Super Air Wipe Vs. Block Type Air Wipe

When you need to cool, blow off or dry extruded objects there are several options available, however only the EXAIR Super Air Wipe delivers the performance, efficiency and versatility that most applications require!  In today’s blog we will contrast some of the differences between the EXAIR Super Air Wipe and block type air wipes.

The split-ring design of EXAIR’s Super Air Wipe offers easy clamping around the surface of the material moving through it and eliminates the need for time-consuming, cumbersome threading.  While Block Type Air Wipes are also of split design the diameter of the material drawn through it can typically only vary by approximately 1/16″!  In contrast the EXAIR Super Air Wipe is effective on materials that can range in size from approximately half the throat diameter up to within a fraction of an inch on the internal diameter.  This range can be as large as five to six inches in our largest Super Air Wipes.  The key is to ensure the material does not contact the Super Air Wipe.

Mounting the EXAIR Super Air Wipe is a snap, it can be accomplished by using either the 1/4 – 20 tapped holes on the downstream side or by utilizing a hard pipe compressed air supply line.  The access to these bolt holes makes it easy to change out in the event the production line runs several different sizes. If needed the included stainless steel 1/4-20 bolts can also be removed and longer bolts could be installed to mount from either side.

Connecting the EXAIR Super Air Wipe to your compressed air supply is straightforward.  For sizes up for 4″ throat diameter a stainless steel braided connecting hose is supplied pre-installed from the factory and a single 1/4″ FNPT inlet is used to supply the entire wipe.  For the 5″ up to 7″ throat diameter there is a single 1/4″ FNPT inlet on each half of the wipe which would need to be connected with compressed air.  Lastly, the 9″ and 11″ sizes from stock each have two 1/4″ FNPT inlet on each half of the wipe which would need to be connected to provide the appropriate flow for optimal performance.

split design1
EXAIR Super Air Wipe features hinged design for trouble-free threading

Another very important consideration is the temperature of the material you are running.  EXAIR Aluminum Super Air Wipes are rated for temperatures up to 400°F (204°C) with the Stainless Steel models rated up to 800°F (427°C).    Typically, block air wipes are made from delrin or polypropylene with a replaceable wear liner,  unfortunately these materials do not tolerate higher temperatures like the EXAIR Super Air Wipes.

Super Air Wipe extrusion save
EXAIR Super Air Wipe cooling an extrusion, high temperatures are not a problem!

To explain how the EXAIR Super Air Wipes work, reference the animation below: Compressed air flows through the inlet (1) of the Air Wipe into the annular chamber (2).  It is then throttled through a small ring nozzle (3) at high velocity.  This primary air stream adheres to the Coanda profile (4), which directs down the angled surface of the Air Wipe.  A low pressure is created at the center (5) inducing a high volume flow of surrounding air into the primary airstream.  As the airflow exits the slot, it creates a conical 360° ring of air that will attach to the surface of the material running through it (6) uniformly wiping the entire surface with the high velocity airflow.

sawworksani
How The Super Air Wipe Works

While block style air wipes have a  fixed performance because they operate off a series of non-adjustable drilled holes, the EXAIR Super Air Wipe operates off an adjustable shim design.  As shown in the figure above the shim sets the gap opening of the ring nozzle (3).  The stock thickness of the stainless steel shim is .002″ (.05mm), shims can be stacked to provide a coarse adjustment in volumetric air flow.  Custom shim thicknesses are also available to tailor the performance to your needs.   The shim thickness coupled with a pressure regulator gives the Super Air Wipes adjustability from a gentle breeze to remove light debris or provide cooling all the way up to a forceful blast to remove more viscous fluids or provide quick cooling.

The EXAIR Super Air Wipe is 1.13″ (29mm) thick on all (11) Aluminum models that range in size from 3/8″ (10mm) to 11″ (279mm) throat diameter and all (5) Stainless Steel models that range in size from 1/2″ (50mm) to 4″ (102mm).

Super Air Wipe Family Photo

The Aluminum Super Air Wipe is available in 11 sizes 3/8″, 1/2″, 1″, 2″, 3″, 4″, 5″, 6″, 7″, 9″ & 11″; the Stainless Steel Super Air Wipe comes in 5 sizes, 1/2″, 1″, 2″, 3″ & 4″…all from stock!

So when you need to cool, blow off or dry extruded material or need expert advice on safe, quiet and efficient point of use compressed air products, give us a call.  We would enjoy hearing from you!

Steve Harrison
Application Engineer
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Super Air Wipe Overview

What do you do when you need to cool, blowoff, or dry extruded objects? How will you support the products to do these tasks, and how will you get your extrusions through them? Consider using engineered compressed air products air for these applications to provide instant on/off capability, fine tuning adjustment of the air flow, low noise levels and OSHA safety. The EXAIR Super Air Wipe is designed to work well with continuous production products like extrusions, wire and cable.

Super Air Wipe extrusion save
Implementing a Super Air Wipe salvaged a $30,000 job for this customer. Read all about it in our Case Study Library (registration required)

The Super Air Wipe is a highly efficient compressed air powered device that provides a uniform 360° air stream that is ideal for blowoff, drying, cleaning and/or cooling of pipe, cable, extruded shapes, hose, wire and more.

The clam shell design of EXAIR’s Super Air Wipe offers easy clamping around the surface of the material moving through it that eliminates the need for time-consuming and cumbersome threading.  All models utilize stainless steel screws and shims and for sizes up to 4″ (102mm) a Stainless Steel wire braided connecting hose is included.  Aluminum models are rated for temperatures up to 400°F (204°C) and stainless steel models for temperatures up to 800°F (427°C).

Mounting the EXAIR Super Air Wipe is very easy, it can be accomplished by using either the 1/4 – 20 tapped holes on the downstream side or by utilizing a hard pipe compressed air supply line.  Connecting the EXAIR Super Air Wipe to your compressed air supply is straightforward, there are (2) 1/4 FNPT compressed air inlets on throat sizes up to  7″ (178mm) diameter (one on each half), while the 9″ (229mm) & 11″ (279mm) diameters have a total of (4) 1/4 FNPT compressed air inlets (two per half) to ensure proper air volume for maximum performance.

Prior to the introduction of the Super Air Wipe, one way to blow off, dry, or clean extruded objects was to use a ring of air nozzles. The high air consumption and noise levels of the nozzles along with inconsistent air velocity often delivered poor results.

 

ring nozzle blow off

The Super Air Wipe, which is similar to the construction of EXAIR Super Air Knife provides a high volume, high velocity airflow that is uniformly ejected from the entire 360° of its inner diameter. The airstream adheres to the surface of the material running through it (Coanda Effect) to effectively wipe, clean or dry surfaces.

To further explain how the EXAIR Super Air Wipes work, reference the animation below: Compressed air flows through the inlet (1) of the Air Wipe into the annular chamber (2).  It is then throttled through a small ring nozzle (3) at high velocity.  This primary airstream adheres to the Coanda profile (4), which directs down the angled surface of the Air Wipe.  A low pressure is created at the center (5) inducing a high volume flow of surrounding air into the primary airstream.  As the airflow exits the slot, it creates a conical 360° ring of air that will attach to the surface of the material running through it (6) uniformly wiping the entire surface with the high velocity airflow.

sawworksani
How The Super Air Wipe Works

The EXAIR Super Air Wipe is 1.13″ (29mm) thick on all (11) Aluminum models that range in size from 3/8″ (10mm) to 11″ (279mm) throat diameter and all (5) Stainless Steel models that range in size from 1/2″ (50mm) to 4″ (102mm).   The performance can be altered by changing the inlet air pressure or by adding an additional shim, which will nearly double the force!

Super Air Wipe Family Photo
The Aluminum Super Air Wipe is available in 11 sizes 3/8″, 1/2″, 1″, 2″, 3″, 4″, 5″, 6″, 7″, 9″ & 11″; the Stainless Steel Super Air Wipe comes in 5 sizes, 1/2″, 1″, 2″, 3″ & 4″…all from stock!

So when you need to cool, blow off or dry extruded objects or are looking for expert advice on safe, quiet and efficient point of use compressed air products, give us a call.  We would enjoy hearing from you!

Steve Harrison
Application Engineer
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Gen4 Super Ion Air Wipe Eliminates Static on Bottling Line

Just recently I worked with our Distributor in Argentina on an application for a manufacturer of bottled water. Once the bottles are filled, a protective security seal is placed along the top of the bottle. This serves two purposes, it prevents any form of tampering as well as keeps the cap of the bottle clean throughout the rest of the manufacturing process. Since most people drink directly from the bottle, this area needs to remain clean and not be exposed to contamination later on in the process.

Their problem was that static was building up on this plastic which caused an improper seal on the cap of the bottle. Further down the processing line, the bottles can be exposed to water that contaminates the bottles. They had to implement an inspection process as it was not acceptable to allow any contaminated bottles to leave the plant. Without a solution, they were losing time due to the necessary inspection as bottles were being rejected at a rate of almost 30%.

IMG_2625

The recommended solution was to install a Model 8164 4″ Gen4 Super Ion Air Wipe just prior to the point in the process where the seal was applied. The plastic material passed through the center of the Super Ion Air Wipe which neutralized the static charge on the material. Without a charge, the seal was applied correctly and they were able to eliminate the need of a manual inspection. After installation, the reject rate dropped to 0%!!

The Gen4 Super Ion Air Wipe provides a uniform 360° ionized airstream and is available in both 2” and 4” ID sizes. Its clam-shell design makes it easy to clamp around a part for neutralizing static electricity and contaminants. The high volume, high velocity airflow attaches itself to the surface and wipes it down with static eliminating ions. The airflow stays attached to the surface and is effective up to 15’ away from where it’s mounted. It’s lightweight and easy to mount using the ¼-20 tapped holes on the back or can also be held into place with just rigid pipe.

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As the temperatures begin to decline, so does the humidity in the air. Drier air results in an increase in static problems. Get ahead of it this year and check out EXAIR’s wide line of various Static Elimination products, all available to ship same-day from stock!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

EXAIR Super Air Wipe Greatly Increases Productivity & Saves Money!

Late last year I received a call from a customer that was using EXAIR Super Air Knives to create an air curtain that protected the lens on their Robotic Welders from weld spatter.  The EXAIR Super Air Knife accomplished this by virtue of its design to deliver a uniform sheet of laminar air flow across its entire length.  While this greatly improved the life of the welder lens and reduced maintenance time, further improvements were needed.

The event that triggered this was the challenge they received from their customer (one of the big 3 automobile manufacturers) to increase their output of welded seat frames by 50%.  While the EXAIR Super Air Knives greatly reduced lens maintenance the consensus was further improvements would facilitate the goal of increasing output 50% .

Super Air Knife laser application
Using the Super Air Knife to protect the welding lens

 

This started the discussion on the possibility of using the EXAIR Super Air Wipe, even though it is primarily used for drying/cleaning of long continuous flow products its airflow pattern (see illustration below) was able to direct the weld splatter down and away from the lens.  This ultimately proved to be more effective at protecting the lens than the laminar air curtain provided by the EXAIR Super Air Knife.

Air Wipe - how it works
Air Wipe – How it work

The installation of the EXAIR Super Air Wipes started on 12/16/2017 and was completed on 12/23/2017. The original production rate was 480 pair of SUV rear seat frames per day running 3 shifts 24/6.

Laser Above SAW Front
Robotic Welder fitted with EXAIR Super Air Wipe

After the Installation of the EXAIR Super Air Wipes, they had improved the production rate to 750 pair/day running 3 shifts 24/5 days per week.  That equates to a productivity increase of 156%, far exceeding the goal of 50%!

Before using the EXAIR Super Air Wipe their maintenance department would clean the Cover Slide on the Laser Welding Head – 3 times per day at approximately 20 min x 3x daily x 6 days / week 6 hours / week.  “With the EXAIR Super Air Wipe we found that we can weld for 10 days before cleaning the Cover Slide” says the customer.

Each Cover Slide costs $195 and those were being replaced weekly, it was a pleasant surprise to find out that only a small amount of dust collects on the Cover Slide now, which is cleaned off in less than a minute

In 10 weeks of Operation they have not replaced a single  Slide since the EXAIR Super Air Wipe has nearly eliminated pitting from the weld spatter.

Also, Cleaning of the Slides is now performed on Saturday’s at the leisure of the maintenance team and not under the strain of production time. The Labor Rate for Maintenance is $75/hour x 6 hours/week = $450 X 50 weeks/year $22,500 plus the cost of the replacement windows at $195 each x 25 weeks = $4,875 savings per year.  Total savings after implementing the EXAIR Super Air Wipe = $27,375 per welding machine!

With the maintenance & replacement cost savings alone it is an easy calculation to make on the purchase of the EXAIR Super Air Wipe’s. That figure is not counting the productivity increase of 156% which allowed them to meet their customers delivery schedule and reduce overtime!

If you would like to discuss increasing the efficiency of your compressed air usage, quieter compressed air products and/or any EXAIR product,  I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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Video Blog : Changing Shims In An Air Wipe

EXAIR’s Air Wipes provide a 360° uniform, high velocity airflow that adheres to the outside surface of a round part, such as pipe, hose, cable, etc., as it passes through the throat or center of the device.

In this short video, we show how to change the shim inside of an Air Wipe, letting you achieve an increase or decrease in outlet flow and force while maintaining the same operating pressure.

If you have any questions, please contact an Application Engineer at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

EXAIR Super Air Wipe Helps Welding Process

Several years prior we had a customer that was using a block-type Air Wipe from a competitor to remove water from an extrusion.  These air wipes were built using materials similar to UHMW and the 2 halves were hinged with air holes drilled into it.  They were using these block air wipes on several lines and decided to try an EXAIR Super Air Wipe after contacting our Application Engineers. The interesting point was that it required 5 block type air wipes to equal the efficiency of 1 EXAIR Super Air Wipe.

Since one EXAIR Super Air Wipe equaled the performance of 5 of the competitor’s products it consumed less air, was less expensive and produced less noise.  Also in space sensitive applications the EXAIR Super Air Wipe is much thinner than the block type.  To highlight this the Super Air Wipe is 1.13″ thick on all 11 models that range from 3/8″ to 11″ throat diameter.

Another clear advantage is performance. The block air wipe performance can only be changed by altering the inlet air pressure while the EXAIR Super Air Wipe can also be changed by adjusting the inlet air pressure or changing the air gap of the Air Wipe. Simply by changing out an internal shim, the air gap will allow more or less volume of compressed air at a given pressure. By changing shims and adjusting pressure, EXAIR Super Air Wipes provide the flexibility which leads to a successful application across industry.

EXAIR’s Super Air Wipes are engineered to use compressed air efficiently and maximize force upon the target.

sawworksani

Compressed air flows through an inlet (1) of the Air Wipe into an annular chamber (2). It is then throttled through a small ring nozzle (3) at high velocity. This primary airstream adheres to the Coanda profile (4), which directs it down the angled surface of the Air Wipe. A low pressure area is created at the center (5) inducing a high volume flow of surrounding air into the primary airstream. As the airflow leaves the Air Wipe, it creates a conical 360° ring of air that attaches itself to the surface of the material running through it (6), uniformly wiping the entire surface with the high velocity airflow.

If you are interested in discussing EXAIR’s Super Air Wipes, I would enjoy hearing from you.

Steve Harrison
Application Engineer

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Super Air Wipe Vs. Block Type Air Wipe

Air Wipes, which provide 360 degree blowoff, are typically used to remove heat, liquid, debris or static from wire, cable, pipe, tube, or extrusions.

We had a customer that was using a block type Air Wipe from a competitor to remove water from an extrusion.  These air wipes are built using a plastic material, typically with some additional ceramic insert to resist abrasion of the wire, the halves are hinged with air holes drilled into each half which carries air through the block and on to the wire. They were using these block air wipes on several lines. The interesting point of this blog is that it required 5 block type air wipes to equal the results of 1 EXAIR Super Air Wipe.

Since EXAIR’s Super Air Wipe equaled the performance of 5 of the competitors it consumed less air was less expensive and produced less noise.  Also in space sensitive applications the EXAIR Super Air Wipe is much thinner than the block type.  To highlight this the Super Air Wipe is 1.13″ thick on all 11 models that range from 3/8″ to 11″ throat diameter.   The performance of the block air wipe can only be changed by altering the inlet air pressure while the EXAIR Super Air Wipe can also be changed by adusting the inlet air pressure OR by adding an additional shim the force can be nearly doubled!

Many of these block type air wipes use a series of holes to direct the compressed air supply at an angle over the material that needs to be cleaned off.  EXAIR’s Super Air Wipe being an engineered compressed air product use’s fluid dynamic’s to create more force as demonstrated below. The air from EXAIR’s Super Air Wipes is a continuous 360 degrees, without the gaps a series of holes creates.

sawworksani
How The Air Wipe Works

Compressed air flows through the inlet (1) of the Air Wipe into the annular chamber (2).  It is then throttled through a small ring nozzle (3) at high velocity.  This primary airstream adheres to the Coanda profile (4), which directs down the angled surface of the Air Wipe.  A low pressure is created at the center (5) inducing a high volume flow of surrounding air into the primary airstream.  As the airflow leaves the wipe, it creates a conical 360° ring of air that attaches itself to the surface of the material running through it (6) uniformly wiping the entire surface with the high velocity airflow.

Block type air wipes are generally available in standard sizes up to 7″ in diameter while EXAIR’s Super Air Wipes are available in stock diameters up to 11″ and we also offer custom sizes to suit many other applications.

If you have any items that need to have a 360 degree blowing pattern, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
Send me an email
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