Light Duty Line Vac For Part Rejection

Today I worked with a long standing customer that was interested in using the Line Vac technology to provide a method for part rejection.  The parts come out of a bin and travel to the next station for final assembly.  There is an accept/reject analysis system along the way, and it was decided that the Line Vac would offer an easy way to remove the part from the conveyor and transport it to a reject bin.

The parts are very small, with 0.093″ to 0.187″ OD and 0.178″ to 0.335″ lengths.  Part weights were 0.27 grams or less, so a very small and light weight item.  Maximum part processing was estimated at less than 6 parts per minute, so low speed and low transfer rates apply.  The final piece of information was the distance for conveyance, and here it was only a few inches up and then 4′ over to the reject bin.

Based on all the information about the parts, the process and the transfer distance, it was determined that the 3/4″ Light Duty Line Vac would be an ideal choice for the application. The unit is available as part of the  model 132075 Light Duty Line Vac Kit, which includes a Automatic Drain Filter Separator and a Pressure Regulator.  The Pressure Regulator is especially important in this application, as it will allow for pressure adjustment to provide the best performance while keeping the compressed air usage to a minimum.

gh_lvthr-hd-ld_754x696p

The EXAIR Family of Line Vacs

 

EXAIR manufactures 3 styles of Line Vac- Light Duty, Standard, and Heavy Duty with either smooth bore hose or NPT threaded ends.  They are offered in 4 types of materials- Aluminum, Type 303 and Type 316 Stainless Steel, and a hardened alloy construction. An important factor in material selection is the abrasiveness of the material to be conveyed.

To discuss your application and how an EXAIR Intelligent Compressed Air Product can help your process, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web
Like us on Facebook
Twitter: @EXAIR_BB

 

You Might be Freezing, but Your Electronics Can Still Overheat

For those of us in the Northern Hemisphere it can be easy to be overrun by static elimination problems during these winter months.  But, colder outside temperatures don’t always mean cooler temperatures for the electronics used in production processes.

dsc08220

This cabinet was facing unaddressed overheating issues before exploring a Cabinet Cooler solution

I received an email from one of our distributors this week describing two applications with failing electronics (shown above and below).  The root cause of failure for both applications was excessive heat inside the enclosures which house electronic devices, even though the ambient air temperatures weren’t abnormally high.  So, we used the Cabinet Cooler Sizing Guide to determine the heat load of each application and make recommendations for proper Cabinet Cooler model numbers.

dsc08223

This cabinet was also overheating, causing problems in the processes controlled by the components inside the cabinet.

What we found was that the heat load in both cases was rather low, but in each case it was enough to cause the electronics to overheat.  When the temperature of the electronic devices exceeds their specified temperature range, they cease to operate, causing downtime of every device tied to the processes they control.  By installing a Cabinet Cooler onto each enclosure, the overheating problem will be quickly and easily solved.  And, because of the relatively low heat load in this application, a small NEMA 12 type Cabinet Cooler was the perfect solution.

If you have an overheating electrical enclosure, whether during the Winter, Spring, Summer, or Fall, contact an EXAIR Application Engineer.  We’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

What Makes Things Easier Than An EXAIR Static Eliminator? Another EXAIR Static Eliminator!

A contract manufacturer, servicing the medical and biotechnology markets, is a long time user of our Ion Air Guns. They’ve had great success with them in keeping their products free from static & dust for years. These are mainly small, hand-held parts, so, when they need to get them clean and static-free during assembly and packaging, EXAIR’s Ion Air Gun is ideal, because it, too, is small and hand-held.

A new process, though, involves the operator needing both hands for assembly. This would mean picking up the Ion Air Gun, blowing off the part, putting it down, and then using both hands to complete the operation. They thought there had to be a better way. And they were right!

The Model 8910 Instant Static Elimination Station offers hands-free control of ionized air flow – a foot pedal turns an Ion Air Jet (whose performance is identical to the Ion Air Gun) on and off with…well, the press of a foot. The Magnetic Base and Stay Set Hose make it easy to install, and even easier to position.

Hand held convenience of the Ion Air Gun (easy) or no-hands convenience of the Ion Air Jet Station (easier.) Your call.

Hand held convenience of the Ion Air Gun (easy) or no-hands convenience of the Ion Air Jet Station (easier.) Your call.

For an even more automated approach, they are considering an EFC Electronic Flow Control. They’re ready to go, right out of the box…the photoelectric sensor will open and close a solenoid valve (installed in the compressed air supply line) based on the setting of the programmable timer unit. With a simple wave of the part in front of the sensor, the operator could activate a preset blow of a few seconds, which would be easy to determine, even easier to set, and…easiest of all…reliably repeat all day long. They’re going to try out the foot pedal first, and that’s just fine by me.  Perhaps there’s such as thing as “too easy,” but man, I hope not.

Even if you’re already using EXAIR products to make things easy, you can call me to see how much easier it might get.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

Speaking of easy...get a FREE AC Sensor with a Static Eliminator order. Promotion ends 1/31/2017!

Speaking of easy…get a FREE AC Sensor with a Static Eliminator order. Promotion ends 1/31/2017!

Explanation of OSHA Standard 1910.242(b)

Open air lines and homemade blow offs violate OSHA standard 1910.242(b) because of harmful dead end pressures. In 1972, OSHA established Standard 29 CFR 1910.242(b) requiring that the outlet pressure of an open pipe, nozzle, air gun, etc., when used for cleaning purposes, must remain below 30 PSI with the intent to protect workers from serious injury. They determined that when dead-ended against the skin, if the outlet pressure reached 30 PSI 0r higher,  it posed a risk of entering the bloodstream through the skin. This is commonly referred to as an air embolism – a serious condition which can be life threatening. Once air has entered the bloodstream, it can restrict the free movement of blood throughout the body, disrupting normal heart function, leading to abnormal heart rhythm, possible lung or brain damage, cardiac arrest, stroke or possible death.

OSHA explains that you can use compressed air for cleaning purposes, as long as the outlet or source is fitted with some type of relief device that drops the outlet pressure to below 30 PSI if dead ended. There are basically two ways to go about gaining compliance. The first is to regulate the operating supply pressure to less than 30 PSI, assuring that the outlet pressure doesn’t exceed the threshold. While this does comply with the Standard, it can negatively affect the performance by reducing the strength of the outlet flow, limiting the usefulness of the blowoff device.

The other method is to use some type of nozzle which includes a pressure reducer or a relief device which will reduce the air pressure to less than 30 PSI if the nozzle is dead ended.

For example, EXAIR engineered air nozzles are designed so the outlet holes cannot be blocked directly. Any potential obstruction of the outlet air holes results in the air having an alternative exit path to avoid injury to operators and personnel.

sag-osha-compliant

With our Super Air Nozzles, the air exits through a series of jets, recessed behind an array fins so the exhausting airflow can never be blocked.

With the design of our Super Air Knife, the cap overlaps the body, leaving a gap on both sides of the knife, allowing the exhausting air to safely vent.

osha-sak

Picture of the Super Air Knife, showing how the cap overlaps the body and cannot be blocked, providing a safe exit path.

ALL of EXAIR‘s engineered products incorporate these principles, providing some type of relief, allowing for the air to safely vent well below the 30 PSI requirement, meeting and in many cases, exceeding the OSHA Standard.

To discuss how EXAIR can help you gain OSHA compliance to improve operator safety, avoid costly fines and improve overall efficiency, contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Super Air Knife Shim Design Reduces Operation Costs

A customer of ours had an application where they needed to cool and dry parts on two conveyors that ran side by side.  A single 36″ Super Air Knife was chosen to provide coverage over the full width and to simplify the air plumbing and installation.  As we learned more about the application, it was discovered that there was 10″ section in the center where the the two conveyors butted up, where no parts would pass through, and hence no air was needed.

Fortunately, the EXAIR Super Air Knives can be supplied with custom shim designs to match the air flow requirements of the application.  These shims can be of various thicknesses to increase/decrease the air flow, of alternate materials such as a stainless steel shim in an aluminum air knife to increase the temperature range, or as in this case, designed to provide specific air flow patterns.

By utilizing the special shim design, it is estimated to save $865 per shift per year in compressed air costs versus the standard configuration.  That is a significant savings, and using less compressed air is high on everyone’s priority list.

Check out the video below to learn more about the EXAIR Air Knives.

akvideo

EXAIR manufactures 3 different types of air knives, in 4 different materials, up to 108″ in length.

To discuss your application and see how an EXAIR Intelligent Compressed Air Product can help your process, feel free to contact EXAIR and one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web
Like us on Facebook
Twitter: @EXAIR_BB

 

 

 

How To Solve A Problem with Compressed Air

In my (almost) six years as an EXAIR Application Engineer, I’ve learned a great many things about the capabilities of our products.  The way we do business sure does make it easy:

  • We readily share application information, as a team.  If you ask me a question, you’re asking all of us.  It does neither of us any good if I tell you something MIGHT work if one of my team knows it WON’T – or if someone knows what else DOES work.  If we can offer a solution, we will.
  • We’ll test your product, free of charge.  This is a popular way of finding out which Line Vac is best for conveying a particular product, for example.
  • If you’re considering a quiet, safe, and efficient EXAIR product as an upgrade, we’ll test your current product in our award winning Efficiency Lab, so you can compare accurate performance data and analyze the expected benefits…which can be dramatic.  Try us on that.
exair-testin

Line Vac conveyance rate testing (left;) Efficiency Lab testing (right.)

 

  • We’ll let YOU test our product, risk-free.  All catalog products come with a 30 Day Unconditional Guarantee.  We invite you to put it through its paces for up to a month.  If it’s not working out, we’ll arrange return for full credit.
  • We’ll do the math.  But first, a disclaimer: strictly comparing the force or flow of an engineered product to an open-end blow off won’t always tell the tale.  Our Intelligent Compressed Air Products are creating a laminar flow which won’t generate as high of a force/thrust as open-end blowing (which is turbulent by nature,) but is MUCH more conducive to efficiency and noise reduction, as well as similar (if not improved) performance.  But back to the math: if you know the metrics you need to meet for spot cooling (like a Vortex Tube, Adjustable Spot Cooler, Cold Gun, etc.) or for liquid spraying (the liquid flow rate and/or pattern size & shape from an Atomizing Spray Nozzle, for instance,) or the heat load that a Cabinet Cooler System can handle, we’ll do the calculations and specify the appropriate product.

Regardless of the application, if it can be solved with compressed air, it’s very likely that we have a great solution.  Call me to find out how we can help.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

M4 Back Blow Nozzle Dries Inside Of Small Cylinders

A few weeks ago I received an inquiry from a customer who was looking to blow water off the inside of a closed cylinder after a zinc bonding process. There are 8 parts that are placed on a manifold which is then inverted and sent into their current blow off setup that includes small open tubes that get inserted into each cylinder to try and blow out the water. This setup worked a little but the issue they were experiencing was the airflow coming out of the tubes was blowing the water up, which caused it to collect in the “bowl” of the cylinder and as the blow off tubes were removed, the water would start to leak back out and down the inside walls again. After the current blow off, the parts are manually removed and inspected for moisture content. If the parts are found to be outside of their tolerances, an operator uses a modified blow gun fitted with a small tube to manually complete the process.

After discussing the particulars with the customer, their needs were two-fold – first they needed a nozzle that wouldn’t push the air toward the end of the tube but something that would direct the air “backwards” so as they placed the nozzle inside, they could hopefully “pull” the liquid out as the nozzle is removed. The second concern was the cylinder had a small 0.390″ diameter opening so the nozzle would need to be small and powerful enough to be able to fit inside the part, while still providing effective blowoff.

Once again, EXAIR offered the perfect solution, our Model # 1004SS M4 Back Blow Nozzle. The Back Blow Air Nozzle produces an even, 360° airflow that is directed away from the end of the nozzle. At only 0.20″ in diameter, The Model # 1004SS is the ideal choice for treating the inside diameter of small hose, pipe, bores (up to 1″) or in this case, small enough to fit inside the opening of the cylinder. With this design blowing the air back away from the end, the water wouldn’t get trapped in the bowl but rather would allow the inside walls of the cylinder to be wiped clean while directing the liquid toward the opening so the water can be removed.

1004ss-airflow-pattern

Dimension and airflow pattern chart for the Model # 1004SS M4 Back Blow Air Nozzle

In addition to the Model # 1004SS M4, we also offer our Model # 1006SS 1/4″ NPT Back Blow Nozzle for use with 7/8″ to 4″ ID’s, as well as our Model # 1008SS 1″ NPT unit for treating large ID”s up to 16″, for larger scale applications

The Model 1006SS cleans metal shavings from inside a pipe.

EXAIR’s Back Blow Nozzle is the perfect choice for cleaning or drying the ID of part or tube.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

%d bloggers like this: