Custom Air Amplifiers for Special Applications from EXAIR

The EXAIR Super Air Amplifiers and Adjustable Air Amplifiers are used in 100’s if not 1000’s of applications and locations across the world.  For cooling, drying, and cleaning of parts as well as venting and exhausting of smokes and fumes, or dust collection – the Air Amplifiers are sure to get the job done.

The Super Air Amplifiers are made of aluminum and are sized from 3/4″ to 8″ to cover a wide range of applications. Compact and lightweight, no electricity, no moving parts, and instant on/off are just a few of the features.

The Adjustable Air Amplifiers are made of aluminum or type 303 stainless steel and are sized from 3/4″ to 4″, and with adjustable output, provide a wide spectrum of performance.  They have the same great features of the Super Air Amplifier with the added benefit of varying force and flow.

2″ Super Air Amplifier and 2″ Stainless Steel Adjustable Air Amplifier

Even with the wide variety of types, sizes, and materials of construction, a customer may have a special need and there are numerous ways that EXAIR can customize the Air Amplifiers.  I’ll touch on several from the basics to the most complex.

  • The Super Air Amplifiers come with a stock shim that sets the performance seen in the catalog. There are other shim thicknesses available if more or less flow is preferred, and they can be installed at the factory if desired.
  • The Adjustable Air Amplifiers are designed for varying output by turning the plug further in to or out of the body. If there is a performance setting that is preferred, we can test, adjust and set it to meet that performance, allowing to be installed and ready for optimum results.
  • If the use of a special material will increase the benefit of the Air Amplifier, we can explore several options with you. One customer needed an Adjustable Air Amplifier with a PTFE plug to help draw a sticky material through a process and prevent the material from adhering to the surface of the Air Amplifier.
  • For those applications where the Air Amplifier is to be installed into a piping system, custom design with flanged ends can be done. Recent designs include stainless steel Adjustable Air Amplifiers with class 150 raised face flanges, and another with sanitary Tri-Clamp style.

Adjustable Air Amplifier with PTFE Plug, Class 150 Raised Face and Sanitary Tri-Clamp Flanges

  • A special High Temperature version was developed for moving hot air to surfaces requiring uniform heating while in a furnace or oven. This special design is rated for environments up to 700°F and its surface is protected from heat stress by a mil-spec coating process.  This special High Temperature Air Air Amplifier was so popular, it became a standard offering and is in stock!

high temp air amplifier1-1/4″ High Temperature Air Amplifier

For over 35 years, EXAIR has been designing and manufacturing the best performing and highest quality products in the marketplace. If you have a special requirement and in need of a custom solution, we’ve got the experience and history to solve most problems.

If you have questions about Air Amplifiers, custom Air Amplifiers, or any of the 15 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer
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Super Air Amplifier Overview – Vent, Exhaust, Cool, Dry, Clean

Vent, exhaust, cool, dry, clean -with no moving parts!  That tag line from the catalog section pretty much says it all about the EXAIR Air Amplifiers, both the Super Air Amplifier and the Adjustable Air Amplifiers. I want to share some more information about the Super Air Amplifiers.

In general, the air amplifiers employ the Coanda effect – a basic principle of fluid flow – to create air motion in their surrounding.  Through intelligent design, this surrounding fluid flow can be manipulated and exploited, creating an amplification of a small amount of compressed air.

AirAmplifiers
Super Air Amplifier

How do they work? In the figure below – a small amount of compressed air flows into the unit (1) to an annular chamber (2). The air is then throttled through a small ring nozzle (3) at high velocity. This primary air stream adheres to the Coanda profile (4), which directs it towards the outlet. A low pressure area is created at the center (5), inducing a high volume flow of the surrounding air into the primary stream. At the exit, you have the combination of flows, resulting in a high volume, high velocity flow.

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How Air Amplifiers Work
Super Air Amplifier Coanda Profile
Close Up of the Coanda Profile

The amplification ratio – the outlet airflow compared to the compressed air flow is dependent upon the cross sectional area of the inlet, and the 3/4″ Super Air Amplifiers have 12:1 amplification ratios all the way up to the 4″ and 8″ Super Air Amplifiers with 25:1 amplification ratios! That is a lot of ‘free air’ to use for cooling, drying and cleaning.  And a lot of air or smoke that can be drawn at the inlet and vented away from the area. For more on the amplification ratios, see this -blog-

Each Super Air Amplifier has a patented shim (patent#5402938) that precisely sets the compressed air flow, and shim sets are available to install to increase the force and flow as needed.

Super Air Amplifier Shims
Patented Shims for the Super Air Amplifier

The balanced outflow of air minimizes wind shear to produce a very quiet, powerful flow at sound levels up to three (3) times quieter than other air movers.  A 4″ Super Air Amplifier operated at 80 PSIG will have a Sound Level of just 73 dBA.

The video below shows the power of the Super Air Amplifier in inducing a high volume flow of surrounding air (for venting) into the primary air stream (for cooling/drying/cleaning)

Typical applications include venting weld smoke, cooling hot parts, drying wet parts, cleaning machined parts, distributing heat in mold & ovens, dust collection, and exhausting vent fumes.

If you have questions about the Super Air Amplifier or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer
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Super and Adjustable Type Air Amplifiers

The EXAIR Air Amplifiers are a powerful, efficient and quiet air mover, whose power can be harnessed for blowoff, cooling and ventilation applications. Using a small amount of compressed air, air amplifiers pull in large amounts of surrounding air to produce a high volume, high velocity outlet flow.  Quiet and efficient, output flows with amplification ratios of up to 25 times are possible. There are two types, the Super Air Amplifier and the Adjustable Air Amplifier.

The Super Air Amplifier, with sizes ranging from 3/4″ to 8″, has a patented design (patent #5402938) that uses a special shim to maintain critical position of the components parts. It is through this critical gap setting that a precise amount of compressed air is passed at exact intervals controlled by the shim toward the center of the of the Super Air Amplifier.  The jets of air create a high velocity flow across the entire cross sectional area, which in turn pulls in large amounts surrounding air, resulting in the amplified outlet flow.  Because the outlet flow remains balanced and minimizes wind shear, sound levels are typically three times lower than other types of air movers. The shims are available in thicknesses of 0.003″ (supplied as standard), 0.006″ and 0.009″, and changing to a larger shim will increase the force and flow of the outlet air. The 8″ Super Air Amplifier is supplied with a 0.009″ shim, with a 0.015″ shim available.

2″ Super Air Amplifier and Patented Shim Design

For high temperature applications (up to 700°F/374°C) a special 1-1/4″ High Temperature Air Amplifier is available, with performance equal to the 1-1/4″ Super Air Amplifier. Its surfaces are protected from heat stress by a mil-spec coating process. The High Temperature Air Amplifier is highly effective at pushing large amounts of hot air to areas that typically remain cool.

The Adjustable Air Amplifier, with sizes ranging from 3/4″ to 4″, does not use a shim, and has an infinitely adjustable air gap, which regulates the air consumption and outlet flow from a light breeze to a powerful blast. A highly effective air mover, it can be tailored to meet the exact air flow and force of your specific application. They are available in aluminum and in stainless steel (Type 303) for food service, higher temperatures (400°F/204°C) and corrosive environments.

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2″ Adjustable Air Amplifier, in Aluminum or Stainless Steel

Force and flow of the Adjustable Air Amplifier is changed by loosening the knurled lock ring and turning the exhaust end to open or close the gap.  Once the desired force and flow is achieved, the knurled ring can be tightened to lock the device at the current setting. Typically, an air gap of 0.002″ to 0.004″ provides the required performance.

The table below summarizes the key features of the Super Air Amplifier and Adjustable Air Amplifier.  Please contact an Application Engineer if you need assistance in making a selection.

Air Amp Selection Chart

Note that EXAIR can manufacture special Air Amplifiers to your specification including special flanged mounting style or with a PTFE plug to avoid sticky material build up.

To discuss your application and how a Super or Adjustable Air Amplifier or any EXAIR Intelligent Compressed Air Product can improve your process, feel free to contact EXAIR, myself, or one of our other Application Engineers. We can help you determine the best solution!

Brian Bergmann
Application Engineer

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Adjustable Air Amplifier Keeps Sensor Cool

Our distributor in China has a customer who visited the United States, while their customer was in the US they saw an EXAIR product installed and wanted to replicate the setup in China. He saw the EXAIR label and reached out to our distributor for help in identifying the part. Taking a quick measurement of the inlet side of the Adjustable Air Amplifier led us to discern it was a Model 6041 1-1/4” Adjustable Air Amplifier.

adjustable air amplifier sensor cooling
EXAIR Model 6041

The product was installed on a baghouse monitoring system. The sensor is used to detect minor leaks within the dust collection system before the leaks create a major problem. The environment in which the sensor was installed results in temperatures that are just above the normal operating temperatures during warmer months and can result in erroneous readings. When this occurs, production is shutdown to prevent a failure of the dust collection system while the filters can be inspected. By installing the Adjustable Air Amplifier to provide a large volume of air and a low level of compressed air consumption, the temperature is able to be maintained within typical operating range for the sensor. This alleviates the need for unnecessary shutdowns (or unnecessary filter replacement), while ensuring that the working environment remains dust-free.

EXAIR’s Adjustable Air Amplifiers are available in both Stainless Steel and Aluminum from sizes ranging from ¾”-4” on the air outlet. The outlet can be ducted as seen in this application, or it can be used as-is. The air gap of the Adjustable Air Amplifier is infinitely adjustable, allowing you to regulate both the air consumption and outlet flow from a “breeze” to a “blast”. In addition to the standard Adjustable Air Amplifiers, we also have a Model 121021 High Temperature Air Amplifier available that is capable of withstanding temperatures as high as 700°F.

Air Amplifiers can be used in a variety of different applications. Not only can they be used in applications requiring cooling, but the air entrainment properties of the amplifier can be used to exhaust smoke as discussed in this application at a foundry. An Adjustable Amplifier can also be used for drying or cleaning parts as well as for conveying light materials.

Regardless of the application, EXAIR has a suitably sized Air Amplifier to fit your needs. If you need an efficient and reliable way to vent, cool, clean, or dry parts give us a call. An Application Engineer would be happy to take a look at your application and provide the best recommendation.

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

Two Types of Air Amplifiers – Volume and Pressure

When the topic of Air Amplifiers comes up, there are two avenues to consider –  is it the air pressure or the air volume that you wish to amplify?  There exists technologies to amplify either parameter, and we will examine them both.

There may be equipment or processes within a facility that operate best at air pressures higher than can be delivered, due to air compressor limitations or the supply system. An Air Pressure Amplifier can take the existing compressed air supply, and boost the pressure allowing for the higher needed air pressure without requiring a dedicated compressor capable of operating at the higher pressure.

An Air Pressure Amplifier is basically an air pump, driven by a portion of the compressed air supply.  The pump cycles and compresses the remaining amount of compressed air to a higher outlet pressure. This higher output pressure can be used to operate the equipment or process that required the pressure levels that the base system could not supply. The drawback is that the pump system consumes a good amount of the compressed air volume, to power the pump which reduces the amount of air available for other equipment or processes.  This drives up the compressed air consumption for the system, and requires the extra capacity to operate.

The other type of Air Amplifier is the kind that amplifies the air flow volume. EXAIR manufactures this type of amplifier.

AirAmplifiers

The air flow amplification works by taking compressed air (1) and directing into an annular chamber (2). It is then throttled through a small ring nozzle (3) at high velocity. This primary stream of air adheres to the Coanda profile (4) and is directed through the outlet. A low pressure area is created at the center, inducing a high volume flow (5) of surrounding air to be drawn in and added to the main air stream. The combined flow of primary and surrounding air exits as a high volume, high velocity flow.

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EXAIR manufactures (2) types of Air Amplifiers, the Super Air Amplifier and the Adjustable Air Amplifier.  In addition, a special model for High Temperature applications is available.  Sizes range from 3/4″ (19mm) to 8″ (203mm) to meet most air flow requirements.  Air amplification ratios start at 12:1 for the 3/4″ model and increase to 25:1 for the 4″ and 8″ models.

Charts and tables are available to help determine the right Air Amplifier for the job.

If you have questions about the Air Amplifiers, or would like to talk about 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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Super Air Amplifiers – Adjustability for Blowoff, Drying, Cooling, Circulation and Ventilation

The Super Air Amplifier is a powerful, efficient, and quiet air mover. Applications currently in place include blowoff, drying, cooling, circulation and ventilation. Sizes from 3/4″ to 8″ are available to best match the air volume that is necessary to achieve the process goals. There are a couple of ways to change the performance of the Super Air Amplifier if either a small or large change to the output flow is required.AirAmplifiers

The chart below shows the Total Output Flow for each of the 6 models. As an example, the Model 120021 or 121021, when operated at 60 PSIG of compressed air supply, will have a total output flow of 120 SCFM. These same devices when operated at 80 PSIG will have a total flow of 146 SCFM. By simply using a pressure regulation device on the compressed air supply, the output performance can be tuned to match the desired outcome.

Capture

For those applications where much greater flow and/or force is needed, the option of installing a thicker shim is available.  The Super Air Amplifiers are supplied with a 0.003″ shim installed (the 8″ model 120028, has a 0.009″ shim as standard) and can be fitted with shims of thicknesses of 0.006″ or 0.009″ (the 8″ model has an optional 0.015″ shim.) Installation of a thicker shim increases the slotted air gap, allowing for a greater amount of controlled air flow.  As a general rule, doubling the shim thickness will double the air flow rates.

Super Air Amplifier Shims
Patented* Shim Design for Super Air Amplifiers

The Super Air Amplifier design provides for a constant, high velocity outlet flow across the entire cross sectional area,.  The balanced outlet flow minimizes wind shear to produce sound levels that are typically three times quieter than other air movers. By regulating the compressed air supply pressure and use of the optional shims, adjustability and flexibility of the unit is wide ranging and sure to meet your process needs.

If you have questions regarding the Super Air Amplifier, or would like to talk about any EXAIR Intelligent Compressed Air® Product, 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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*Patent #5402938

Air Amplifiers – What is an Amplification Ratio?

On Friday my colleague, Russ, blogged about the Super Air Amplifier (see that BLOG here, including a video demo)  In discussing the Air Amplifiers, the topic of amplification was mentioned. Today, I’d like to expand a bit further the amplification aspect of the Air Amplifier performance.

As the name of the device implies, the compressed air used by the Air Amplifier is added to, and thus ‘amplified’, the total output flow of the unit. Depending on the size and type of Air Amplifier, the amplification ratio starts at 12:1 and goes up to 25:1, with the ratio being the output flow to the compressed air usage.

AirAmplifiers.jpg
Super Air Amplifier and Adjustable Air Amplifier

EXAIR offers (2) types- the Super Air Amplifier and the Adjustable Air Amplifier.  The Super Air Amplifier uses a patented shim technology to maintain a precise gap, which controls the compressed air flow and expansion through the unit.  As the expanded air flows along the Coanda profile, a low pressure area is created at the center which induces a high volume flow of surrounding air into the primary air-stream.  The combined flow of primary and surrounding air exhausts from the Air Amplifier in a high volume, high velocity flow.  The larger diameter units have a greater cross sectional area with larger low pressure areas, resulting in greater amplification ratios.

The Below table shows the amplification ratios.

SuperAirAmplifierPerformance

The Adjustable Air Amplifier does not use a shim, but rather has an infinitely adjustable gap, allowing for fine adjustment of performance.  Force and flow is changed by turning the exhaust end to adjust the gap, and is then locked into place. The method of the amplification is the same as for the Super Air Amplifier, and the amplification ratios are similar and shown below.

AdjustableAirAmplifierPerformance

The Super Air Amplifiers and Adjustable Air Amplifiers are ideal for use in applications and processes that require cooling, drying and/or cleaning of parts, or the ventilation of confined areas or weld smoke or the exhausting of tank fumes.

If you have questions regarding the Air Amplifier, or would like to talk about any EXAIR Intelligent Compressed Air® Product, 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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