the full EXAIR Swivel fittings offering. Each of the 9 Swivel Fitting models offers a 25° from center line adjustment for a total of 50° full range of adjustment. The Swivel fittings are an ideal accessory for a variety of EXAIR products.  For more product details see our product page.  For any questions or fitment suggestions contact an Application Engineer.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

Cooling Nylon Parts and Brushes with the Adjustable Spot Cooler

A robotics company called last week looking for a recommendation for a cooling device to use in their nylon plastic machining operation. They have a six axis robot, fitted with abrasive brushes, that “cleans” the part profiles as they are being moved from the milling area to the inspection location. The brushes were effective in removing the fines and particulate from the parts but they were starting to experience an increase in the amount of rejects as the brushes were generating heat, causing deformities to the profile.

Their initial thought was to use a liquid type method of cooling but with the parts having some small recesses and cavities that might trap fluid, this wasn’t going to be a reliable option for them. Another area of concern with using an air cooling device, was if the airflow was too forceful, the smaller parts they process may have the potential to “move” while being held by the robotic arm which could scratch or blemish the part.

After further conversation about the process, I recommended they use our Adjustable Spot Cooler in the application. The Adjustable Spot Cooler incorporates a Vortex Tube to produce a cold airstream as low as -30°F with an ambient air supply temperature. Using the temperature control valve, they can easily adjust the temperature drop and the volume (SCFM) of air being exhausted, to “dial” in the device to provide an adequate level of cooling while controlling the outlet flow to not disrupt the hold on the part itself. With the integral magnetic base and flexible tubing, they could easily mount the unit to the arm of the robot while directing the cold air to blow across the brushes and the part to keep them cool.

Model # 3825 Adjustable Spot Cooler System includes 2 extra generators to allow for more or less cooling capacity and airflow.

EXAIR offers a wide variety of spot cooling products for many different processes and uses. For help selecting the best option to fit your need or to discuss another product, give me a call, I’d be happy to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

 

 

 

Atomization Nozzles For Better Grain Processing

I have been working with a customer from the grain milling industry.  They take a grain like corn, and mill it to sizes that range from coarse product like grits to fine product like flour. The customer had a special application where steam was injected into a mixing screw process to add moisture to the grain.  Steam can be expensive and dangerous to work with, due to the energy required to make, store, transport and use, along with the high temperatures and pressures involved.

The customer was aware of our products from previous work we had done involving Super Air Knives.  He approached me about the Atomizing Nozzles and whether they could be used to replace the steam injection system.  We reviewed the process details such as target flow rate, the spray pattern desired, and the available distance from the target we had to work with.   We determined that (3) of the EF1030SS – External Mix Flat Fan, each capable of delivering 14 Gallons Per Hour, were the solution.  The nozzles would be placed equidistant along the mixing screw, to provide an even delivery of water.

ef1030ss

EF1030SS

 

To operate the nozzles, all that is needed is a supply of water, and 3.5-15.1 SCFM of compressed air at 10-95 PSIG.  Varying the liquid and air pressure will change the flow rate and pattern size of the spray.  Charts are published to help with the set-up and tuning of the nozzles to match the process needs.

CaptureCapture

The use of the Atomizing Nozzle allows for precise application of very fine droplets.  For the External Mix type, droplets sizes of 39 to 57 micron are possible.  Smallest droplet size is achieved by operating at higher air pressures and lower liquid pressures.

EXAIR also manufactures Internal Mix type nozzles and even a Siphon type, that can operate under siphon or gravity fed conditions  (no liquid pump/pressure is required.)  Nozzles are available with flow rates from 0.1 to 303 Gallons per Hour, in flow patterns such as Narrow Angle Round, Wide Angle Round, Flat Fan, and 360° Hollow Circular.

To discuss your application and how the EXAIR Atomizing Spray Nozzle can be a benefit at your facility, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Twitter: @EXAIR_BB

A Cold Gun Increase Speed for a Reel Manufacturer

When it comes to die stamping, friction generates heat.  Heat can be a big cause in slowing production and decreasing tool life.

Reel Film

A reel manufacturer was seeing the effects of the heat in their process.  They had a stamping machine that was creating sprocket holes in the outer edge of a 35mm film.  These holes are used for advancing the reel strip through printers, projectors, and processing machines.  They had to be particularly careful, as film materials warp easily with heat.  Some of us remember the film reels that would bubble and burn out when the film stopped in the projector.  (I am giving away my age a bit).  So, speed was critical as they did not want to create any quality issues.

They were intrigued with the EXAIR Vortex Tubes as it can generate cold air by only using compressed air.  Vortex Tubes do not use refrigerants or have any moving parts.  They are very compact and can fit into tight places.  If they could reduce the temperature in the stamping process, then they could speed up production.

Compact Vortex Tube

With the Vortex Tubes, EXAIR adds accessories to help with installations for different applications.  For this customer, the Cold Gun Aircoolant System was the best product to deliver the cold air.  I recommended the model 5315 Cold Gun System.  This product generates 1000 BTU/hr of cooling power, and it has a Dual Point Hose Kit to target both sides of the film reel.  It includes a magnetic base to securely position it on the stamping machine, and two 1” flat nozzle ends to attach at the end of the Dual Point Hose Kit.  These flat nozzles would help to direct the cold air in between the two stamping plates.   They were able to keep the film reel and the die stamp cool as they sped up their operation.  Even with the additional speed, they also noticed that the die stayed sharper 20% longer before they had to rework.

Cold Gun with Dual Hose Point

If you believe that heat is slowing down your system, EXAIR may have a product to keep it cool.  With the customer above, heat was a “reel” problem.  With the Cold Gun System, we were able to increase their productivity and decrease their downtime.  You can contact an Application Engineer to discuss your application if you believe that temperature is affecting your process.

