High Power Super Air Nozzles Provide Forceful Air Flow

When considering the application of a compressed air product, we have an awful lot of discussions with callers about the amount of force generated.  Now, if that’s all you want, you’re not going to get more force from compressed air flow from anything but an open ended blow off.  There are problems inherent with this: it’s unsafe, it’s loud, and it’s a horribly inefficient way to use compressed air.  By the time they’ve called EXAIR, they probably know this, but the main concern is still the same: solving their application.

Good news is, you don’t need a lot of FORCE for most blow off situations.  Think about it…how much do sawdust, machining chips, coolant droplets, etc., weigh, anyway?  All you really need to do is optimize the air flow, which is EXACTLY what EXAIR Intelligent Compressed Air Products are engineered & designed for.  So, we talk a LOT about how often a high amount of force isn’t needed in compressed air blowing applications.

Then…I got a call from a user who needed force.  They had an air knife installed to blow parts out of a mold, as the halves separated.  There’s a rectangular array of parts in a multi-cavity mold, and the air knife just wasn’t getting them all out, all the time.

The air knife, was, of course, originally chosen for its efficiency, but it just wasn’t delivering the needed “punch.” They even tried other shim thicknesses (which increases the outlet air gap) to increase the flow & force delivered, and that helped a little, but wasn’t 100% effective.

The solution came in the form of an array of HP1125-9212 2″ High Power Flat Super Air Nozzles, supplied with 12″ Stay Set Hoses.  They’re able to mount these closer to the mold than the air knife, and the ability for each nozzle to operate independently meant they were able to be aimed precisely where they can do the most good.  They are now able to evacuate the molds the first time, every time.

Sometimes, you DO need the high force of the HP1125 2″ High Power Flat Super Air Nozzle

If you have questions about how to get the most out of your compressed air use, give me a call.

Russ Bowman
Application Engineer
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Part Ejection Improved by Choosing the Right Air Nozzle

Recently, I was able to work with a gentlemen from a stamping company that produces small metal stamped lids for the cosmetic industry.  He was frustrated because the current blow off setup, a copper tube and nozzle (shown below), was too weak and narrow to be effective with parts ranging from 1″ to 2.5″ wide.  Whenever a lid did not get completely discharged, the machine would jam and double hit on the next cycle, ruining (2) parts in the process, not to mention, potentially damaging the the tooling.

blowoff

Stamping Operation with Original Nozzle

After reviewing the process, which is very high speed, we wanted a strong, concentrated blast of air that matched the part profile to maximize the air flow contact patch.  We agreed the model HP1125 – 2″ High Power Flat Super Air Nozzle would be a good nozzle to implement and test.  In addition to the Nozzle, the customer ordered the model HP1132SS Shim Set, to allow for flow and force adjustment of the nozzle to obtain the best possible performance under production conditions.  The HP1125 nozzle provides 2.2 lbs of force with the standard .025 patented shim installed, and can be decreased or increased by changing the shim to .020″ or .030″ thick. Preliminary testing has proven successful, and reliability testing and data collection is underway.

2 Inch Flat

2″ Flat Super Air Nozzle

EXAIR has available, the Air Nozzles Blowoff Guide, a handy reference with 23 pages of technical data for OSHA safe nozzles and Safety Air Guns for every application imaginable.

blowoff guide

The EXAIR Air Nozzles Blowoff Guide

To discuss your part ejection, blowoff, cooling or drying application, feel free to contact EXAIR and one our  Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Maintenance Free And Proud Of It

Caller: Do you sell rebuild kits?
Me: Yes, but…why?

This is a WAY oversimplified summary of the start of a popular conversation that an EXAIR Application Engineer might have with a caller looking to restore a particular product to proper operation. Truth is, most of our products have no moving parts, and if you supply them with clean, dry air, they’ll run maintenance free, darn near indefinitely. We’ve documented this in specific cases regarding a Reversible Drum Vac from 1999, a Vortex Tube from 1987, and a Cold Gun from 1985.

Product & year of manufacture, from top left: Reversible Drum Vac (1999,) Cold Gun (1985,) Vortex Tube (1987.) All still performing within factory specifications.

Product & year of manufacture, from top left: Reversible Drum Vac (1999,) Cold Gun (1985,) Vortex Tube (1987.) All still performing within factory specifications.

Caller: So…DO you sell rebuild kits?
Me: Yes, but…only when necessary.

It’s important to note that none of the products mentioned above needed any parts replaced to return to service. Sometimes, a good cleaning is all that’s required. We can help you with a video tutorial if you want to know how to restore a Reversible Drum Vac, an Air Knife, or an Atomizing Spray Nozzle, for instance.  And we’re making new videos all the time for product maintenance, operation, tips & tricks, etc.

Caller (again): So…you DO sell rebuild kits?
Me: Yes, of course!  I mean, who wouldn’t sell rebuild kits for their products?

Take our Safety Air Guns, for example. We offer Service Kits, if the trigger and/or internal valve of a Soft Grip or Heavy Duty Safety Air Gun starts to wear or leak, it’s super easy to replace. We’ve also got replacement springs for the “fail shut” feature of the ball valve of a Super Blast Safety Air Gun. Just about anything else that could be wrong with a Safety Air Gun’s performance can be addressed by cleaning the nozzle.

We also recently added Rebuild Kits for our Atomizing Spray Nozzles to inventory. These contain all of the seals (and moving parts, for the No-Drip models) to restore an EXAIR Spray Nozzle to rated performance.

Keep your EXAIR Atomizing Spray Nozzle (left) in perfect working order with a simple & inexpensive Rebuilt Kit (right of the nozzle.) Contact an Application Engineer to select the one for your product.

For other products, we can also provide replacement gaskets & seals for the Reversible Drum Vac & Chip Trapper products, O-rings for the Line Vacs, Chip Vacs, and Heavy Duty Dry Vacs, new elements for Filter Separators & Oil Removal Filters…just to name a few.

Bottom line: if your EXAIR product isn’t performing the way it used to, give me a call.  It will be my pleasure to help you get it working like new, so that you can continue to get the most out of it.

Russ Bowman
Application Engineer
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EXAIR’s High Velocity and Adjustable Air Jets – Now Available in Stainless Steel

Newly released, the EXAIR High Velocity Air Jet and Adjustable Air Jet are now available in Type 303 Stainless Steel, providing greater durability, corrosion resistance and a higher maximum temperature rating of 400 °F.  Type 303 stainless steel has good resistance to mildly corrosive atmospheres along with good oxidation resistance at elevated temperatures, making the stainless steel Air Jet a great choice for blowoff or part drying in your harsh environment. Both types of Air Jets are also available in brass, for applications at 275°F and below, and when corrosion resistance is not as critical.

6013ss

Model 6013SS – High Velocity Air Jet

Air Jets utilize the Coanda Effect – wall attachment of a high velocity fluid – to produce air motion in their surroundings. As illustrated above, a small amount of compressed air to the inlet (large black arrow) is throttled through an internal ring nozzle above sonic velocity.  A vacuum is produced, resulting in large volumes of surrounding, or “free” air, being pulled in through the jet (blue arrows.)

air jet How Air Jets Work

Both the outlet and inlet can be ducted for remote positioning applications.

If the end is blocked, flow simply reverses at well below OSHA dead end pressure requirements, ensuring safe operation.

The High Velocity Air Jet comes standard with an .015″ shim, and a Shim Set is offered that includes .006″ and  .009″ shims to provide additional adjustability and control.  The Adjustable Air Jet has a variable gap design, and can be adjusted and locked to meet the required airflow and thrust parameters.

When you are needing a simple solution to reduce excessive air consumption and noise levels on compressed air blowoff operations, EXAIR has a large line of Air Nozzles and Jets to solve your problems. You can contact an Application Engineer to discuss which Air Jet or Nozzle to best fit your application.

Brian Bergmann
Application Engineer

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Video Blog: How to Adjust an EXAIR Adjustable Air Nozzle

Here is an informal video on how to adjust the EXAIR Adjustable Air Nozzle models #1009 and #1009SS and explanation of the benefits of proper adjustment.

 

John Ball
Application Engineer
EXAIR Corporation

Practice Makes Perfect

2016 Eagles

NEW Eagles Football Jersey for 2016

Last year, I wrote a few blogs about how I was an assistant coach for my oldest son’s youth football team. We had an amazing season that ended with a 2nd round playoff loss and a 3rd place finish overall. Not too shabby for a new group of players and coaches. Now, the new season is upon us with practice beginning next Monday. Our new roster is pretty much the opposite of last season, as we now have 11 returning players from last year’s team and 4 newcomers. The coaching staff has stayed intact as well, so we are hoping to improve on last year’s successes and bring home the championship this year! But hey, we are talking about 7 and 8 year old boys here, so ANY type of success is a win in itself.

After a brief coaches meeting over the weekend, we have decided to hold practice 3 days a week this year, compared to 2 days last. We are hoping the extra practice will help us implement some more pass plays in the offense and work on extending our defensive sets, which cost us at the end of last year. For me personally, I am excited to see how my own son has grown from his first season of learning how to block and tackle the right way, to being more involved in the offense. He is one of the fastest kids on the team but got a little nervous whenever we tried to get him the ball on a rush or pass play. He and I have spent A LOT of time this spring and early summer, throwing the ball and working on his ball carrying skills. From what I’ve seen in our yard, I am pretty excited to see what unfolds on the football field. I keep telling him that he’s going to have some dropped passes and fumbled balls, but the important thing is to not get discouraged and keep trying. After all, practice makes perfect.

Here at EXAIR, we adopt the same philosophy. We are dedicated to putting in the time and effort to develop new and useful compressed air operated products. The following is a list of some new products now available:

  • New 2.5″ and 3″ Line Vac and Threaded Line Vac in 316SS and High Temperature construction

    Standard Line Vac: aluminum or SS

    Standard Line Vac in aluminum or stainless steel

  • New 2.5″ and 3″ Heavy Duty Line Vac with smooth or threaded ends. Hardened Alloy Construction for better abrasion resistance.

    Heavy Duty Line Vac: Hardened Alloy Construction and High Performance

    Heavy Duty Line Vac: Hardened Alloy Construction and High Performance

To discuss these new products or any EXAIR product, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Multiple Choice

My oldest son got his driver’s license last week.  There was a popular commercial for an insurance company, a while back, that touted how “life comes at you fast,” and that’s been the story of my week:

Friday: Son passes driver’s exam, first time, 100%. Proud Dad moment.
Saturday: Dad & Son go used car shopping. Pride has a price tag.
Sunday: Dad & Son bond while detailing new (to us) car. Son learns what to do when engine in 10 year old car stalls while backing out of driveway cold. Pride usually is followed by lesson in humility.
Monday: Mom adds Son to auto insurance policy. Insurance agent no longer concerned about funding retirement. Pride is getting expensive.
Monday part 2: Son learns valuable lesson about leaving lights on when parking at school in pre-dawn hours. Dad’s portable jumpstarter finds new home in trunk of Son’s car. Lessons in humility have caused pride to approach pre-licensing levels.
Tuesday-present: Enjoying what we can of a return to incident-free normalcy (and I hope I didn’t just jinx it by putting that in writing.)

We had quite a few choices, looking at cars in our (limited) budget range. Having these choices allowed us to choose the features that most appealed to us. They were pretty much all small-to-mid-size used cars with automatic transmissions and fuel efficient (read: small) engines. The one we settled on was the same model (and a year newer) as one I’d owned previously. It was one that had proved reliable, and safe…I was in an accident in that one where the air bag deployed, and I walked away with no injuries. Safety is a big selling point for me, especially where my family is involved.

When we speak with customers at EXAIR, many times, we too, can offer multiple choices to provide a solution.

I had the pleasure of helping a caller with a chip removal application recently. The application was to solve a problem with stringy chips wrapping around a plastic cylindrical part as it was turned on a lathe. The initial thought was to use a Super Air Nozzle to blow them away. Our Model 1100 1/4 NPT Zinc Aluminum Super Air Nozzle was discussed…inexpensive, low air consumption, easy to mount (we also talked about Stay Set Hoses and Magnetic Bases,) and super quiet.

EXAIR Model 1100 Super Air Nozzle is commonly used in point-of-cutting debris removal applications.

EXAIR Model 1100 Super Air Nozzle is commonly used in point-of-cutting debris removal applications.

The second thought was to use a small Line Vac to convey the debris away. Small footprint, easy to install, collection of waste in a receptacle away from the machine, still easy on air use & noise level.

Model 6080 3/4" Line Vac is also used in point-of-machining applications, removing debris from the site altogether.

Model 6080 3/4″ Line Vac is also used in point-of-machining applications, removing debris from the site altogether.

The third option came up when discussing tool life. Turns out, one of their machinists was familiar with our Cold Guns, and how they had been used to markedly improve tool life while eliminating the need for coolant at a previous job. This turned out to be all it took for them to try the Model 5215 Cold Gun Aircoolant System.

EXAIR's Cold Guns not only blow debris away, but also provide cooling for tool life improvement.

EXAIR’s Cold Guns not only blow debris away, but also provide cooling for tool life improvement.  With (4) Models to choose from, we’ve got the right one for your needs.

Any of the three options – Super Air Nozzle, Line Vac, or Cold Gun – should have solved this application successfully, with different benefits. They simply chose the one with the benefits that appealed to them the most.

If you have an application regarding compressed air product use that you’d like to discuss, give me a call. We’ll cover all the bases, and get the one that works best for you.

Russ Bowman
Application Engineer
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