More Power? I DO Think So…

We occasionally get calls from folks who are looking for “more power” – and it always brings that classic 1990’s sitcom “Home Improvement’s” Tim “the Tool Man” Taylor to mind. Well, not so much Tim’s “more power” mantra, but the ubiquitous response from his long-suffering sidekick, Al Borland:

Al knows it.  George Foreman knows it. Lisa knows it.  Even Tim knows it, this time.

Sometimes, they’re looking for a product to replace what they’re currently using…something they’re not getting desirable results from. Other times, they have an EXAIR product in place, and it’s just not getting the job done.

Our first response is, of course, to make sure they’re getting a sufficient supply of air to their product, no matter whether it’s ours or not. If you’re familiar at all with our blogs, you know we write about this frequently:

The Importance of Proper Compressed Air Supply Lines

Video Blog: Proper Supply Plumbing for Compressed Air Products

Improper Installation and Associated Problems

3 Common Mistakes in Your Compressed Air System

Once we’ve made sure that the product is indeed receiving appropriate air supply, we can look at adding to the flow rate and force of the air stream. We’ve made it easy to do that with a variety of blow off products by designing them with a replaceable shim.

All of our Air Knife products (Super, Standard, and Full Flow) will ship with a 0.002” thick shim installed. These will perform superbly in a wide variety of general industrial blow off applications. If this doesn’t provide the force needed for your application, we carry Shim Sets for any Air Knife that will allow you to double, triple, or even quadruple the air flow for amplified thrust. Some common examples are stubborn debris in tight spaces (like the fins of a fin-and-tube heat exchanger) or removing oil from a corrugated surface.

From left to right: Super, Standard, and Full Flow Air Knives.

 

Like the Air Knives, our Air Wipes (Super and Standard) are built with 0.002” thick shims, which can be easily replaced for additional flow and force. Like when the Air Wipe is getting all the coolant off an extruded & machined part, but some stubborn, hair-like fibers need a little more “oomph” to remove.

 

Super (left) and Standard (right) Air Wipes come in sizes from 1/2" to 11".
Super (left) and Standard (right) Air Wipes come in sizes from 1/2″ to 11″.

Yes, those were real calls I took. Yes, they had sufficient air flow. Yes, the extra shims worked like a champ.

Similar to our Air Knife products, our Flat Super Air Nozzles also incorporate a replaceable shim. In fact, you have your choice of standard Models with a 0.015” thick shim installed, or High Power Models with a 0.025” thick shim. Shim Sets with a variety of thicknesses from 0.005” to 0.030” are available for either of these.

Model 1126 (Zinc Aluminum) or 1126SS (316SS) 1" Flat Super Air Nozzles (left) have replaceable shims (middle), same as Model 1122 (Zinc Aluminum or Model 1122SS 2" Flat Super Air Nozzles (right.)
Model 1126 (Zinc Aluminum) or 1126SS (316SS) 1″ Flat Super Air Nozzles (left) have replaceable shims (middle), same as Model 1122 (Zinc Aluminum or Model 1122SS 2″ Flat Super Air Nozzles (right.)  High Power versions of both are also available from stock.

Our Super Air Amplifiers and High Velocity Air Jets incorporate patented shims that make for the highest amplification flows available, anywhere. These are available, from stock, in Shim Sets or individually.

High Velocity Air Jets and Super Air Amplifiers use patented shims for optimum performance and efficiency.
High Velocity Air Jets and Super Air Amplifiers use patented shims for optimum performance and efficiency.

If you have an air blowing application that you’d like to get a little (or a lot) more out of, give us a call. Prepare for a discussion on proper air supply first (of course,) but we’ll be more than happy to help in any way that we can.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
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EXAIR Super Air Wipe Provides Measurement Process Improvement

One of the most repeatable aspects of EXAIR products is the ability to make sustainable, measurable improvements to an application.  Whether the application need is for spot cooling to improve process speeds, static elimination to eliminate defects, or debris blow off to improve quality, EXAIR products fit the bill time and time again.

Air Wipe cleaning shavings from hub
Model 2403 Super Air Wipe used to clean shavings from OD of hub

In the photo above the hub is used as a quality checking device after a machining process.  The hub remains stationary while a machined part is brought into the application via robot.  During the mating of the machined part to the hub, to check proper fit and tolerance, small chips were becoming trapped between the hub measurement sensors and the machined part.

To eliminate this disturbance a 3” Super Air Wipe was installed to keep the OD of the measuring hub clean and free of debris.  Since installing the Super Air Wipe, debris and damage related measurement errors have been reduced to zero.

These tighter quality control capabilities have increased the efficiency of the application and reduced the need to rework existing product.

If you have a similar application, or one for which you think an EXAIR solution may be viable, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Super Air Wipe Removes Unwanted Water In Application

Super Air Wipe
EXAIR’s Super Air Wipe removes water from a cooling bath on a plastic coated wire production line.

In an email sent to me from a Russian reseller I was asked for assistance with an Air Knife application, and whether we could make a circular knife to assist blow off of industrial oil.  Fortunately, we not only can, but we do and we have them in stock.  Our Super Air Wipe is a formidable product to assist with OD blow off of a variety of applications.

For example, one of our distributors is working with their client on a way to increase production line speed.  The application has a plastic coated line that passes through a dip tank after a certain stage in the production process.  After treatment and before the next stage which takes place in a closed-top container, the water on the surface of the plastic line needs to be removed.

To remove the water and allow for faster line speed (thereby allowing for greater throughput in the application) a Super Air Wipe is installed.  The Super Air Wipe can blow off the excess water, preventing/removing a process disturbance at the next stage in production.

All EXAIR products are designed to maximize the use of compressed air, and to solve problems in industrial applications.  If your application has a need for a compressed air based solution, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Improper Installation and Associated Problems

I had a customer contact me this week wanting to replace his existing Super Air Wipe with a different product because he was starting to see a drop in the performance. He was considering a switch to one of our Super Air Amplifiers because he was familiar with another company who was using one to blow off moisture from their “all-thread” piping production line, which was somewhat similar to his application.

Rather than just pursue the opportunity for the quick sale, I decided to dig a little deeper and see what issues he was experiencing. He is using (2) of our 1” Aluminum Super Air Wipes, Model # 2401, mounted on each end of a blast chamber to remove the treatment solution on their 0.3” round wire in order to contain the solution inside the chamber. The Super Air Wipe provides a 360° uniform, high velocity airflow that adheres to the passing material surface, wiping the entire surface area clean. Easily clamping around the material passing through due to it’s split design.

Super Air Wipe

 

After reviewing the pictures provided by the customer, there were several issues that potentially could have been contributing to the decreased performance:

1)  The Super Air Wipe was mounted in the incorrect direction, causing the customer to actual blow the solution out of the chamber rather than containing it.

2) The wire was not running concentric to the throat of the Super Air Wipe, contacting the edge of the Super Air Wipe unit and removing the edge of the coanda profile for a section of the knife .

3) Since the solution was being pulled through the Super Air Wipe due to the improper direction explained in problem 1, the solution was depositing and building up near the exit of the air flow, negatively affecting the performance.  In some areas it had even bridged over the air gap causing there to be no flow of compressed air.

The decline in performance is due to the gradual solution depositing on the Super Air Wipe. Initially, it had enough performance to remove the solution from the wire but continued to lose air flow and its ability to remove the solution as it built up around and upon the exit air pathways.

I discussed these concerns with the customer and rather than changing to a completely different product, I recommended ordering replacement Stainless Steel Super Air Wipes and mounting the units in the proper direction/orientation. This would provide better wear resistance, eliminate the build-up and contain the treatment solution inside the chamber as desired.

With help maximizing the performance of your existing EXAIR product or to discuss a new application, please contact one of our Application Engineers.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN