A large manufacturing shop recently purchased a high speed band saw to cut aluminum. It was equipped with a mechanical rotating brush system to clean the blade as it ran, but this was unable to keep up with the volume of coolant-soaked chips that were produced at higher speeds. They had two options:
*Run the saw at a slower speed (and actually, their production schedule would not allow this, so technically there was only one option…)
*Come up with a reliable method of cleaning the saw blade (this is where EXAIR comes in.)
This has made a “night-and-day” difference for this sawing operation:
*In the first week they had the saw, they went through four saw blades…when the teeth get clogged with chips, they don’t cut right; they get hot; and they fail.
*The inability of the brush system to remove the chips caused them to accumulate in the belt pulley housings…operators were spending 2-3 hours A DAY just to shut down the saw and clean them out.
*The excess of chips also caused the blade’s guide bearings to fail, which caused almost a day’s worth of down time to replace.
*The Maintenance Supervisor was called to the saw repeatedly during the work day to address these, and many other minor, malfunctions due to the inability to remove the chips.
This saw is now operating at the capacity they intended when they purchased it. All for about $400, and that includes the door hinge they used to install it and allow for precise positioning (how cool is that?)
One of the great things about being an EXAIR Application Engineer is the variety of applications that find their way through our proverbial doors. In a given day we could be anything from solve static problems for a garment manufacturer to prevent an overheating condition at a pumping station.
The latter of the applications mentioned above has played out over the last few days with an end user of our products in Kuwait. This end user operates a sewage pumping station which uses 10 dry well pumps located 30m (99 ft.) below ground. The rooms which house the pumps are not cooled, and as a result, the bearings within the pumps tend to overheat and take considerable time to cool.
What this application needed was an efficient and effective way to cool these motors (and their bearings) from a measured high of 90°C (194°F) to ambient temperatures. And, when it comes to a convective heat transfer such as that found when cooling by passing an airflow over a material, the greater the volume of air, the greater the cooling.
Enter the Super Air Amplifier. An air amplifier will multiply the volume of air fed through the unit. For example, if we supply a 4” Super Air Amplifier with 80 PSIG line pressure, it will consume 29.2 SCFM and move a volume of 730 SCFM at the outlet of the unit. At a distance of 6” away, the air volume will further amplify to 2,190 SCFM.
What this means for this application, is that we can use a small amount of compressed air to generate HUGE air flows over these motors, bringing down their temperatures and preventing the overheating condition.
If you have a similar application or are in need of a potential EXAIR solution, contact an EXAIR Application Engineer.