Month: July 2023

Custom Super Air Amplifier

Published on by Jordan T ShouseLeave a comment

A customer called in looking to incorporate some more airflow to help materials flow properly through their processing line. This line included several legacy machines, so we had to get creative to fit something with in the system in place. It just so happened there were several 3/4″ FNPT ports in the sections where the increased air flow was needed!

So we came up with a 3/4″ Super Air Amplifier, 120020. But rather than the typical smooth OD outlet we extended it a bit and put a 3/4″ MNPT thread on the end! See it below next to a photo of the 120020.

Right side is a stock 120020, and to the left is the Custom 120020 with a 3/4″ MNPT threaded outlet!

EXAIR’s Super Air Amplifiers achieve air amplification ratios ranging from 12:1 on our smallest units and up to 25:1 for our 4” and 8” models. EXAIR’s Super Air Amplifiers utilize a patented shim design to maintain critical positioning of component parts. This allows a precise amount of compressed air to be released at exact intervals toward the center of the Super Air Amplifier. This creates a constant, high velocity outlet flow across the entire cross-sectional area. Free, ambient air is entrained through the unit, resulting in high amplification ratios. The balanced outlet airflow minimizes wind shear to produce sound levels far lower than other similar air movers.

Super Air Amplifiers are supplied with a .003” thick shim that is ideal for most applications. Flow and force can be increased by replacing the shim with a thicker .006” or .009” shim. The flow of air is also controlled by adjusting the input pressure supplied to the amplifier. Higher pressures increase both the force and flow, while lower pressures decrease both force and flow. All Super Air Amplifiers are available in kits that come with a shim set as well as a suitably sized pressure regulator and auto-drain filter.

EXAIR has a solution for you if you need to move A LOT of air, even if we need to customize it to fit perfectly in your application. Also, this custom product only took a few weeks to produce, so delivery times are still reasonable!  Reach out to an Application Engineer today if you have an application that you believe could be served with a low-cost, simple solution!

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS

Customized Cooling

Published on by Brian FarnoLeave a comment

Have you ever walked through a production facility and actually looked at and in electrical cabinets? If you did, you would find very few that are identical and even ones that are similar sizes; the internals can be drastically different. When I was in the metal cutting industry customizing, installing, and servicing CNC machines, the same model machine may have different drives for an extra option and can easily add additional heat load to the panel. Bring this up because it’s time we talk about how the dimensions of a panel are not enough to select the level of cooling needed.

Some manufacturers of air movers and “traditional” enclosure cooling method devices will use merely the dimensions of a panel to estimate a heat load and then treat the panel for the worst case scenario. Sometimes it may even be a worst-case scenario for that size of panel. I’m here to tell you from experience that’s not always the best option. This is why we like to have additional information, an “inside man” on the panel, if you will. We want to know exactly what kind of air temperatures we are seeing so that we can use that information combined with some math to determine an acceptable heat load that needs to be dissipated.

The information permits us to size the Cabinet Cooler system for your exact panel; even if you have two that are the same size but one of them has some additional drives or circuits running through it, we can account for that. The reason it is essential to size each panel that has anything different in it is that all devices have some level of efficiency. So the power they consume isn’t 100% converted into their intended function. This results in some level of heat generation. That means different internal components, and different heat loads, easy as that.

This is one of the reasons we took so much care when designing and refining our Cabinet Cooler Calculator. Each variable will impact the heat load and model selection for the Cabinet Cooler System. Some major factors, such as solar heat load and cabinet color, are even accounted for when panels are located outside. We even account for existing fans that will need to be removed to seal the panel. This is because all of these factors directly affect the amount of cooling needed.

Suppose you are looking to cool down some electrical cabinets throughout your facility and want to fully understand what heat load you may need to dissipate and maintain a safe operating environment; check out our Cabinet Cooler Calculator, or contact an Application Engineer today. In that case, we can size the system while we are talking on the phone with you.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

How Does EXAIR Fit Into the NIOSH Hierarchy of Controls?

Published on by Tyler DanielLeave a comment

The Occupational Health and Safety Act of 1970 established the National Institute for Occupational Safety and Health, also known as NIOSH. This organization was founded with the goal of researching worker safety and health, and providing guidelines for employers to create safe and healthy workplace environments. A division of the Centers for Disease Control and Prevention (CDC), NIOSH has been diligently working to ensure that information is accessible to those who want to improve the safety of their operations.

On the NIOSH section of the CDC website, they’ve published a helpful guide for helping you to control and minimize the risk of exposure to hazards in the workplace. This hierarchy of controls provides a framework from most to least effective in terms of the way you manage these hazards and the exposure to your operators. This hierarchy of controls contains (5) levels of actions that can be taken to reduce or remove hazards from the workplace. In order of most to least effective, these controls are:

  1. Elimination
  2. Substitution
  3. Engineering Controls
  4. Administrative Controls
  5. Personal Protective Equipment (PPE)

 The least effective option for mitigating risks may not have been what you originally thought. PPE, or personal protective equipment, is something I’m sure you talk about often with your operators. Would you believe that this is ranked as the least effective method of preventing risks? This is because equipment can become easily damaged, may be uncomfortable and not always used when necessary, or simply used in an improper manner. We’ve all been guilty of doing something that we know we should’ve likely worn some PPE for, just out of convenience. Since it’s so easy to forget or simply not use, it makes PPE the least effective method when it comes to enhancing safety.

