Stories From The Field: Automotive Plant Tour

Throughout my years I have been in many manufacturing facilities. Oddly enough, I have seen nearly every part of a passenger car manufactured and then fully assembled. The amount of compressed air applications in automotive supplier and manufacturing facilities are tremendous. Here are some stories from just a few we have encountered over the years, and all of them can be found in our Application Database.

Air Wipe – How it works
  1. A component manufacturer, specifically a steering and transmission component manufacturer was having issues with machined parts coming out of a CNC machine with too much oil based cutting fluid on them and not passing inspection process because the oil would throw off the automated measuring system. The part was a splined shaft that the high surface tension oil stayed in the splines. The part was removed from the machine via robotic loader and set onto a fixture. The path to the fixture was outfitted with a Super Air Wipe so the robotic loader could move the part into and out of the air wipes’s airflow and remove the oil. The converging airflow of the Super Air Wipe was ideal to keep the peaks and valleys of the shaft clean of oil and they were able to direct oil back into the cutting machine so no separate collection system was needed.
Robotic Welder fitted with EXAIR Super Air Wipe

2. A seat bracket manufacturer had issues protecting the lenses on their vision systems from welding spatter. They were again able to reduce the replacement / repair downtime by installing a 9″ Super Air Wipe in front of the robotic mounted lens and keep the spatter / fumes from ever making it to the lens, resulting in expanded run times between repair / downtime.

Cooling with Air Amplifiers

3. A forging company manufacturing the pistons was having issues reducing the temperature of the pistons as they were assembled to the connecting rods. The solution for them was to install a series of Super Air Amplifiers over the fixtured, indexing line and at each dwell station a Super Air Amplifier would activate and cool down the assembly by moving large volumes of ambient air mixed with small amounts of compressed air onto the surfaces.

4. An automotive manufacturer had issues with stamping shavings and welding debris staying on the surface of parts and fixtures resulting in rework and defective parts. Implementing a series of Super Air Nozzles, and Super Air Knives resulted in debris removal that saved tooling rework as well as production reject parts.

5. Another automotive / recreational vehicle manufacturer needed help with their torture test machine for suspension components. They were utilizing fans to try and keep shock sensors cool and replicate air movement. electric fans were not able to provide a focused airflow and so enter the Super Air Amplifiers. These have also been utilized on engine torture test machines.

1 – Chevrolet Corvette C7 2014 – LT1 Engine Testing on Dyno

These are just a select few of the actual applications that I have actually help with over the course of the years. As a whole, we have helped endless number of automotive industry applications. It doesn’t matter if you are in the automotive industry or just a garage tinkerer, contact and Application Engineer and let us help you with your point of use compressed air application today.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

1 – Autoblog_gr; Chevrolet Corvette C7 2014 – LT1 Engine Testing on Dyno – retrieved from https://www.youtube.com/watch?v=N3h8imnOPwU on 8/31/2022

Air Amplifiers to Increase Volume of Airflow Aid in Cooling, Cleaning, Circulation, Venting

Air Amplifiers are a perfect solutions for utilizing air for Venting, Exhausting, Cooling, Drying, or Cleaning with no moving parts. As the name implies, these tools produce a high volume and a high velocity of outlet flow. These are very quiet, efficient and can amplify your air consumption up to 25 times… Here is a great diagram and description of exactly how these work:

Air Amplifiers use the Coanda Effect to generate high flow with low consumption.

As you can see, these fine pieces of engineering genius have no moving parts, and require no electricity. You can easily control the flow, force and velocity by opening or closing the air gap (fixed with a shim) and regulating the the supply air. These can also be ducted on each end to either pull in or remove air or fumes from one room or area to another.

SUPER?? What makes our Super Air Amplifier super? I’m glad you asked. The Super Air Amplifier has a patented design that uses a special shim to maintain critical position of the component parts. This results in a precise amount of compressed air to be released at exact intervals towards the center of the Super Air Amplifier. These jets of air create a constant, high velocity outlet flow across the entire cross-sectional area. This balances out the airflow to maximum performance, this simultaneously minimizes wind shear, causing sound levels up to 3 x’s quieter than other comparable air movers. To completely understand how much air this Super Air Amplifier amplifies (try saying that fast 5 times), please see the below chart.

As you can see, the amplification ratio is between 12 and 25 x the amount of air consumed. For the right applications, these are game changers… Pro tip – notice that even the highest level still falls under OSHA guidelines for noise!!

If you have any questions, or would like to discuss your application directly, please reach out today. We would love to speak with you, and help wherever we can.

Thank you for stopping by,

Brian Wages

Application Engineer

EXAIR Corporation
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“Free” Ambient Air Entrainment w/ EXAIR’s Super Air Amplifiers

When working with a cooling application, many customers will immediately look to the Vortex Tube and Spot Cooling product lines. While this may be the best solution for some applications, cold air is not always the best method that we have available for cooling. EXAIR’s Super Air Amplifiers are very effective at reducing the temperature of a part without requiring cold air. The Super Air Amplifiers get their name due to their ability to entrain ambient air and “amplify” the supplied compressed air. You’ll often see us referring to the air amplification ratios achieved with our products. This is a ratio of the supplied compressed air relative to the entrained “free” air that comes from the ambient environment.

Due to their ability to entrain large amounts of ambient air, we can move a high volume of air across the surface of the part and quickly lower the temperature. I like to compare this to blowing on a hot cup of coffee just as it’s been brewed. The temperature of the air coming from your mouth is around 98.6°F, the same as your body temperature. Coffee can be as hot as 185°F when fresh. Due to the temperature differential between your breath and the hot coffee, we’re able to achieve a reasonable amount of cooling just by simply blowing across the surface. Typically, when the target temperature of the part or material needs to be around ambient temperature or higher; the best solution for cooling is going to be a Super Air Amplifier.

EXAIR’s Super Air Amplifiers achieve air amplification ratios ranging from 12:1 on our smallest units and up to 25:1 for our 4” and 8” models. EXAIR’s Super Air Amplifiers utilize a patented shim design to maintain critical positioning of component parts. This allows a precise amount of compressed air to be released at exact intervals toward the center of the Super Air Amplifier. This creates a constant, high velocity outlet flow across the entire cross-sectional area. Free, ambient air is entrained through the unit, resulting in high amplification ratios. The balanced outlet airflow minimizes wind shear to produce sound levels far lower than other similar air movers.

Super Air Amplifiers are supplied with a .003” thick shim that is ideal for most applications. Flow and force can be increased by replacing the shim with a thicker .006” or .009” shim. The flow of air is also controlled by adjusting the input pressure supplied to the amplifier. Higher pressures increase both the force and flow, while lower pressures decrease both force and flow. All Super Air Amplifiers are available in kits that come with a shim set as well as a suitably sized pressure regulator and auto-drain filter.

EXAIR has a solution for you if you need to move A LOT of air. Reach out to an Application Engineer today if you have an application that you believe could be served with a low-cost, simple solution!

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

Understanding EXAIR Air Amplifiers and Air Pressure Amplifiers

Adjustable Air Amplifier

I take many calls regarding Air Amplifiers but sometimes I get calls that confuse EXAIR Air Amplifiers with air pressure amplifiers. EXAIR’s Air Amplifiers and air pressure amplifiers are fundamentally different and have different purposes.

First, EXAIR’s Super Air Amplifiers and Adjustable Air Amplifiers increase air volume, not pressure. Air pressure amplifiers increase air pressure from typical system pressure of 80-130PSIG up to 5000 PSIG. Air pressure amplifiers are an excellent solution for applications that require higher air or nitrogen pressure such as increasing force for clamps or presses and pressure testing processes. They are also known as air boosters.

Air Amplifiers use the Coanda Effect to generate high flow with low consumption.

EXAIR Air Amplifiers are a low cost way to move air, smoke, fumes and light materials. These Air Amplifiers use the Coanda effect to create a low pressure area which draws in surrounding air to efficiently deliver a high volume of air on to a target. Using a small amount of compressed air as their source, Air Amplifiers are among the most efficient products within EXAIR’s entire product line. EXAIR Air Amplifiers will create output flows up to 25 times their consumption rate and deliver it at a high velocity. The entrainment of outside air amplifies the total volume of air output which also increases force, cooling ability and circulation.

EXAIRs Air Amplifiers have no moving parts, assuring maintenance-free operation. Fine tuning flow, vacuum and velocity are easily controlled by regulating the pressure. For gross adjustment of air flow and vacuum an internal shim is used to increase or decrease the internal “air gap” that the compressed air flows through. Both vacuum and discharge ends of the Air Amplifier can be ducted, making them ideal for drawing fresh air from another location, or moving smoke and fumes away.

I hope this helps distinguish EXAIR Air Amplifiers versus air pressure amplifiers. If you have questions regarding EXAIR Intelligent Air Products please contact one of our Application Engineers as we are always ready to help.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@EXAIR.com
Twitter: @EXAIR_EK