 

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Photo: Movie Reel Film Cinema by JanBaby.  Creative Commons CC0 Public Domain.

Another Unique Solution in an Aluminum Processing Plant

Fine dust particles needed to be removed from this belt on the underside of a conveyor

A few months back I wrote about the impact of installing Super Air Knives in an aluminum processing plant.  Those Super Air Knives solved a recurring problem with cleaning alumina dust around conveyors and reduced costs for the end user by over $80k.

That same customer has also found a method to remove fine dust from the underside of the conveyor belt in an application area not suitable for an Air Knife.  In this application there was no dust collection system in place to carry away the fines as they are blown off of the belt, so a different type of solution was needed.

Model 150200 Heavy Duty Line Vac provides the vacuum needed to remove the dust fines.

That solution was to install a Heavy Duty Line Vac affixed to a vacuum hood to remove fines from the belt and convey them back to the head chute.  The only problem with this setup was that the 2” Heavy Duty Line Vac produced a bit too much vacuum flow than what was really needed in the application.  So, a pressure regulator was installed to allow for adjustment and fine tuning of the vacuum solution.  The customer was able to adjust the operating conditions for the Line Vac and minimize compressed air use while maximizing the vacuuming effect on the fines stuck to the conveyor.

The Line Vac used in this application quickly and easily solved a chronic problem plaguing this manufacturer.  By installing this vacuum solution they were able to prevent build-up of dust and debris underneath the conveyor which originally required shutting down the line to clean.  This improved process uptime, reduced cleaning costs, and increased throughput in the application.

If you have an application in need of a vacuum solution, consider an EXAIR Line Vac.  And, if you have any questions, contact an EXAIR Application Engineer.  We’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Music And The Mini Cooler

Recently, EXAIR Corporation offered CPR (cardiopulmonary resuscitation) training to employees. I already carry certification, so I held down the fort while some of the other Application Engineers received this training. As a middle aged man, I have to admit that my interest in my co-workers’ abilities to respond to a matter of this nature is not entirely unselfish.

One of the key parts of CPR training is the rate of the chest compressions. While most people couldn’t accurately replicate 100 beats per minute on demand, almost everyone is familiar enough with some popular songs with a rhythm close to that.  The song they always bring up in CPR training is “Stayin’ Alive” by the Bee Gees. Depending on how you feel about disco, another option is “Another One Bites The Dust” by Queen. Pro tip: it might be considered bad form to sing that one out loud while performing CPR.

Speaking of music, while I was holding down said fort during this morning’s training session, I had the pleasure of assisting a caller in the music business: a piano restoration & tuning professional. A frequent job for them consists of resetting tuning pins, which requires drilling numerous small holes (a grand piano can have as many as 250) into a hardwood board. They’re pressed in, so it’s critical that they fit the newly-drilled hole precisely. If the drill bit gets too hot, it can expand in diameter, making the hole ever-so-slightly bigger than it should be. The heat can also cause the surface of the hole ID to glaze. Both of those things can cause problems with the pin fitting securely in the hole.

The EXAIR Model 3808 Mini Cooler System was an ideal solution – it’ll keep the drill bit cool & clean with a constant stream of cold air. It’s compact and quiet, and only uses 8 SCFM @100psig…well within the capacity of many smaller air compressors.

If you’d like to “get in tune” with a spot cooling solution, I can help…call me. Oh, and in case you wanted to know which song with about 100 beats per minute I’d use for CPR:

Russ Bowman
Application Engineer
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Increased Temps = Time For A Cabinet Cooler

This past Monday, we kicked off the start to the new Spring season, which means warmer temperatures are in the forecast. Here in Cincinnati, we are expecting temps in the low 40’s up to the high 60’s. We’ve written a couple blogs in the past few weeks about the changes in temps and weather and the proverbial “spring cleaning” and the use of our Vacuum Systems for industrial cleanup.

Another area of concern relating to the increased temps is the overheating and contamination of electrical control panels in industrial environments. As the temperatures go up, many companies are looking for a fast solution and will open the doors on the panel and use a fan to blow air across the sensitive controls. While this method does provide some cooling and seems like a quick fix, you are also introducing dirty, potentially humid air into the enclosure which can result in failures and lost production.  Not to mention, this is an OSHA violation which can lead to potential injury to operators  and/or costly fines.

What seems like a simple fix is actually a BAD idea!

EXAIR’s Cabinet Coolers are a reliable, maintenance free way to keep electrical enclosures cool, dry and clean. The Cabinet Coolers are compressed air operated, with cooling capacities ranging from 275 Btu/hr. up to our largest Dual System of 5,600 Btu/hr. The units discharge the cold air into the cabinet at a slight positive pressure which expels the hot, dirty air, leaving only the cool, clean, dry air from the system. Systems are available for continuous operation, maintaining a 45% relative humidity on a completely sealed cabinet, ensuring no condensation develops inside the cabinet. Our Thermostat Controlled Systems are available in 120VAC, 240VAC or 24VDC, providing a more economical operation by only using compressed air when needed to reach the desired temperature set point. Our thermostats are preset at the factory to 95°F but are adjustable to meet your specific temperature requirement.

How the EXAIR Cabinet Cooler System Works

In order to properly recommend a unit, we need to know the internal heat load of the cabinet or watt loss of the controls inside. We realize this information is sometimes not readily available, so to help simplify the process, we have a Sizing Guide available, which provides the pertinent information requited to calculate the current load. Of course, you can always give us a call and an application engineer can help you over the phone as well.

Cabinet Cooler Sizing Guide

 

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

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