Eliminating False Image Readings Using The Gen4 Stay Set Ion Air Jet

I was recently contacted by a medical device manufacturer who was interested in implementing a Static Eliminator in their production process. They have a manually operated vision station where a plastic substrate, about the same size as a credit card, is placed into a nest then a small amount of liquid is deposited onto the surface. An operator takes a picture of the liquid and substrate and the image is analyzed. The part is stationary in the nest until the image is taken.  When the station is done, the plastic part is manually removed from the nest.

After some internal testing, they determined that static build up on the plastic part was causing the liquid to move, or “bounce” as they placed it, which was leading to a significant drop in their manufacturing yield due to faulty readings. The cycle time from taking the initial  image and the analysis results is roughly 2 seconds so they were needing something that would quickly remove the charge on the plastic part.

The customer was able to email some photos and after further review, EXAIR recommended they use our Gen4 Stay Set Ion Air Jet in the process. The Gen4 Ion Air Jet is a compact ionizer delivering a quiet, focused ionized air stream to quickly eliminate the static charge on the surface of a material or object. Operating at 20 PSIG, the Gen4 Ion Air Jet is capable of dissipating a 5kV charge in 0.45 seconds while maintaining a low sound level of only 67 dBA. The Ion Air Jet entrains ambient air at a rate of 5:1 and the airflow can be adjusted from a “blast” to a “breeze” simply by increasing or decreasing the inlet pressure. The Gen4 Stay Set Ion Air Jet includes our 12” Stay Set Hose which holds position until it is physically repositioned and a magnetic base for easy installation.

If you have an application that requires a concentrated, ionized airflow or for help with selecting the best product to fit your need, give me call at 800-903-9247 for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Product Overview – High Lift Reversible Drum Vac

Are you needing to move a thick fluid, move liquid farther or higher? Do you have a below grade sump or pit you’re looking  to empty? Then EXAIR has the solution for you, enter the High Lift Reversible Drum Vac. Like the standard Reversible Drum Vac, the High Lift RDV is a compressed air operated, liquid only vacuum with no moving parts or motors that can fail,  like those in traditional electrically powered vacuums. What separates the High Lift RDV from the traditional version is the higher vacuum it achieves which allows you to lift liquids up to 15′, move liquids up to 20′ and handle fluids with viscosity as high as 1400 centipoise.

The High Lift Reversible Drum Vac is a high powered vacuum able to lift liquids up to 15′ and fill a 55 gallon drum in less than 85 seconds!

The High Lift Reversible Drum Vac features a two-way pump constructed of stainless steel and a built-in safety relieve valve to avoid over pressurizing or over-filling the drum. Air consumption is minimal, at 43 SCFM @ 80 PSIG, while maintaining a low noise level of only 83 dBA. In “empty” mode, the HLRDV achieves a flow rate of 30 gallons per minute (water) to quickly empty the drum.

Systems are available in 30, 55 and 110 gallon capacities in 3 different variations:

The Standard Systems include the High Lift Reversible Drum Vac, shutoff valve, 20′ vacuum hose, standpipe, 90° quick release elbow and aluminum chip wand.

Model # 6195, 6195-30 and 6195-110

Deluxe Systems include all of the items shown above in the “Standard” System and adds a drum dolly, ABS plastic spill recovery kit, (2) extension wands, crevice tool, skimmer tool and a magnetic tool holder.

Model # 6295, 6295-30

And Premium Systems include all of the items in “Deluxe” Systems and adds the drum with lock ring and lid, heavy duty aluminum tools and 20′ compressed air hose.

Model # 6395, 6395-30, 6935-110

EXAIR Products: Silencing Mufflers Overview

OSHA Standard 29 CFR 1910.95(a), relating to permissible noise exposure levels, states that when employees are subjected to sounds in excess of 90 dBA, some type of control should be used to reduce the sound level. In an industrial setting, it’s very common to find the exhausting air from air operated devices such as actuators, diaphragm pumps or cylinders for example, to produce sound levels well above the allowable limits set forth in the Standard. EXAIR offers a variety of different Silencing Mufflers that help to reduce this  noise level, while also increasing operator safety.

 

Reclassifying Mufflers are available in 1/8″, 1/4″, 3/8″, 1/2″, 3/4″ and 1″ NPT sizes

EXAIR’s Reclassifying Mufflers offer noise reduction up to 35 dB and are available in sizes ranging from 1/8″ to 1″ NPT. These types of mufflers are often considered”dual-purpose” as they not only reduce the noise level but also remove oil from the exhaust airflow by incorporating a removable filter element.  The exhausting oil mist is reduced from 50 PPM (parts per million) to only 0.015 PPM, when the device is operated at 100 PSIG. In addition, there is a bowl on the bottom to capture any residual oil and a 1/4″ tube adaptor to allow for easy draining.

