Gen4 Super Ion Air Knife Removes Fibrous Material from Conveyor Belt

Conveying System

A factory was having some issues in losing plastic material underneath and around their conveyor system.   The conveyor moved plastic fibers from an extrusion process into a hopper.   The conveyor belt was made of a rubber material that was 17” wide, and the plastic fiber was made from HDPE.  As the conveyor went around the end to dump the fibers into the hopper, some of it would stick to belt and sides of the conveying system.  Some fiber material would fall onto the ground which would require cleaning and loss of material.  They attempted to place a brush flap against the conveyor belt to knock the material off, but it was not very effective.  The brush flap actually generated more static as well as created wear marks on the belt from contact.  The customer sent a picture of the problem and wondered if EXAIR could help them with this application.

Gen4 Super Ion Air Knife Kit

With plastic fibrous material and rubber belts, the two non-conductive surfaces will generate static.  Static can have a strong force that will cause the material to “stick” to surfaces.  The higher the static voltage, the stronger the force.  As you can see in the photo, the material is sticking to the belt as well as to the sides.  For this application,  I recommended the model 112224 Gen4 Super Ion Air Knife Kit.  The Gen4 Super Ion Air Knife is uniquely designed to have two functions in this application.  The Super Ion Air Knife uses 40 parts of ambient air with every one part of compressed air, making it very efficient.  With the laminar air stream that comes from the Super Air Knife, it can carry both positive and negative ions from the attached Gen4 Ionizing Bar to remove any type of static charge.  With this combination, it becomes a very effective non-contact scraper to remove the fibers and not wear on the conveyor belt.  The model 112224 kit includes the 24” (610 mm) long Super Air Knife with a Gen4 Ionizing Bar attached; power supply, filter, regulator, and a shim set.

The reason for the 24” (610 mm) extended length was to keep the fibers from collecting to the outside area of the conveyor (as shown in the photo above).  With the compact and lightweight design, it could easily be positioned below the conveyor.  As the fiber material would come around the conveyor, the ions carried by the air stream would neutralize the static as well as remove the material from the belt and the sides.  When the customer mounted the Gen4 Super Ion Air Knife in place, the plastic fibers dropped into the hopper and not onto the floor underneath.

Spillage is wasteful, costly, and time consuming to cleanup.  If you have excess waste from your conveying system, EXAIR will have the product to help you.  For the customer above, the Gen4 Super Ion Air Knife made it possible to claim more material, removed the hazard from buildup on the floor, and reduced cleaning time.  You can contact an Application Engineer to review your application.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

 

FREE EXAIR Webinar – May 23, 2018 at 2:00 PM EDT

Warmer temperatures are quickly approaching, which may seem like a welcome change for personal reasons, but in a processing line, the increased temperatures can wreak havoc on sensitive components found in an electrical control panel.

EXAIR Corporation will be hosting a FREE webinar titled “Intelligent Solutions for Electrical Enclosure Cooling” on May 23, 2018 at 2:00 PM EDT.

(click on the photo to register – it’s FREE!)

By attending this interactive session, you will learn the difference between the 3 most common NEMA ratings for electrical control panels found in an industrial setting, NEMA Type 12, 4 and 4X. We’ll provide examples of traditional, yet unreliable, methods of cooling and the concerns associated with using these types of devices.

Next we will explain how ignoring heat related issues can cause machines to shut down due to failed electrical components, resulting in lost production and increased maintenance costs, negatively affecting a company’s bottom line.

In closing, we’ll show how using an engineered, compressed air operated solution can reduce  downtime by providing a low cost, maintenance-free way to cool and purge control panels with no moving parts.

CLICK HERE TO REGISTER

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

The Case for the Chip Vac

EXAIR Chip Vacs come in a range of sizes, and options, to meet the needs of most any clean up job.

The season for spring cleaning – spring, that is – is upon us (here in the Northern Hemisphere anyway) so it’s time to start looking for ways to make the task as easy and hassle-free as possible. That’s my take, anyway…and if you feel the same trepidation (or maybe even dread) as me, then this blog is for you. If you are one of those people who LIKES cleaning (you know who you are,) there’s something here for you too.  Without further ado, let’s talk about the EXAIR Chip Vac Systems.

The first thing you should know is that, like all EXAIR Intelligent Compressed Air Products, Chip Vac Systems are compressed air operated.  Why is this important?

*Safety – there’s no electric power cord or cable to trip over, damage, or get wet…all of which can be an electrocution hazard.

*Consistency – unlike a typical shop vac, which has a motor driven impeller/propeller to generate the vacuum flow, the Chip Vac creates powerful direct flow action from the compressed air supply.  With no moving parts in the way, there’s nothing to trap debris or clog the line.  If it can fit through the hose, the Chip Vac can suck it into the drum.  Every time, all the time.

*Reliability – electric motors can overheat and burn out if you run them continuously for long periods of time – or if you start and stop them frequently.  Not so with the Chip Vac…it’s pulling rated vacuum and flow as soon as you cut in air to it.  And if you supply it with clean, dry air, the Chip Vac will operate darn near indefinitely, maintenance free.

At EXAIR, our motto of being “easy to do business with” applies to not only all aspects of Customer Service and Technical Support; it’s even integral to our systems design.  What does this mean for the Chip Vac?

*Versatility – we make Chip Vac Systems for 30, 55, or 110 gallon drums.  If you don’t already have an open top drum to install one on, we can supply the drum too.

*PortabilityDeluxe Chip Vac Systems come with a dolly for your drum, so you can roll it wherever you need it.  The 30 Gallon Chip Vac Systems are compact enough to fit through just about any passageway that you can walk through.  But in tighter constraints…

*Portability, part 2Mini Chip Vac Systems come complete with a 5 gallon drum that can be easily carried or lifted to just about anywhere you need it to go.  The Deluxe System even comes with a dolly, for total portability.

*Resourcefulness – because they fit standard drums, they’re easy to move from one drum to another.  This is of particular value to machine tool operators who work with different materials: they can use the Chip Vac on one drum to vacuum up aluminum chips from one job, and then move it to another to clean up stainless steel chips from another job.  This makes recycling quick, easy, and profitable.

If you’d like to find out more about how EXAIR Chip Vac Systems – or any of our Industrial Housekeeping Products, can improve the efficiency and safety of your cleaning tasks (Spring or otherwise,) give me a call.

Russ Bowman
Application Engineer
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Air Nozzles, Air Jets and Swivels

EXAIR’s Engineered Air Nozzles and Air Jets provide a superior solution to minimize compressed air usage and reduce noise levels for compressed air blow-off operations.

Air Nozzles and Jets – when compared to commonly used open copper tubes or pipes the compressed air savings can be as high as 80%. With less compressed air, sound levels are greatly reduced.  A 10 dBA noise level reduction is typical.  All EXAIR Air Nozzles and Jets meet OSHA guidelines for dead end pressure and sound level exposure requirements.

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EXAIR has engineered air nozzles for virtually any application 

EXAIR Nozzles are designed and manufactured to take advantage of the Coanda (wall attachment of a high velocity fluid) effect which can amplify the airflow up to 25 times. The compressed air exits through the small holes on the nozzle which entrains the surrounding air. The effect from this is a high volume, high velocity blast using less compressed air.  EXAIR manufactures many sizes and styles of air nozzles from the smallest, but quite powerful Atto Super Air Nozzles to our largest 1-1/4 NPT Super Air Nozzle.  We also offer Flat Super Air Nozzles, and the Back Blow style nozzle for cleaning out tubes, pipes, channels or holes from 1/4″ to 16″ in diameter.

All of our Air Nozzles are engineered to meet or exceed OSHA Standard 1910.24(b) for 30 PSIG dead end pressure, they cannot be dead-ended as there is always a route for the air to escape so the outlet pressure will never reach 30 PSIG. In addition, our products are going to meet the OSHA Standard CFR 29 – 1910.95(a) for allowable noise exposure levels.
EXAIR Air Jets also utilize the Coanda effect to produce air motion in their surroundings.  A small amount of compressed air (1) is throttled through an internal ring nozzle above sonic velocity.  A vacuum is produced, pulling in large volumes of surrounding, or ‘free’ air, through an around the jet (2).  The exit flow is the combination of the two air sources (3).

air-jet
How an Air Jet Works

EXAIR manufactures Air Jets in two types, High Velocity, and Adjustable with materials of construction of brass and Type 303 Stainless Steel.  The High Velocity Air Jet uses a changeable shim to set the gap, controlling the force and flow of the air.  The Adjustable does not use a shim, and has a micrometer gap indicator and locking ring to allow for varying force and flow performance.

AirJetFamily
EXAIR Air Jets – High Velocity type on the left, Adjustable type on the Right
Swivel Fittings available from M4 up to 1″ NPT

EXAIR’s Swivel Fittings make it easy to adjust the position of the Air Nozzles and Air Jets.  The fittings allow for movement of 25° form the center axis for a total movement of 50°.  There are nine different models available and all of them are made from stainless steel

If you would like to discuss blow off, noise levels, dead end pressure or any of EXAIR’s intelligent compressed air usage solutions, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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Keep Small Parts Cool with EXAIR’s Mini Cooler

As they always say, “big things come in small packages”. Oftentimes, some of the things that have the most value or quality are quite small. Jewelry or diamonds certainly come to mind as some high-quality items that are relatively small in size. One little product we have at EXAIR is the Mini Cooler. Don’t let the word “Mini” fool you. EXAIR’s Mini Cooler packs a powerful punch while using minimal compressed air and not taking up valuable space on your shop floor.

minicoolerWFAM_500
Single and Dual Point Mini Cooler

The Mini Cooler is a proven, reliable way to reduce downtime and increase productivity on a wide variety of operations involving small parts where heat is causing a problem. With just an ordinary supply of compressed air as the power source, the Mini Cooler uses Vortex Tube technology to produce a 20°F (70°F compressed air temp) stream of cold air. This cold air can be directed to the part to prevent heat build-up that can cause premature tool wear, affect part tolerances and improve product finish. The Mini Cooler consumes just 8 SCFM of compressed air when operated at 100 PSIG, making it an ideal solution when available compressed air is at a premium.

The Mini Cooler can be used for a wide variety of applications, many of which we’ve blogged about here before. This application discusses a manufacturer that made surf casting bags used by fishermen fishing straight off of the beach. They had problems with the needle overheating and breaking which in turn damaged the finished product. Not only were they wasting materials, but also time spent periodically replacing the needles on the sewing machines. A focused stream of cold air from the Mini Cooler was all it took to remedy the situation.

Another application that I had the pleasure of seeing while visiting in Hungary was at a manufacturer of cataract lenses. They were using both the Adjustable Spot Cooler and the Mini Cooler in the milling process of the lenses. The cold air from the Mini Cooler replaced expensive and messy liquid coolant and was capable of maintaining a consistent temperature on the lens to prevent warping.

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Mini Cooler used to maintain a low temperature on cataract lenses during inspection.

The Mini Cooler is available with both single and dual cold outlets, depending on the part needing to be cooled. The kit will include the Mini Cooler, a swivel Magnetic Base for precise mounting and positioning, either a Single or Dual Point Hose Kit, and a Manual Drain Filter with a mounting bracket included. If you’re experiencing heat related troubles on a small application, take advantage of EXAIR’s Unconditional 30-Day Guarantee and give the Mini Cooler a try. You’ll be HEATED if you don’t!

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

Pressure – The Inner Working of the Basic Pressure Gauge

Everyday here at EXAIR we talk about pressure, specifically compressed air pressure. The other day I was looking up our model 9011, 1/4″ NPT Pressure Gauge , and it got me to wondering just how does this small piece of industrial equipment work. The best way to find out is to tear it apart.

9011_exair

Most mechanical gauges utilize a Bourdon-tube. The Bourdon-tube was invented in 1849 by a French watchmaker, Eugéne Bourdon.  The movable end of the Bourdon-tube is connected via a pivot pin/link to the lever.  The lever is an extension of the sector gear, and movement of the lever results in rotation of the sector gear. The sector gear meshes with a spur gear (not visible) on the indicator needle axle which passes through the gauge face and holds the indicator needle.  Lastly, there is a small hair spring in place to put tension on the gear system to eliminate gear lash and hysteresis.

