It’s Starting to Look a Lot Like Static Season

Well the dog days of summer have come to an end, and the cold dry air of winter is on the horizon! There’s one other thing that comes along with the cold dry air of winter, and that’s SANTA! (Sorry that was the child in me).

Actually, it’s STATIC! During the warmer months the moisture in the air does a good job at eliminating a good amount of excess static charge. But as that cold dry air comes into play you need another way to rid your production of static or things will start to go wrong.

Foam Static
Static holding foam bead material to a surface.

In many painting or finishing applications dust and debris from the ambient environment can settle on the part prior to painting or coating. Just blowing them off with a standard air gun won’t remove all of the particles if they’re statically charged. The static must be neutralized in order to remove it or it’ll cause imperfections in the paint or coating. This often results in a high amount of rejected parts that must be scrapped out.

Other processes that benefit from static removal include printing, slitting, molding, sheeting/trimming, shrink wrapping and packaging.

Static Eliminators
Static Eliminators

Break out your fall / winter gear and enjoy the cooler weather and activities that accompany the coming of Fall, but don’t let static wreak havoc in your processes. EXAIR has a wide range of solutions available that are designed to solve these problems. Give an Application Engineer a call and we’ll be happy to help recommend the best solution.

Jordan Shouse
Application Engineer

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Friction Loss – Pressure Drops – Fitting Restrictions – Why Compressed Air Plumbing Matters

Over the weekend I was working on a car in my driveway and I needed a large volume of air at the far end of the car to try and unplug a clogged sunroof drain line.  Rather than trying to move the car while it was mostly taken apart, I just hooked up another air line extension and started to go to the drain.   Even knowing what I know as an EXAIR Application Engineer about lengths of tubing, air restriction, and fitting restrictions, I went ahead with the quick and easy “fix”.

An example of pressure drop from a compressed air quick disconnect.

I grabbed another 30′ – 3/8″ i.d. air line with 1/4″ quick disconnects (see why this is wrong with this blog) on both end, rather than getting out the 50′ long 1/2″ i.d. air line that I have with proper fittings that then reduce down to a 1/4″NPT at the end to tie into most of my air tools. By doing so I ended up hooking up a Safety Air Gun which then gave a very light puff of air into the tube and the clog in the line went nowhere.  As a matter of fact, it was almost like it laughed because the tubing vibrated as if the clog said, “Pfft I am going nowhere.”

I then, stepped back and evaluated what I had done in a rush to try and get a job done rather than taking the extra five minutes to get the proper air line to do the job.   I then spent 10 minutes putting that hose up and getting out the correct hose.  Then, with a whoosh and a thud the clog was launched into my yard from the clogged drain port and I finished the repairs.

If only I had watched Russ Bowman’s spectacular video on Proper Compressed Air Supply Plumbing the day before. Rather than wasting time with the quick “fix” that cost me more time and didn’t fix anything I should have taken a little more time up front to verify I had properly sized my lines for the job at hand.

If you would like to discuss compressed air plumbing, appropriate line sizes, or insufficient flow on your compressed air system, please contact an EXAIR Application Engineer.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

HEPA Vac Improves Cleaning Process AND Keeps Operators Safe!

On a recent visit with our Hungarian Distributor, I had the pleasure of visiting an automotive leather manufacturing plant. They process and cut to order a wide variety of different styles of leather used in the manufacturing of European automobiles. In one of their machines, a grinding process is performed that smooths out the cut edges of the material before they’re stitched together.

The grinding process itself is self-contained within the machine, but the significant amount of leather dust created needs to be periodically cleaned out. If not, it ends up accumulating on some of the internal components and increasing the downtime and maintenance required on the machine. Due to this, they implemented a 2x per shift cleaning operation.

The machine has several tight spaces inside where the dust accumulates. They’d shut off the machine and blow out the dust. Then, sweep up all of the dust into a dustpan and dump it in the trash. This entire process took approximately 30 minutes each time for 1-hr/shift. With three shifts operating 24/7, that’s 3-hrs/day of lost production time for this particular cleaning process, still less than what they were experiencing as a result of the machine downtime when they weren’t regularly cleaning it.

HDHEPAVac559

However, the primary concern of theirs was that they were now blowing dust all over the shop causing a potential health hazard to their operators. They wanted a solution that would allow them to clean the machine, without presenting an additional hazard. We tested with a Mini Chip Vac first, but the dust was a bit too fine and was still passing through the filter bag.

For fine dusts such as this, the Heavy Duty HEPA Vac is the more suitable option. After testing the Heavy Duty HEPA Vac, it was clear that this was the solution they were hoping for. The high-powered vacuum made quick work of the dust inside, while keeping it contained inside of the drum by the HEPA filter.

They still need to stop and clean the machine out 2x/shift, but now the process only took 10 minutes. They reduced their overall downtime on this machine per day by 2/3 to just 1hr, while keeping their operators safe. While this wasn’t the reason for looking at new solutions, it was definitely an added benefit. If you’re looking for a maintenance-free vacuum system for cleaning up in your facility, EXAIR has a wide range of Industrial Housekeeping solutions available from stock.

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

Effectively and Efficiently Remove Chips and Debris from Blind Holes

I was recently contacted by an automotive parts manufacturer that was looking for a solution for cleaning out blind holes in a variety of machined parts. After discussing the application, we settled on a 1697SS-6-CS VariBlast Compact Safety Air Gun with Pico Nozzle, 6” Extension, and a Chip Shield. The small M5 nozzle at the tip of the gun allowed them to insert it inside of the hole and dislodge the hard-to-reach chips inside of the holes.

1697SS VariBlast Compact Safety Air Gun

This worked very well for removing the chips, but they were encountering an unexpected issue as these chips were now getting lodged in other areas of the part as they were ejected. They then had to visually inspect the entire part after each blowoff to ensure that everything was completely removed.

What they thought to be an ideal solution, ended up not being the best fit. They gave us a call back to inquire about an alternative solution. We offer another product, the Deep-Hole Vac-U-Gun, that is capable of both removing chips and debris from blind holes and also vacuuming it away simultaneously.

This addresses the problem of dislodged chips being caught elsewhere on the parts. Fortunately, EXAIR offers an unconditional 30-day guarantee for all stock products. They were able to return the previously purchased gun and apply the credit towards the purchase of the Deep Hole Vac-u-Gun system.

The Deep Hole Vac-u-Gun is a low-cost solution to quickly remove chips and contaminants from grooves, containers, and drilled holes. In applications where simply blowing the debris out of the hole isn’t suitable, simply position the Deep Hole Vac-u-Gun over the hole and press the trigger. A small blow tube (3) dislodges and lifts the chips while the large suction tube (5) vacuums them away. The operator is then protected from flying debris since the contaminants are then contained within the suction tube and directed into a filter bag or other container with the included vacuum hose.

Sometimes we don’t always get it right on the first try. But, with the ability to take advantage of the 30-day guarantee we’ll make sure to get the best product to you for your application. With same day shipments with orders received by 3:00 ET for stock products, EXAIR can get a solution out to you quickly!

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

NFL is Back! But So is Static……

bengals
View of Paul Brown Stadium

I awoke on Sunday with a bit more pep in my step. It’s been a long and dreary past 7 months (8 or more months for unlucky fans like me), but this day marked another early season NFL Sunday. Wives across the U.S. were collectively rolling their eyes as their husbands perched themselves comfortably on the couch, cold beer in hand, glued to the television screen from dawn ‘til dusk. It’s an exciting time for many, especially us Bengals fans, as the season is ripe with hope and cautious optimism. Fantasy leagues are in full swing, and my apologies to any of you who elected to draft Le’Veon Bell with your 1st pick this year….. However, with the arrival of football season, there is  an unwelcome guest that begins to rear its ugly head: static electricity.

As summer ends and moves towards fall and winter, the air becomes much drier. And because moisture in the air can mitigate some static charge, the dry air allows more static to be present. You may be familiar with the unpleasant shock you get from the door knob after walking across a carpeted surface. While this type of shock doesn’t generally cause any sort of problems, in many industrial processes this static electricity can cause a wide range of different issues. These may manifest simply as nuisance shocks to the operator similar to the door knob example, but it can also cause problems with finish quality, materials jamming/tearing, sheet feeding problems, product clinging to itself or rollers, and dust clinging to product.

In many painting applications, particularly in the automotive industry, dust and debris from the ambient environment can settle on the part prior to painting. Just blowing them off with a standard air gun won’t remove all of the particles if they’re statically charged. The static must be removed in order to remove it or it’ll cause imperfections in the finish after painting. This often results in a high amount of rejected parts that must be scrapped out. I recently visited with a company who handles the painting of small interior automotive parts. The parts are housed on shelves in a dusty environment. This dust settles on the parts while they’re waiting to be painted and just using an air gun alone wasn’t taking care of the problem. In this setup, they were rejecting nearly 60% of all painted parts after inspection.

IMG_3902
Automotive parts after painting

We brought with us a Model 8193 Gen4 Ion Air Gun to replace their regular compressed air gun. The Ion Air Gun is an ergonomic handheld gun that combines low air consumption along with an incredibly fast static decay rate. After taking a reading both before and after with a Model 7905 Static Meter, it was clear that the Ion Air Gun was the right tool for the job. The static eliminating ions were carried to the surface of the part which not only removed the static charge, but also the dust particles clinging to the surface. By replacing their two standard guns with Ion Air Guns, the reject rate was reduced to just under 10% after painting!!

GEN4-iag_500xsq
Model 8193 Gen4 Ion Air Gun

Break out your favorite football team’s gear and enjoy the cooler weather and activities that accompany the coming of Fall, but don’t let static wreak havoc in your processes. EXAIR has a wide range of solutions available that are designed to solve these problems. Give an Application Engineer a call and we’ll be happy to help recommend the best solution. And to all of my fellow Bengals fans out there, WHO DEY!

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

 

Bengals photo courtesy of  Nunya Biz via Flickr Creative Commons License

Compressed Air Flows At The Speed Of Technology At EXAIR

I don’t know that any enterprise can give you a better idea of the scope, width, and breadth of American manufacturing quite like the automotive industry:

*Pick a raw material – rubber, steel, plastic, glass, just to name a few – modern day production of all of these has been heavily influenced by the way they’re used in automobiles.

*Pick a manufacturing process – welding, cutting, molding, machining, mechanical & electrical assembly, again; just to name a few – car makers have revolutionized them all, oftentimes to the benefit of many other industries that have used…and adopted…these technological improvements.

*Pick a business.  OK; this is going to depend on where you are.  I’m in Cincinnati, Ohio.  I can be on Interstate 75 Northbound in under 10 minutes, and four hours later (and on one tank of gas, thanks to the fuel efficiency of my American made automobile,) I can be in Detroit, Michigan – the land of the “Big Three.”  And I’ll pass dozens, if not hundreds, of buildings within sight of the highway that house businesses whose largest customers are automotive industry types.

We brag on American manufacturing occasionally, because we’re proud to be a part of it, and to support so many different aspects of it.  What got me thinking about all of this was a call I got recently about our Cold Gun Aircoolant Systems, and how one might be used in a particular machining application.  They machine transmission parts and, due to the specifics of a new material and a subsequent operation, they needed to eliminate the liquid coolant.  This is a ‘textbook’ situation for a Cold Gun – the part in question is small, and just needs a quick shot of cold air during the process, so they got a Model 5215 Standard Cold Gun, put it on the machine, and turned off the coolant…forever.

With four models to choose from, we've got most any cooling application covered.
With four models to choose from, we’ve got most any cooling application covered.

This is one of, literally, hundreds of applications where EXAIR’s line of engineered compressed air products is making all the difference in the world.  If you’d like to discuss how we can help you keep up with the speed of technology, give me a call.

Russ Bowman
Application Engineer
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