Sintered Bronze Mufflers are available in #10-32, 1/8″, 1/4″, 3/8″, 1/2″, 3/4″, 1″, 1-1/4″ and 1-1/2″ NPT sizes, as well as 1/2-20 UNF female for use with solenoid valves
Straight Through Mufflers are available in 1/4″, 3/8″ and 3/4″ MNPT x FNPT

Sintered Bronze Mufflers are a relatively low cost option, commonly used with air cylinders as they can be installed quick and easy. We offer 1o different sizes, ranging from #10-32 for small installations, up to 1-1/2″ NPT for larger scale applications. The noise reduction depends on the size of the muffler and back pressure, which can occur from dirt or particulate clogging the muffler, restricting the exhausting airflow from passing through the porous sintered bronze.

Our Straight Through Mufflers are made of corrosion resistant aluminum and are lined with a sound absorbing foam, capable of reducing noise levels up to 20 dB. We offer 3 different sizes, 1/4″, 3/8″ and 3/4″ NPT, with a male thread on one end and female thread on the other. We incorporate this muffler design into our Cold Guns and Adjustable Spot Coolers and they are commonly used with our Vortex Tubes, Cabinet Cooler® Systems and E-Vac® Vacuum Generators as well.

Heavy Duty Mufflers are available in 1/4″ and 3/8″ FNPT

Lastly, the Heavy Duty Mufflers feature an internal, 50 mesh stainless steel screen, to protect against contaminants in the airflow,  and a corrosion resistant aluminum outer shell. In most cases, the sound reduction can be as high as 14 dB and we offer 2 different sizes, 1/4″ and 3/8″ FNPT. These types of mufflers are regularly used on the hot air exhaust of our Vortex Tubes.

For help with product selection or to discuss a particular process, please contact one of our application engineers at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Adjustable Spot Cooler Provides Needed Cooling In Sunglass Lens Manufacturing

A little while back, I worked with a large eyeglass manufacturer on a sunglass lens cooling application. In their setup, they were dry cutting film-coated lenses with a router and after the lenses are cut, they are passed through several different rinse cycles and inspected for scratches or other damage. They were seeing a high number of reject parts and determined that the heat being generated by the tooling, was causing the irregularities. In an effort to alleviate the condition, they used a section of open flexible tubing to blow compressed air at the bit, which helped a little, but they were still concerned with the amount of scrap material.

I recommended they use our Model # 3825 Adjustable Spot Cooler System in the process. The Adjustable Spot Cooler incorporates a Vortex Tube to provide a temperature drop from the incoming supply air temperature. Using the temperature control valve, the exhausting air temperature and flow can be adjusted to fit the application. The system includes a flexible hose to focus the cold air to the desired area until re-positioned. The system also features a magnetic base that allows for easy mounting. By incorporating the filter separator included in the system, they can remove any moisture and/or contaminants in the air supply, relieving any concern with contamination or damage to the part.

Model 3825 Adjustable Spot Cooler System

If you have a cooling application you’d like to discuss or for help selecting the best product to fit your need,  give me a call at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

sunglasses image courtesy of passer-by via creative common license.

 

People of Interest: Daniel Bernoulli – 2/8/1700 to 3/17/1782

Daniel Bernoulli was born in Groningen, Netherlands on February 8, 1700  and was part of a large family heritage of famous mathematicians – His father Johann Bernoulli, one of the first founders of calculus, his uncle Jacob Bernoulli and his older brother Nicolous. When he was only 7 years old, Daniel began to take an interest in mathematics but his father convinced him that there was no financial gain to be had in mathematics and recommended he focus his studies in business instead. Reluctant at first, Daniel would take his father’s advice under the one condition, that his father would tutor him in calculus and his theories of kinetic energy.

At 13 years old, Daniel attended Basel University where he studied logic and philosophy completing his bachelor’s degree by the age of 15 and earning his master’s degree just 1 year later. Over the years, Daniel’s relationship with his father was strained as a result of him plagiarizing his father’s findings. Eventually, his father passed without reconciling with Daniel. At 24, Daniel became a Professor of Mathematics  at a University in Venice but resigned from the position just 9 years later in 1733.

His most recognized mathematical contribution, Bernoulli’s principle, came in 1938 while performing energy conservation experiments, and he published the results in his book entitled Hydrodynamica . He discovered that when fluid travels through a wide pipe into a smaller, more narrow pipe, the fluid begins to move  faster. He determined that the volume or amount of fluid moving through the pipe remains unchanged but will conform to the shape of the pipe or container as it flows. He concluded that the higher the pressure, the slower the flow of the liquid and the lower the pressure, the faster the liquid flow.

The same principle can be applied to air. As air moves around an obstruction or object, it follows the profile of the part and begins to speed up.

Take for example our Super Air Nozzles. The compressed air exits the nozzle through a series of jets which induces a low pressure around the profile of the nozzle, drawing in ambient air. This entrainment of air, up to 25 times or more, results in a high outlet flow at minimal compressed air consumption.

Super Air Nozzle air entrainment

Many of the products offered by EXAIR incorporate this science which can lead to a more efficient operation by lowering compressed air demand ultimately reducing operating costs. To see how our products can help you save money while increasing process performance, contact an Application Engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Bildnis des Daniel Bernoullius image courtesy of Universitätsbibliothek Leipzig via creative commons license

 

Improving Auger Cleaning Process Using 2″ Flat Super Air Nozzles And Swivels

I recently worked with a customer who was looking to improve the cleaning process on the  inside of one of their screw augers. They were currently using a couple of 1/4″ pipes as air wands to clean the left over powder on the auger blades and direct it toward a chute at the bottom which fed into another auger used for recovery. While the setup worked somewhat, they were concerned with the amount of air they were using as well as the OSHA safety concerns associated to using open ended pipes and excessive noise levels.

The customer was able to send a sketch of their current setup and after some further conversations, I recommended our Model # 1122 2″ Flat Super Air Nozzle and our Model # 9053 1/4″ NPT Swivel Fitting. The 2″ Flat Super Air Nozzle produces a 2″ wide, high velocity laminar airflow and uses only 21.8 SCFM (80 PSIG) while maintaining a low sound level of only 77 dBA. The Swivel Fitting allows for 50 degrees of movement, so they can achieve the best angle to direct the air to the critical areas.

2″ Flat Super Air Nozzle
Swivel Fittings available from M4 up to 1″ NPT

All of our Air Nozzles are engineered to meet or exceed OSHA Standard 1910.24(b) for 30 PSIG dead end pressure, they cannot be dead-ended, there is always a path for the air to safely exit so the outlet pressure will never reach 30 PSIG. In addition, our products are going to meet the OSHA Standard CFR 29 – 1910.95(a) for allowable noise exposure levels as well.

If you are looking to reduce air consumption and noise while improving operator safety, give us a call at 800-903-9247 for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Order An Industrial Vacuum System Through 5/31/18 And Receive A Free Vac-u-Gun

From now through May 31, 2018, we are offering a FREE Vac-u-Gun with any order for one of our Industrial Housekeeping Vacuum Systems. The Vac-u-Gun is a multi-purpose tool that can be used to vacuum or transfer material from one location to another or it can be used as a powerful blow gun to clean debris off of the surface of a part or workstation. There is no electricity required to operate and no moving parts to wear out, providing for a safe, maintenance free operation.

Change from a vacuum gun to a blow gun in a matter of seconds!

When choosing one of our vacuums, selection can be simplified depending on what type of media you are needing to pickup. Our systems are going to be either solids handling or liquid handling.

Our Chip Vac Systems are the ideal choice when looking to vacuum dry or damp debris left over from machining operations and delivers them to a standard open top steel drum. For more abrasive material, such as sand or steel shot used in sandblasting processes, the Heavy Duty Dry Vac provides superior wear resistance due to it’s proprietary hardened alloy construction.

If you are looking to vacuum liquids we offer our Reversible Drum Vac and High LIft Reversible Drum Vac providing higher suction lift, up to 180″ H2O.

Our Chip Trapper and High Lift Chip Trapper are also used in liquid applications but these systems incorporate a filter bag inside the drum to capture any suspended solids in the liquid so only clean fluid is pumped back into the reservoir or tank.

In dusty applications we offer the Heavy Duty HEPA Vac which uses the same vacuum as the HD Dry Vac but this system provides a higher level of filtration meeting HEPA requirements of 99.97% filtration at the 0.3 micron level.

All of these products are In-Stock, Ready To Ship.

To take advantage of the offer, you need to order using the promotional Model number. Ordering is easy – you can email the order to orders@exair.com or place your order online at www.EXAIR.com. If you’d rather place your order over the phone or have any technical questions about our products, you can call us at 800-903-9247 and one of our reps will be happy to assist.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN