I have recently had the pleasure of working with a customer developing a method of delivering air to trapped miners during a multi-man mine rescue mission. The federal government mandates that in the event of an explosion, miners must have a safe place to retreat for a minimum of 96 hours. This system will provide them with a supply of air during that period of time. In the initial stages, they had tried using some old venturis left over from a previous project. While this did work, they weren’t as effective or efficient as they needed. Through a little bit of research, they found EXAIR.
Generally, the Super Air Amplifier utilizes a source of compressed air. In this case, instead of using compressed air as the source, they’re using cryogenic liquid air. That air passes through a series of cold plates and heat exchangers and gets to the Super Air Amplifier at about 70°F. This air is then carried into the chamber, giving the miners a source of clean air.
EXAIR Super Air Amplifiers utilize a patented shim design that allows the unit to entrain ambient air at a rate of up to 25:1 from the compressed air supply. This balanced outlet airflow minimizes wind shear, producing sound levels that are typically three times quieter than other air movers. The Super Air Amplifiers are supplied with a .003” slotted air gap and can be adjusted by replacing the shim with a thicker .006” or .009” shim or by regulating the air pressure supplied to it. In addition to making gross adjustments to the airflow by changing the shim thickness, flow can also be dialed in by regulating the air pressure supplied. All Super Air Amplifier Kits come complete with the a properly sized Auto-Drain Filter to keep the air clean and dry, a Pressure Regulator to “dial” in the airflow, and a shim set. When the filter is installed just upstream of the Super Air Amplifier, there is no need to perform any regular maintenance. With no moving parts to wear out, you can expect many years of reliable operation.
Do you have a cooling or drying application that could benefit from a Super Air Amplifier? Contact an Application Engineer today to find out how EXAIR can help you save compressed air in your application!
When seeking a suitable solution for cooling or drying your parts, you may be tempted to try out a low-cost fan to get the job done. While fans do a great job of keeping you cool during the warmer months, they’re not the best choice for cooling or drying parts. Have you ever noticed that when standing in front of a fan the flow pattern is not consistent? This is due to the nature in which the fan blades create that air flow by “slapping” the air as they spin rapidly. The air flow that exits from the fan is turbulent and is not as effective as the laminar air flow pattern that is produced by EXAIR’sSuper Air Amplifier. The Super Air Amplifier utilizes a patented shim design that maintains a critical position of the air gap and creates a laminar air flow pattern that will exit the outlet of the unit.
In addition to providing laminar air flow more conducive for cooling and drying, the Super Air Amplifier provides much more air that can be directed at the target. A standard 2.36” x 2.36” DC operated fan provides anywhere from 12-27 CFM at the outlet, depending on the model. For comparison, a Model 120022 2” Super Air Amplifier will provide 341 SCFM at the outlet when operated at 80 psig. At just 6” away from the outlet, this value increases to 1,023 SCFM!! When compared to the fan outlet air flow, the Super Air Amplifier produces more than an 1,100% increase in air volume!
When replacing a fan with a Super Air Amplifier, the process time can be dramatically reduced. The increase in air volume significantly reduces the contact time that your part will need to be exposed to the air flow, allowing you to increase your line speed and decrease the overall production cost of the part. This is achieved due to the nature in which a Super Air Amplifier draws in air from the ambient environment. At amplification ratios as great as 25:1, the Super Air Amplifier is the best way to move a lot of air volume across the part with very little compressed air supplied to it. Check out the video
In addition to providing laminar airflow and increasing the volume of air, the Super Air Amplifier is also infinitely adjustable through one of two ways. Each size Super Air Amplifier has a shim set that can be purchased. Swapping out the stock shim for a thinner shim will reduce the compressed air consumption, force, and flow. Installing a thicker shim will increase it. Additionally, the force and flow can also be adjusted by regulating the input supply pressure through the use of a pressure regulator. With sizes ranges from ¾” up to 8”, there’s a Super Air Amplifier for all applications. Give us a call today to see how you can optimize your process by replacing your fans with one or more Super Air Amplifiers.
EXAIR’s product offerings contain many products that can be used for cooling. The focus of this blog will be Super Air Amplifiers. These often times get placed in a head to head competition with an electric fan. The best part, they easily come out on top.
Our own Tyler Daniel produced a great video showcasing how efficient it is to cool a part using the Super Air Amplifier rather than a fan.
When looking at the benefits other than performance and rate of cooling due to air entrainment, many customers prefer the Super Air Amplifier due to the fact there are no moving parts. This comes into play when cooling within in a hard to reach area or within a harsh process is needed. Placing an electric motor with a blade held on by fasteners may not be desirable from a maintenance standpoint. The Super Air Amplifiers do not require electricity, meaning there is not a motor or bearings that would need to be replaced or inspected.
Another benefit is the small footprint of the Super Air Amplifier. This can also be seen within the video above where the Air Amplifier is shown is able to produce 341 SCFM (9,650 SLPM) in amplified airflow. This gives the ability to place a small unit inside of a chamber that needs large volumes of air flowed through it. For instance, a rotomolded part that has a large chamber and it needs surfaces to be cooled in order for the part to hold its shape from the mold rather than warp. This can also be coupled with the fact that a Super Air Amplifier can be ducted on either the suction or discharge side in order to retrieve cool air or move the warm air out of the area.
Speaking of warm, the Super Air Amplifiers are also manufactured to withstand up to 275°F (135°C) from stock. Stainless Steel and High-temperature models go well beyond that temp, as seen above. Custom-designed (flanges and different materials are common) versions are also available in short lead-times.
If you would like to discuss the benefits to a Super Air Amplifier further, feel free to contact us.
How did a past inventor help generate efficient compressed air products for EXAIR? In the early 20th century, Henri Coanda who was a Romanian aeronautical engineer that built an experimental Coanda-1910 airplane. There are some debates if the airplane actually flew, but he invented a curved surface for a wing to generate a Coanda effect. The Coanda effect is the “tendency of a fluid jet to stay attached to a convex surface”1. Thus, a moving stream of fluid will follow the curvature of the surface rather than continuing to travel in a straight line. The Wright Brothers who flew the first airplane in the state where EXAIR is located, Ohio, used the Coanda effect to create lift. With a curved profile, the air will adhere to the surface, causing a low pressure which makes the airplane fly.
EXAIR uses this Coanda profile to make some of our Intelligent Compressed Air Products™. Like the airplane wing, our curved surface will also create a low pressure. How does this help? Well, high pressure will always travel to low pressure. Instead of lift, we use the low air pressure to entrain ambient air. This ratio is what we call the amplification ratio. The higher the amplification ratio, the higher the efficiency for a blowing device. Two main compressed air products that EXAIR manufactures use this type of profile; Air Knives and Air Amplifiers. I will cover both below.
The Air Knives that use the Coanda profile blows air along the length of the knife at a 90o angle from the exit. We offer two types; the Standard Air Knife and the Full Flow Air Knife. The Standard Air Knives are made in Aluminum or Stainless Steel with blowing widths up to 48” (1219mm). The inlet ports are at each end; so, the overall length is 1” (25mm) longer. The Full Flow Air Knives have the port or ports on the back. The air blows out the entire length of the air knife. The maximum length is 36” (914mm).
Both types of air knives use the Coanda profile to generate a low pressure as the air exits the gap and “hugs” the curve (reference photo above). This low pressure draws ambient air into the air stream at a 30:1 amplification ratio for both the Standard Air Knife and Full Flow Air Knife. So, for every one part of compressed air, we entrain 30 parts of ambient air. Besides efficiency, it also adds mass to the air stream for a hard-hitting force. With this engineered profile, the air stream is laminar which gives a consistent force across the entire length and reduces noise levels. Not only will they save you money, but they are also OSHA safe.
The Air Amplifiers use the Coanda profile in a circular form to pull in dramatic amounts of free surrounding air. The Coanda effect is able to generate a low pressure to blow air for cooling, cleaning or removing smoke and debris efficiently and quietly. The Air Knives above blow a flat stream of air while the Air Amplifiers will blow a conical air stream. They can reach amplification ratios up to 25:1. The Super Air Amplifiers use a patented shim to increase efficiency.
Unlike fans, they blow a laminar air stream for quick cooling. They do not have any moving parts or motors to wear, so they are very quiet. EXAIR manufactures five different sizes from ¾” (19mm) to 8” (203mm). The Adjustable Air Amplifiers have a plug that can be adjusted to control the blowing force from a breeze to a blast. For cleaning surfaces, this is a nice feature to “dial” in to exactly what you need. We also manufacture five different sizes in aluminum and stainless steel ranging from ¾” (19mm) to 4” (102mm). Both Air Amplifiers can be attached to ducts to remove debris, heat or smoke from the area.
Utilizing the Coanda effect allows for massive compressed air savings. Whether it is a flat or round air stream, EXAIR can do this with high amplification ratios. If you would like to discuss further how our Air Knives or Air Amplifiers can help you in your applications, please contact us. An Application Engineer will be happy to help you. History has shown us a way to increase efficiency when using compressed air. And you can take advantage of it with the Coanda profile. Thank you Mr. Henri Coanda.