When the pressure inside the Bourdon-tube increases, the Bourdon-tube will straighten. The amount of straightening that occurs is proportional to the pressure inside the tube. As the tube straightens, the movement engages the link, lever and gear system that results in the indicator needle sweeping across the gauge.

Pressure Gauge Top

The video below shows the application of air pressure to the Bourdon-tube and how it straightens, resulting in movement of the link/lever system, and rotation of the sector gear –  resulting in the needle movement.

If you need a pressure gauge or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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EXAIR Heavy Duty Dry Vac: Overview

Heavy Duty Dry Vac Family

When it comes to industrial vacuums, wouldn’t it be nice to have a durable, long lasting vacuum that is quiet?  There is such a vacuum that has these qualities; the EXAIR Heavy Duty Dry Vac System.  This vacuum system has no moving parts, no motors to fail, or bearings to wear.  They only require compressed air to operate.  The Heavy Duty Dry Vac is used to vacuum solid materials like plastic, sand, and even denser materials like steel shot.  The vacuum pumps are made from a hardened alloy construction to resist wear and abrasion, and it is designed to generate a strong vacuum level measuring -60” H2O (-15 KPa) at 80 PSIG (5.5 Bar).  To accommodate the multiple types of industrial applications, EXAIR offers the Heavy Duty Dry Vac Systems with different options and drum sizes.

The unique design of the Heavy Duty Dry Vac is incorporated in the modified lid that will fit onto a standard 55-gallon, 30-gallon, or 110-gallon drum (209L, 114L, or 418L respectively).  A 0.1-micron filter bag mounts in the center of the lid to allow excess air to escape and to contain the contamination inside the drum.  The large surface area of the filters allows for extended use before replacement while the high efficiency will keep the fine particles from re-entering the environment.  Under the drum lid, EXAIR used some features to help reduce the noise level even further.  We added a silencing foam and an extended hose.  This will muffle the noise and direct the contamination toward the bottom of the drum.  With these additional features, the noise level is only 82 dBA at 80 PSIG (5.5 bar).  Measure that against any electric vacuum.

Heavy Duty Dry Vac System

The Heavy Duty Dry Vac Systems come in three different options to best fit your application.  The standard option comes with the drum lid described above and a latching ring to attach to the drum.  It also comes with 10 feet (3m) of an anti-static hose, 20 feet (6m) of a compressed air hose, an aluminum chip wand, a hose hanger, a gauge, and a manual operational valve.  This option is available with three different drum sizes.  For example, model 6197 is for the 55-gallon drum (209L), model 6197-30 is for the 30-gallon drum (114L) and model 6197-110 is for the 110-gallon drum (418L).

Deluxe Heavy Duty Dry Vac System

The second option is the Deluxe Heavy Duty Dry Vac System.  This option will include all the items in the standard option plus aluminum tools, a tool holder and a drum dolly.  The upgraded aluminum tools include a floor tool, crevice tool, skimmer tool with detachable brush, and a two-piece double bend wand.  They are easily attached to the hose for quick cleaning of material spills.  The Deluxe system is a great option for getting into tight areas, hard-to-reach places, and large floor areas.  This option is also available in three drum sizes.  For example, model 6297 is for the 55-gallon drum (209L), model 6297-30 is for the 30-gallon drum (114L) and model 6297-110 is for the 110-gallon drum (418L).

Premium Heavy Duty Dry Vac System

If you do not have a drum to use in your facility, no problem.  EXAIR offers a steel drum in the Premium Heavy Duty Dry Vac Systems.  The Premium package has all the items in the Deluxe option plus a heavy-duty steel drum.  We offer the Premium option for all three sizes as well.  For example, model 6397 will include the 55-gallon drum (209L), model 6397-30 will included the 30-gallon drum (114L) and model 6397-110 will include the 110-gallon drum (418L).

If you get tired of throwing away your electric vacuums for burned up motors, you should try the EXAIR Heavy Duty Dry Vac System.  They will definitely extend the useful life, make it much quieter to operate and vacuum denser heavier materials quickly.  For U.S. and Canadian customers, we offer a 30-day unconditional guarantee to try the units.  If you need help to determine which Heavy Duty Dry Vac option would best suit your application, you can contact an Application Engineer at EXAIR.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb