Application Database: Compressed Air Use in the Automotive Industry

EXAIR uses many different methods to connect with our customers.  We have our website, social media, blogs, publications etc. We like to share solutions for some of the most common pneumatic problems in the industry.  EXAIR generated a large collection of application information where EXAIR products have already solved problems and improved processes.  We organized them by Application and by Industry.  In this blog, I will show you how to use our Application database; specifically, for the Automotive Industry.

Compressed Air Systems are considered to be a fourth utility within industries because they use a large amount of energy.  Whether an air compressor that uses fuel for portable units or that uses electricity, it is important to use this system as efficiently as possible.  This would also apply to the Automotive industry.  EXAIR has a library of different processes in which we already improved these areas safely and efficiently.  If you are part of the Automotive industry, it could benefit you to take a peek at the areas that we already improved, established OSHA safety, and saved money.

Here is how you can find this library.  First, you will have to sign into EXAIR.  Click here: Log In.  Once you fill in the proper information, you can then retrieve a great amount of resources about EXAIR products that we manufacture.   The Application database is under the Knowledge Base tab.  (Reference photo below).

At the Application Search Library, we have over one thousand applications that we reference.  In the left selection pane, we organized then in alphabetical order under two categories, Application and Industry.

Scroll down in the selection pane until you come to the sub-category: Industry.  Under this Sub-category, you will find three selections that are related to this blog: Automation, Automobile Recycling, and Automotive.  We have other applications as well that may relate to your specific processes if you scroll up and down the list like; Part Ejection and Machining.  You will find many product applications that have already improved processes and solved problems.

Why is this important?  If you are a plant manager or owner, the value of the Application Database can improve your current processes with pre-qualified results.  Within the Automotive industry, simple solutions can be found to address those “nagging” issues that you see every day.  For crisis situations and shutdowns, EXAIR categorized these applications in a way to reference quickly and easily.  And since EXAIR has a high volume of stocked items, we can get the parts to you very fast so you can quickly be on your way to a solution.

In today’s market, companies are always looking for ways to cut cost, increase productivity, and improve safety.  EXAIR can offer engineered products to do exactly that.  With the “been there and done that” solutions already described in the Application Database; you can have confidence in finding a way in solving pneumatic issues.  If you do not sign up at www.EXAIR.com and take advantage of these offerings, you will be missing out on a great tool to optimize your compressed air system.

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

 

Next Level Customer Service

I recently spoke with a customer who is a casting / machining manufacturer.  They had an automated cell that was finish machining a feature on a cast aluminum part then placing it on a conveyor belt for an operator to pick up and continue processing.

The parts were placed 3 pieces wide per row and the conveyor would index with every three parts.   The operator would pick three pieces up and transfer them to another station during the machining time.  These parts were carrying residual machining coolant and debris onto the outbound conveyor.

The operator would blow them off with a handheld blow gun and all the coolant and chips would generally end up on the floor in the area causing a slip hazard.  The focus of the project is to eliminate the safety hazards and leave the parts as clean as possible for the inspection and further process.

The metal parts were positioned similar to the parts I placed in the mock up picture below.  The conveyor the customer has is an open mesh conveyor so the process will work better than if it was a solid belt like in the mock up.

The bulk of the concern from the customer was the outside of the part and they stated that anything to blow out the internal is a bonus.  The objective is to get as much coolant off as possible.   For that we recommended they span the conveyor with a Super Air Knife Kit to blow all the parts off at once.  This is mounted closely in the mock up because the customer had space restrictions.

The Super Air Knife Kit with Universal Air Knife Mounting System will firmly mount the knife over the parts and leave adjustment if needed.
The model 1103 Mini Super Air Nozzles with Stay Set Hoses of various lengths easily bend into place and hold their positioning for the side hole on each part.

Then, because the parts are always placed in the same location with the same orientation we can locate the ID hole with a Mini Super Air Nozzle on a Stay Set Hose of varying length to reach each set of parts as they come through.  Once I had the idea and the products in place I delivered the customer  a quote and dimensional CAD file for each part.

Another recommendation was to use a regulator and filter to control just the knife then operate the three nozzles off their own regulator and filter so that the forces between the two can be varied and the performance of the other is not effected.  Accompanying the models were installation sheets for each item as well.   Followed by the pictures of this mock up for their application.

Needless to say the customer was amazed that we would go to such lengths just to give them more assurance than our 30 day guarantee.  They were extremely thankful and are pleased we shipped from stock and met their installation window.

If you are looking for a creative solution, next level customer service, same day product availability, or just a nice human to talk to about compressed air, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Adjustable Air Amplifier Transfers Plastic Bag Scrap

Many times EXAIR products are used to help sort materials based on their weight or their density by providing a consistent force against a series of targets that should be of the same density or weight, but when they are not, the airflow can be “tuned” to remove the non-conforming parts.

aal-vacuum
Model 6042 Aluminum Adjustable Air Amplifier rejects empty pouches.

In this case, our customer (a packaging automation specialist) was working with a form fill and seal machine that was dedicated to making pouches 2” x 8” and filling them with a food product. In some cases, the pouches would not become filled with product and needed to be removed from the line. So, our customer devised a way to mount model 6042 2” Adjustable Air Amplifier along-side the travel of the pouches and set the input pressure and air gap setting to get optimum vacuum capture velocity to suck away empty ones and leave the full ones in-tact. Above you can see a photo that the customer took while mocking up the application at their facility. You can see the hose connected to the output to direct the empty pouches to a wire basket below.

A couple of things in this application made use of the Adjustable Air Amplifier the best choice. The first was the funnel-shaped suction area on the back side of the Adjustable Air Amplifier. This optimizes the Air Amplifier’s ability to draw in ambient air to propel it to the outlet. In doing this the un-filled, light-weight, plastic pouch becomes caught in the high velocity stream and thus gets carried away as desired. The second thing is that since compressed air is the source of power, the customer has infinite adjustability over the amount of suction force that they can apply to the pouch in the application. They can adjust the air gap opening on the Adjustable Air Amplifier to have a coarse adjustment of air consumption as well as vacuum level. Then, they have a finer adjustment that a pressure regulator can provide to really dial in the suction force as they need it to be for removal of the empties.

The idea here is that while Air Amplifiers are generally used for their output flow to cool targets and provide a significant Blowoff force, they can also be used to draw in not only smoke and fumes but also other lightweight items like the empty pouches above.

If you have a need to set up any kind of sorting process, maybe just to separate two different recycling streams or perhaps it is a need to perform a quality control function as shown above, think about EXAIR and our many solutions in this area.

Neal Raker, International Sales Manager
nealraker@exair.com
@EXAIR_NR

EXAIR Intelligent Compressed Air Products Are Automation’s Best Friend

For decades, children and adults (really cool ones, anyway) have enjoyed the popular board game, Mouse Trap:

The fun of the game is that it exaggerates the notion of providing an overly complicated solution to a simple problem – a notion made famous by Rube Goldberg, whose namesake machines are as thought-provoking as they are entertaining to watch.

As fun as Rube Goldberg machines are, there are actually ways to engineer something “just enough” – that’s what automation engineers strive to do every day; and EXAIR is here to help.

Probably the most popular feature, for automated applications, of engineered compressed air products is instantaneous performance.  For example:

  • When an electric motor-powered blower is used for a blow off, cooling, or drying application, there’s going to be a “ramp-up” period to reach full rated flow.  Not so with an EXAIR Intelligent Compressed Air Product, like a Super Air Wipe, Super Air Knife, Super Air Nozzle, Super Air Amplifier, etc.  They are generating their rated flow as fast as you can open the supply valve.

    EXAIR Intelligent Compressed Air Products such as (left to right) the Super Air Wipe, Super Air Knife, Super Air Nozzle, and Super Air Amplifier provide instant on/off performance, at rated levels.
  • Likewise, vacuum pumps necessarily take some time to develop their rated vacuum level.  But the venturi in an EXAIR E-Vac Vacuum Generator draws its full rated vacuum flow as soon as the compressed air is turned on.  The peak vacuum level is achieved in the amount of time it takes to pull the air out of the lines or vessel.

    These are all examples of how an E-Vac pick-and-place system is just a solenoid valve away from being an automated process.
  • All EXAIR Atomizing Spray Nozzles can be fitted with a No Drip feature, which allows instant on/off control, simply by opening/closing a valve in the compressed air supply line.  This is often done with a solenoid valve tied in to the machine controls, or with an EXAIR EFC, Electronic Flow Control (more on that in a minute.)  They can handle up to 180 cycles per minute, for quick bursts of atomized mist, on demand.  No other method of liquid flow control can match that kind of performance.

    Fine mist liquid spray, on demand, from an EXAIR No Drip Atomizing Spray Nozzle.
  • EXAIR Spot Cooling Products, Cold Guns, and Cabinet Cooler Systems all use Vortex Tube technology.  This “splits” a supply of compressed air into a hot, and cold air flow.  Unlike refrigerant, chilled water, or cryogenic gas methods, they don’t rely on conduction or convection heat transfer between materials, so cold (and hot) air is produced, at rated flow and temperature, instantly.  They, too, can be turned on & off as often as needed…there are no moving parts to wear or damage.

    The unique phenomenon of the Vortex Tube principle makes cold air instantly for as long – or short – a time as needed.

Automation projects often incorporate existing logic, controls, timers, etc. to actuate the process.  For example, if you wanted to use a Chip Vac to vacuum debris from a chop saw, you can simply wire a solenoid valve into the power switch of the saw…it’ll run while the saw runs, and stop when the saw is turned off.

EXAIR’s award winning EFC Electronic Flow is ready to go, right out of the box.

If there are no existing logic, controls, timers, etc., EXAIR has a solution for those cases too: the EFC Electronic Flow Control.  We have four models to accommodate up to 350 SCFM of compressed air flow – that’s ten feet worth of Super Air Knives.  The EFC consists of a photoelectric sensor that opens/closes a solenoid valve, based on the programming of the integral timer.  It’s a stand alone system that doesn’t require input from, nor is it affected by, any external factors.

Automation projects can get pretty intricate.  EXAIR Intelligent Compressed Air Products are aimed at keeping their involvement as simple as possible.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook