This video showcases just how easy it is to install a Super Air Wipe or a Standard Air Wipe onto an extrusion line. The split ring design makes it possible to install or remove from the line without having to thread the product, all within a minute or less.
If you would like to discuss your application, or any point of use compressed air application, please contact us.
EXAIR’sGen4 Super Ion Air Wipe provides a uniform 360 degree ionized air stream that clamps around a continuously moving part to eliminate static electricity and contaminants. It is ideal for removing dust, particulates and personnel shocks on pipe, cable, extruded shapes, hose, wire and more. This engineered product has undergone independent laboratory tests to certify it meets the rigorous safety, health and environmental standards of the USA, European Union and Canada that are required to attain the CE and UL marks. It is also RoHS compliant. New design features include a metal armored high voltage cable to protect against abrasion and cuts, a replaceable emitter point, integrated ground connection and electromagnetic shielding.
The Gen4 Super Ion Air Wipe uses a small amount of compressed air to entrain high volumes of ambient air. Two shockless ionizing points powered by our Gen4 UL Component Recognized 5kV Power Supply fills the air stream with static eliminating ions. That airflow impacts the surface of the material running through the air wipe and neutralizes the charge.
The Gen4 Super Ion Air Wipe, which compliments EXAIR’s complete line of Gen4 Static Eliminators, has an aluminum construction that is lightweight and easy to mount using the tapped holes provided. Two sizes include a 2 inch (51mm) diameter and a 4 inch (102mm). There are no moving parts to wear out. Visit EXAIR.com to see the entire Gen4 Static Eliminator product line and 1/2 inch through 11 inch Super Air Wipes for applications without static.
EXAIR manufactures two types of Air Wipes; the Standard Air Wipe™ and the Super Air Wipe™. They are designed to blow an air stream in a concentric pattern around the outside of pipes, cables, extruded shapes, hoses and much more. In this blog, the focus is on the features and benefits of the Super Air Wipes. Their unique design, variety of sizes, and construction definitely makes this product “Super”.
The Super Air Wipes are used to blow-off, cool, clean and dry products. The air is blown in a conical 360o pattern completely around the outside of parts. EXAIR engineered a Coanda profile to entrain large amounts of ambient air. This will increase efficiency by using less compressed air and still generate a large force to perform the task. The Coanda profile is set at a 30o angle to increase the contact area and keep debris away from the portion of the product that has already been cleaned.
The construction of all the Super Air Wipes is also unique. It has a split design to allow for an opening to place around the part which eliminates the need to thread material through the wipe. They also use stainless-steel screws and stainless-steel shims. For diameters up to 4” (102mm), they will come with a braided stainless-steel hose to connect both halves. The stainless-steel components give the units better corrosion resistance, higher temperature ratings, and more durability. EXAIR manufactures the Super Air Wipes with two different body materials, aluminum and 303 stainless steel. EXAIR stocks the aluminum models with inner diameters from 3/8” (10 mm) for wire and cables up to 11” (279mm) for large pipes and hoses. The aluminum models have a temperature range good to 400oF (204oC). We also stock the stainless-steel models from ½” (13mm) to 4” (102mm) inner diameters, and they have a temperature range up to 800oF (427oC). If you require different diameters or materials, don’t be afraid to ask. EXAIR also makes specials.
We offer more than just the Super Air Wipes. We also have kits to help get the most out of the air wipes. A kit will include the Super Air Wipe, a filter, a regulator and a shim set. The filter will remove bulk liquids and debris from the compressed air to keep the performance optimal. The Regulator is used to control the force. This helps to not over-use the amount of compressed air required for the job. With a regulator, you can make fine adjustments to get the proper amount of air. For coarse adjustments, you can add shims to increase the air flow and force. They are easy to install on the Super Air Wipes to allow for applications to have more cooling, faster drying, and better removal for tough debris. For cleanliness and control, the Super Air Wipe Kits would be recommended for your application.
Here are some additional advantages in using the EXAIR Super Air Wipes that I did not cover. They are OSHA safe in dead-end pressure and noise exposure. So, they are quiet. In each half of the bodies, we placed pre-tapped holes for easy mounting for brackets or attachments. They do not have any moving parts or require any electricity to operate. The non-contact wiping actions that the Super Air Wipe can provide helps to support cleaning items without affecting the surface finish. Also, you won’t have to worry about replacing cloths or brushes that will slow production and wear over time.
With the creation of the Super Air Wipe, uniform cleaning, cooling, and blowing around the outside of parts is a simple task. You don’t have to worry about a variety of nozzles to target the circumference, or a fabricated blow-off device that will waste air and take much time out of your day. A simple purchase of the Super Air Wipe is all you need. If you need help in selecting the proper product for your application, you can contact an Application Engineer at EXAIR for help.
In the winter, as the temperature gets colder and colder and the air is getting drier and drier, static becomes a larger problem. In the summer, water in the air can help dissipate the electrons that we pick up as we move around, but when the air is drier, the static charge collects and clings to surfaces, building up until… zap! This can be a huge problem for companies as static can cause products to bunch up and not process correctly. Or even worse static can build so much it can shock electrical devices causing costly repairs and downtime. That’s whyEXAIR has a full catalog of static eliminating products, and we will talk about them and what each product is best suited for!
The most popular Static Eliminator we sell is our Gen4 Super Ion Air Knife! By combining a Gen4 Ionizing Barwith a Super Air Knife, The Gen4 Super Ion Air Knifeprovides rapid static elimination AND blows off any dust, chips, or debris that was being statically held to the surface. The laminar curtain of ionized air not only maximizes the rate of static dissipation, but is also ideal for stripping/sweeping away any debris, leaving a clean, static-free surface. No more jamming, tearing, nuisance shocks to operators, dust attraction, or any of the other host of problems associated with static electricity.
EXAIR’sGen4 Super Ion Air Wipe provides a uniform 360° ionized airstream that is simple to clamp around a part for reducing static electricity and cleaning contaminants. It is great for use on pipe, cable, extruded shapes, hose, wire and much more. We offer the Gen4 Super Ion Air Wipe in either 2” or 4” inner diameter, it is powered by compressed air and an external power supply. The Gen4 Super Ion Air Wipe generates both positive and negative ions that are transmitted the emitter points located on the i.d. of the wipe. Since static charges can be either negative or positive it is easy to eliminate both states of charge due to the mixed polarity of ions being generated.
To put it simple the Gen4 Ion Air Cannon is based on the mechanics of the 2″ diameter Super Air Amplifier with added static reduction capabilities and as its name implies it amplifies the supply air up to 25 times! This highly engineered product is very effective at cleaning product and reducing static at distances of up to 15′ away.
EXAIR’s Gen4 Ion Air Jet is a compact ionizer that is capable of delivering a concentrated ionized airflow that will cover a precise spot without disturbing the rest of the process. The quiet, focused air stream can quickly eliminate the static charge on surfaces. At a pressure of 80 psig the Gen4 Ion Air Jet is capable of dissipating a 5kV charge in .18 seconds!
In addition to providing rapid static decay, the Gen4 Ion Air Jet also helps to minimize compressed air use while maximizing the ionizing airflow. Utilizing a specially designed shim, the Gen4 Ion Air Jet entrains ambient air at a rate of 5:1. The airflow can easily be adjusted from a forceful blast to a gentle breeze simply by increasing or decreasing the inlet pressure to the ionizer.
Ion Air Jet on a Stay set hose.
Ion Air Jet
You can also get the Gen4 Ion Air Jetin a handheld gun option, this is called our Gen4 Ion Air Gun. This is great for applications where your operator is doing the static elimination and blow several times a shift by hand.
If you have an application that you believe would be better served by the use of an EXAIR Gen4 Static Elimination product, give us a call.
When you need to cool, blow off or dry extruded objects there are several options available, however only the EXAIR Super Air Wipe delivers the performance, efficiency and versatility that most applications require! In today’s blog we will contrast some of the differences between the EXAIR Super Air Wipe and block type air wipes.
The split-ring design of EXAIR’s Super Air Wipe offers easy clamping around the surface of the material moving through it and eliminates the need for time-consuming, cumbersome threading. While Block Type Air Wipes are also of split design the diameter of the material drawn through it can typically only vary by approximately 1/16″! In contrast the EXAIR Super Air Wipe is effective on materials that can range in size from approximately half the throat diameter up to within a fraction of an inch on the internal diameter. This range can be as large as five to six inches in our largest Super Air Wipes. The key is to ensure the material does not contact the Super Air Wipe.
Mounting the EXAIR Super Air Wipe is a snap, it can be accomplished by using either the 1/4 – 20 tapped holes on the downstream side or by utilizing a hard pipe compressed air supply line. The access to these bolt holes makes it easy to change out in the event the production line runs several different sizes. If needed the included stainless steel 1/4-20 bolts can also be removed and longer bolts could be installed to mount from either side.
Connecting the EXAIR Super Air Wipe to your compressed air supply is straightforward. For sizes up for 4″ throat diameter a stainless steel braided connecting hose is supplied pre-installed from the factory and a single 1/4″ FNPT inlet is used to supply the entire wipe. For the 5″ up to 7″ throat diameter there is a single 1/4″ FNPT inlet on each half of the wipe which would need to be connected with compressed air. Lastly, the 9″ and 11″ sizes from stock each have two 1/4″ FNPT inlet on each half of the wipe which would need to be connected to provide the appropriate flow for optimal performance.
Another very important consideration is the temperature of the material you are running. EXAIR Aluminum Super Air Wipes are rated for temperatures up to 400°F (204°C) with the Stainless Steel models rated up to 800°F (427°C). Typically, block air wipes are made from delrin or polypropylene with a replaceable wear liner, unfortunately these materials do not tolerate higher temperatures like the EXAIR Super Air Wipes.
To explain how the EXAIR Super Air Wipes work, reference the animation below: Compressed air flows through the inlet (1) of the Air Wipe into the annular chamber (2). It is then throttled through a small ring nozzle (3) at high velocity. This primary air stream adheres to the Coanda profile (4), which directs down the angled surface of the Air Wipe. A low pressure is created at the center (5) inducing a high volume flow of surrounding air into the primary airstream. As the airflow exits the slot, it creates a conical 360° ring of air that will attach to the surface of the material running through it (6) uniformly wiping the entire surface with the high velocity airflow.
While block style air wipes have a fixed performance because they operate off a series of non-adjustable drilled holes, the EXAIR Super Air Wipe operates off an adjustable shim design. As shown in the figure above the shim sets the gap opening of the ring nozzle (3). The stock thickness of the stainless steel shim is .002″ (.05mm), shims can be stacked to provide a coarse adjustment in volumetric air flow. Custom shim thicknesses are also available to tailor the performance to your needs. The shim thickness coupled with a pressure regulator gives the Super Air Wipes adjustability from a gentle breeze to remove light debris or provide cooling all the way up to a forceful blast to remove more viscous fluids or provide quick cooling.
The EXAIR Super Air Wipe is 1.13″ (29mm) thick on all (11) Aluminum models that range in size from 3/8″ (10mm) to 11″ (279mm) throat diameter and all (5) Stainless Steel models that range in size from 1/2″ (50mm) to 4″ (102mm).
The Aluminum Super Air Wipe is available in 11 sizes 3/8″, 1/2″, 1″, 2″, 3″, 4″, 5″, 6″, 7″, 9″ & 11″; the Stainless Steel Super Air Wipe comes in 5 sizes, 1/2″, 1″, 2″, 3″ & 4″…all from stock!
So when you need to cool, blow off or dry extruded material or need expert advice on safe, quiet and efficient point of use compressed air products, give us a call. We would enjoy hearing from you!
What do you do when you need to cool, blowoff, or dry extruded objects? How will you support the products to do these tasks, and how will you get your extrusions through them? Consider using engineered compressed air products air for these applications to provide instant on/off capability, fine tuning adjustment of the air flow, low noise levels and OSHA safety. The EXAIR Super Air Wipe is designed to work well with continuous production products like extrusions, wire and cable.
The Super Air Wipe is a highly efficient compressed air powered device that provides a uniform 360° air stream that is ideal for blowoff, drying, cleaning and/or cooling of pipe, cable, extruded shapes, hose, wire and more.
The clam shell design of EXAIR’s Super Air Wipe offers easy clamping around the surface of the material moving through it that eliminates the need for time-consuming and cumbersome threading. All models utilize stainless steel screws and shims and for sizes up to 4″ (102mm) a Stainless Steel wire braided connecting hose is included. Aluminum models are rated for temperatures up to 400°F (204°C) and stainless steel models for temperatures up to 800°F (427°C).
Mounting the EXAIR Super Air Wipe is very easy, it can be accomplished by using either the 1/4 – 20 tapped holes on the downstream side or by utilizing a hard pipe compressed air supply line. Connecting the EXAIR Super Air Wipe to your compressed air supply is straightforward, there are (2) 1/4 FNPT compressed air inlets on throat sizes up to 7″ (178mm) diameter (one on each half), while the 9″ (229mm) & 11″ (279mm) diameters have a total of (4) 1/4 FNPT compressed air inlets (two per half) to ensure proper air volume for maximum performance.
Prior to the introduction of the Super Air Wipe, one way to blow off, dry, or clean extruded objects was to use a ring of air nozzles. The high air consumption and noise levels of the nozzles along with inconsistent air velocity often delivered poor results.
The Super Air Wipe, which is similar to the construction of EXAIR Super Air Knife provides a high volume, high velocity airflow that is uniformly ejected from the entire 360° of its inner diameter. The airstream adheres to the surface of the material running through it (Coanda Effect) to effectively wipe, clean or dry surfaces.
To further explain how the EXAIR Super Air Wipes work, reference the animation below: Compressed air flows through the inlet (1) of the Air Wipe into the annular chamber (2). It is then throttled through a small ring nozzle (3) at high velocity. This primary airstream adheres to the Coanda profile (4), which directs down the angled surface of the Air Wipe. A low pressure is created at the center (5) inducing a high volume flow of surrounding air into the primary airstream. As the airflow exits the slot, it creates a conical 360° ring of air that will attach to the surface of the material running through it (6) uniformly wiping the entire surface with the high velocity airflow.
The EXAIR Super Air Wipe is 1.13″ (29mm) thick on all (11) Aluminum models that range in size from 3/8″ (10mm) to 11″ (279mm) throat diameter and all (5) Stainless Steel models that range in size from 1/2″ (50mm) to 4″ (102mm). The performance can be altered by changing the inlet air pressure or by adding an additional shim, which will nearly double the force!
So when you need to cool, blow off or dry extruded objects or are looking for expert advice on safe, quiet and efficient point of use compressed air products, give us a call. We would enjoy hearing from you!
Late last year I received a call from a customer that was using EXAIR Super Air Knives to create an air curtain that protected the lens on their Robotic Welders from weld spatter. The EXAIR Super Air Knife accomplished this by virtue of its design to deliver a uniform sheet of laminar air flow across its entire length. While this greatly improved the life of the welder lens and reduced maintenance time, further improvements were needed.
The event that triggered this was the challenge they received from their customer (one of the big 3 automobile manufacturers) to increase their output of welded seat frames by 50%. While the EXAIR Super Air Knives greatly reduced lens maintenance the consensus was further improvements would facilitate the goal of increasing output 50% .
This started the discussion on the possibility of using the EXAIR Super Air Wipe, even though it is primarily used for drying/cleaning of long continuous flow products its airflow pattern (see illustration below) was able to direct the weld splatter down and away from the lens. This ultimately proved to be more effective at protecting the lens than the laminar air curtain provided by the EXAIR Super Air Knife.
The installation of the EXAIR Super Air Wipes started on 12/16/2017 and was completed on 12/23/2017. The original production rate was 480 pair of SUV rear seat frames per day running 3 shifts 24/6.
After the Installation of the EXAIRSuper Air Wipes, they had improved the production rate to 750 pair/day running 3 shifts 24/5 days per week. That equates to a productivity increase of 156%, far exceeding the goal of 50%!
Before using the EXAIRSuper Air Wipe their maintenance department would clean the Cover Slide on the Laser Welding Head – 3 times per day at approximately 20 min x 3x daily x 6 days / week 6 hours / week. “With the EXAIRSuper Air Wipe we found that we can weld for 10 days before cleaning the Cover Slide” says the customer.
Each Cover Slide costs $195 and those were being replaced weekly, it was a pleasant surprise to find out that only a small amount of dust collects on the Cover Slide now, which is cleaned off in less than a minute
In 10 weeks of Operation they have not replaced a single Slide since the EXAIRSuper Air Wipe has nearly eliminated pitting from the weld spatter.
Also, Cleaning of the Slides is now performed on Saturday’s at the leisure of the maintenance team and not under the strain of production time. The Labor Rate for Maintenance is $75/hour x 6 hours/week = $450 X 50 weeks/year $22,500 plus the cost of the replacement windows at $195 each x 25 weeks = $4,875 savings per year. Total savings after implementing the EXAIR Super Air Wipe = $27,375 per welding machine!
With the maintenance & replacement cost savings alone it is an easy calculation to make on the purchase of the EXAIRSuper Air Wipe’s. That figure is not counting the productivity increase of 156% which allowed them to meet their customers delivery schedule and reduce overtime!
If you would like to discuss increasing the efficiency of your compressed air usage, quieter compressed air products and/or any EXAIR product, I would enjoy hearing from you…give me a call.