Moving up one notch on the scale we have administrative controls. These are also at the lower end of the effectiveness spectrum. These types of controls are centered around making changes to the way personnel works around the equipment. This can be achieved through implementation of training to correct operating procedures, cleanliness of the workplace, personal hygiene practices (proper hand-washing after handling hazardous materials for example). These, again, rely on the operator to listen and act in the way they’re trained.

Engineering controls reside in the middle of the effectiveness range. These are implemented by design changes to the equipment or process that reduces the risk of hazard. These controls can be very effective in protecting people regardless of the actions or behaviors of the operators. They are higher in cost generally than an administrative or PPE control, but can make operating costs lower and allow for a cost savings over the long-term.

Substitution is where EXAIR’s Intelligent Compressed Air Products come into play. By offering engineered solutions that meet or exceed OSHA Standards 29 CFR 1910.242(b) and 29 CFR 1910.95(a), EXAIR’s line of Safety Air Guns, Air Nozzles, and other engineered blowoffs will ensure your operators are not at risk when using our equipment. Anywhere you’re performing some sort of compressed air blowoff process, it’s important to be using equipment designed with safety in mind.

The most effective, but usually the hardest to implement, is elimination. This involves physically removing the hazard from the process. In many cases, a complete elimination is not going to be possible. That’s when you turn to the substitution method and look to EXAIR for a solution.

With years of industry experience under our belt, we’re well-equipped to help you improve safety in your workplace through a variety of off-the-shelf products. Give us a call today and we’ll be happy to discuss how we fit into your facility’s processes!

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

Twitter: @EXAIR_TD

Hierarchy of Controls Image:  used from  Public Domain

A Referral for the Chip Trapper: Made by EXAIR, and Used by EXAIR.

Published on by John BallLeave a comment

Being that EXAIR is a manufacturing plant, we also have CNC equipment that utilizes coolant to reduce tool wear.  The downtime for cleaning and replacing the coolant was too long.  To speed things up, as time is money, EXAIR created a system to clean the coolant and replace it back into the sump.  I want to share the features and benefits that we see in using our EXAIR Chip Trapper. 

One of the biggest issues with coolants is the breakdown of the fluid.  This can be caused by bacterial growth, tramp oils, and a lack of filtration.  Since we began using our Chip Trapper System in our machining area, we’ve seen some great improvements.  I spoke with our lead machinist, and he gave me the following points: 

  • The complete coolant change-out went from every 4 months to once a year. 
  • Reduced the number of barrels of coolant concentrate from 10 barrels to 4 barrels per year.  Roughly $5,000 in annual savings
  • Bacterial growth is dramatically reduced as the Chip Trapper aerates the coolant.
  • Filter bags will remove the chip fines and tramp oils, keeping the coolant fresh. 
  • The time to get the CNC machines back to operational status and making parts went from 2 hours to ½ hour.

CNC machines now come with spindle coolant features.  This new technology helps with the need to increase speeds and feed rates.  The coolant is pumped to the top of the machine and fed directly through the spindle.  This type of spindle uses a rotary union, which keeps the coolant in the spindle while spinning at a high rate of speed.  The rotary union is very expensive and costly to replace.  They are very susceptible to dirty coolant.  If a seal within the rotary union begins to leak inside the machine, you will not be able to diagnose the problem until the machine fails.  The Chip Trapper will help reduce this chance and keep your machine from incurring extreme expenses.

Chip Trapper Cut Away

The unique feature of the Chip Trapper is the vacuum pump.  The vacuum units do not have any moving parts, so they are maintenance-free, quiet, and long-lasting.  Without electric motors, the operator will be safe from electrical shock.  They only require compressed air to operate.  We offer two types: the Chip Trapper System and the High Lift Chip Trapper System.  The Chip Trapper System is a great tool for coolant sumps on the floor level.  The High Lift Chip Trapper System has a bit more power to draw in liquid from sumps below floor level and for fluids with higher viscosity.

EXAIR has three different volumes to select.  We have 30 gallon (113 L), 55 gallon (208 L), and 110 gallon (416 L) drums.  The system comes complete with a drum dolly, a 20 foot compressed air line, a shut-off valve, a chip wand, two 5 micron washable filter bags, and a vacuum hose.  The filter bags can be replaced with ones of a different micron to increase efficiency or filter life.  We have 1-micron, 25-micron, 100-micron, and 200-micron filter bags.  If you are not sure which would work best for your coolant, EXAIR does offer a sample pack that will include one of each micron rating, model 901060-SP.  And if it gets really messy in the machine shop, you can add a Spill Recovery Kit to clean up the liquid off the floor.

If you would like to know more about the EXAIR Chip Trapper System, an Application Engineer will be happy to help you.  You can take advantage of the features and benefits that the Chip Trapper provides: ease of use, extended coolant life, no electric motors to fail, and quick change-over.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb