Music And The Mini Cooler

Recently, EXAIR Corporation offered CPR (cardiopulmonary resuscitation) training to employees. I already carry certification, so I held down the fort while some of the other Application Engineers received this training. As a middle aged man, I have to admit that my interest in my co-workers’ abilities to respond to a matter of this nature is not entirely unselfish.

One of the key parts of CPR training is the rate of the chest compressions. While most people couldn’t accurately replicate 100 beats per minute on demand, almost everyone is familiar enough with some popular songs with a rhythm close to that.  The song they always bring up in CPR training is “Stayin’ Alive” by the Bee Gees. Depending on how you feel about disco, another option is “Another One Bites The Dust” by Queen. Pro tip: it might be considered bad form to sing that one out loud while performing CPR.

Speaking of music, while I was holding down said fort during this morning’s training session, I had the pleasure of assisting a caller in the music business: a piano restoration & tuning professional. A frequent job for them consists of resetting tuning pins, which requires drilling numerous small holes (a grand piano can have as many as 250) into a hardwood board. They’re pressed in, so it’s critical that they fit the newly-drilled hole precisely. If the drill bit gets too hot, it can expand in diameter, making the hole ever-so-slightly bigger than it should be. The heat can also cause the surface of the hole ID to glaze. Both of those things can cause problems with the pin fitting securely in the hole.

The EXAIR Model 3808 Mini Cooler System was an ideal solution – it’ll keep the drill bit cool & clean with a constant stream of cold air. It’s compact and quiet, and only uses 8 SCFM @100psig…well within the capacity of many smaller air compressors.

If you’d like to “get in tune” with a spot cooling solution, I can help…call me. Oh, and in case you wanted to know which song with about 100 beats per minute I’d use for CPR:

Russ Bowman
Application Engineer
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Compressed Air Flows At The Speed Of Technology At EXAIR

I don’t know that any enterprise can give you a better idea of the scope, width, and breadth of American manufacturing quite like the automotive industry:

*Pick a raw material – rubber, steel, plastic, glass, just to name a few – modern day production of all of these has been heavily influenced by the way they’re used in automobiles.

*Pick a manufacturing process – welding, cutting, molding, machining, mechanical & electrical assembly, again; just to name a few – car makers have revolutionized them all, oftentimes to the benefit of many other industries that have used…and adopted…these technological improvements.

*Pick a business.  OK; this is going to depend on where you are.  I’m in Cincinnati, Ohio.  I can be on Interstate 75 Northbound in under 10 minutes, and four hours later (and on one tank of gas, thanks to the fuel efficiency of my American made automobile,) I can be in Detroit, Michigan – the land of the “Big Three.”  And I’ll pass dozens, if not hundreds, of buildings within sight of the highway that house businesses whose largest customers are automotive industry types.

We brag on American manufacturing occasionally, because we’re proud to be a part of it, and to support so many different aspects of it.  What got me thinking about all of this was a call I got recently about our Cold Gun Aircoolant Systems, and how one might be used in a particular machining application.  They machine transmission parts and, due to the specifics of a new material and a subsequent operation, they needed to eliminate the liquid coolant.  This is a ‘textbook’ situation for a Cold Gun – the part in question is small, and just needs a quick shot of cold air during the process, so they got a Model 5215 Standard Cold Gun, put it on the machine, and turned off the coolant…forever.

With four models to choose from, we've got most any cooling application covered.
With four models to choose from, we’ve got most any cooling application covered.

This is one of, literally, hundreds of applications where EXAIR’s line of engineered compressed air products is making all the difference in the world.  If you’d like to discuss how we can help you keep up with the speed of technology, give me a call.

Russ Bowman
Application Engineer
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Mini Cooler Cools Hot Glue Beads

A few weeks ago I worked with a nail and staple gun manufacturer on a glue cooling process involving their collated nail strips. To keep the nails together, they place a small amount of hot glue across the body of the nails and then have an open air line blowing compressed air on the glue to secure a good bond between the pieces. The current process used to work great, but they recently made a change to the type of glue they were using and now they are starting to see more rejects as the heat from the glue isn’t able to be removed quick enough with ambient air. The customer is familiar with EXAIR as they currently use some of our other products in various applications throughout their plant but in this particular case, they were unsure of the best product to fit their needs so they reached out for assistance.

nails
Example of collated nail strip

For this particular application, I suggested the customer use our Mini Cooler. The Mini Cooler is specifically designed for small area or small part cooling applications. The Mini Cooler uses less compressed air than our Cold Gun but still produces the same 50°F temperature drop from the incoming supply air temperature. So say your plant air is 70°F, you would see 20°F air being exhausted from the unit. The device features a flexible hose, allowing the user to focus the cold air to the desired location, in this case right at the glue which would provide the quicker, more reliable solution the customer was needing. Installation is a breeze as well, thanks to the included magnetic base, you don’t need to make any expensive modifications or add any type of mounting brackets to the existing setup.

3808
The Mini Cooler is the ideal choice for small part cooling.

EXAIR offers a wide variety of spot cooling products that provide a low cost, maintenance free solution for large or small scale cooling processes. With help selecting the best product to fit your specific need or to discuss your particular application, please contact an application engineer for assistance.

Best Regards,
Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Nails image courtesy of Joy Kirr via Creative Commons license

 

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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Cold Gun Keeps Analyzer 31°F Cooler to Prevent Failure

A few months ago I had worked with a customer on a finned heat sink, cooling application. The heat sink is part of their TOC analyzer which is a device that detects and measures total organic carbon levels found in a fluid sample. The part of the plant where the analyzers are located has several pieces of equipment generating heat in the ambient environment close to 110°F. When the temperature gets this high, the analyzers begin to overheat, resulting in faulty readings and they will ultimately shut down. They were wanting to install a device that could blow cold air across the heat sink on the analyzer to prevent it from overheating.

After discussing the application with the customer, I recommended our Model # 5315 Cold Gun Aircoolant System with two cold outlets. The Cold Gun produces a 50°F temperature drop from compressed air supply temperature and provides 1,000 Btu/hr. of cooling capacity. For example, if your compressed air supply temperature is 70°F you would effectively see 20°F air being discharged from the cold exhaust. The Dual Point Hose Kit splits the cold airflow into 2 separate streams, providing for a wider coverage area.

5315_SCGdual
Model # 5315 Cold Gun System with dual point hose kit

The customer decided to order a single unit and after a week of testing replied back…

“We tried one a week ago with excellent results! We are installing three more today.  The other five will be here today and tomorrow.

Thank you so much for your help! Our analyzer is running 31°F cooler than it had been with no more overtemp failures!”

It goes without mentioning, but this is the type of positive feedback we are thrilled to hear! It feels incredible when a customer takes time out of their busy schedule to acknowledge how EXAIR products provided the perfect solution for their needs!

BUT the story doesn’t end there… just last week, over 2 months since our last correspondence, the customer sent me another email that read…

“Just a follow up on the effectiveness of the cold air guns. We have not experienced a single failure of our TOC analyzers since the guns were installed two months ago.

The cold air solved the problem of our analyzer overheating — even during the hottest part of the summer.

Thank you for your excellent recommendation!”

I let the customer know how much we appreciated the awesome news and how happy we were to be able to solve their problem. At the end of the day, that’s what we strive for, to provide the best and largest selection of Intelligent Compressed Air Products on the market today.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

 

 

 

EXAIR Has Solutions For Skin Problems (Really)

The EXAIR Chip Trapper filters solid debris from your coolant that can not only clog the supply lines to the tooling, but also provide a LOT of surface area for the growth of bacteria. This can really foul the air in a machine shop, and sometimes, it can mess with your skin, causing a rash or infection. Honestly, this isn’t a HUGE problem…I’ve fielded a handful of calls about it over the years, though, so when I got the call from a machinist last week who wanted to talk about a possible solution for a skin problem, I immediately thought of the Chip Trapper.

Well, immediately after I thought about this old commercial (I’ve written before about how I watched way too much television growing up. Don’t judge.)

Turns out, though, his problem wasn’t bacterial – it was an allergic reaction he was having with a specific additive in the coolant used on a particular machine tool. He mentioned that it was a mist coolant application, so I immediately thought of the Cold Gun Aircoolant System.

Of, course, right after I thought about this commercial (seriously; stop judging.)

To my knowledge, it’s the first time we’ve ever applied a Cold Gun to solve a skin problem – we’re almost always looking at them to avoid the mess of coolant spray, or to increase tool life in situations where traditional machine tool coolant is impractical (or impossible) to use.

With four distinct models to choose from, we've got a Cold Gun System to meet your needs.
With four distinct models to choose from, we’ve got a Cold Gun System to meet your needs.

If you’d like to find out how EXAIR products can save you from:

*Excessive compressed air consumption
*High sound levels
*Static charge problems
*Heat damage to your electronics
*Labor intensive “bucket and ladder” bulk conveyance operations
*Trips to the dermatologist (no, really)

Then give me a call.  We can even talk about vintage TV commercials (I won’t judge either.)

Russ Bowman
Application Engineer
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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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