Back Blow Air Nozzles Clean Inside Diameters

They say time flies when you’re having fun. Maybe that’s why I found it a little hard to believe it’s been almost two years since we introduced the Back Blow Air Nozzles. They’ve become yet another “textbook” solution to a great many applications:

*Model 1004SS M4 Back Blow Air Nozzles are used to dry the inside of a closed cylinder after a zinc bonding process.  They’re also fitted to Model 1204SS-12-CS M4 Back Blow Safety Air Gun to remove chips & cutting fluid from freshly cut pipe ends.

*Our Model 1006SS 1/4 NPT Back Blow Air Nozzle won Plant Engineering Magazine’s “Product Of The Year” Bronze Award in 2015, and are successfully employed in a wide range of uses:

  • Blowing out splined bores by a gear manufacturer
  • Quickly cleaning out spindles between tool changes by a CNC machinery operator
  • Removing the last bits of powder from spent toner cartridges by a printing equipment recycler

*The Model 1008SS 1 NPT Back Blow Air Nozzle is becoming famous in hydraulic cylinder repair shops…after a cylinder bore is honed, one quick pass of the powerful blast it produces cleans bores from 2″ to 16″.  We can even put it on the Model 1219SS Super Blast Back Blow Safety Air Gun, with a 1ft, 3ft, or 6ft extension.

EXAIR Back Blow Air Nozzles come in three sizes, for bores from 1/4″ to 16″ in diameter!

If you want to see how they work, check out this video:

I could have sworn Lee Evans just made that video, but apparently, it’s over a year old now.  Time does indeed fly, and I promise we’re having fun!  If you’d like to find out more about how a Back Blow Air Nozzle – or any of our engineered compressed air products (old or new) – can make your operations quieter, more efficient (and hence, probably, more fun,) give me a call.

Russ Bowman
Application Engineer
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Super Air Wipe Helps Shield a Lens

Super Air Wipe Kit

A tier 2 automotive company makes small metal boxes with a process which includes laser welding and a vision inspection system. The machine was programmed to weld different components onto the metal enclosure. During the welding operation, an optical sensor would check the quality of the welds. The vision system used a lens to protect the sensor from welding slag and debris. After a few operations, they started seeing false positives in the welding areas, and the metal enclosure would be flagged for rejection. In investigating the issue, they found that the lens was getting dirty from the welding operation. Because of the sensitivity of the sensor, it would detect the debris and marks on the lens and signal for poor weld. The lens was doing its part in protecting the sensor from damage; but, they needed a way to shield the lens from dirt and slag during the welding operation and visual inspection.

With this process, the machine would weld metal fasteners onto an enclosure by laser. The optical sensor would move along the welded areas to check the quality. In a lead/lag operation, the vision system would check the welds after a few seconds of cooling. So, both operations were occurring at the same time but at different intervals. When they started to see the rejection rate increase, they would have to stop the operation, clean the lens, and verify the integrity of the welds. In some cases, they would have to replace the 1 ¼” diameter lens especially if a piece of welding slag marred the surface. With incorrect rejections and lens cleaning, downtime was hurting their production rates and cost.

This customer wanted to use compressed air because it is a powerful and invisible way to create a shield. Since EXAIR is a leader in efficient and effective ways to use compressed air, they contacted us for help. Initially, I suggested a Super Air Knife to deflect any slag and debris from the lens surface. I showed a prior solution to a very similar issue; “Air Shielding a Laser Lens” (Reference below). But, because of the proximity to the part and the limitation in space, the Super Air Knife  configuration in the solution below would make it impossible to use. They were looking for a product that could be mounted either flush or behind the surface of the lens and still protect it.

Air Shielding a Laser Lens

To accommodate for this request, we had to direct the compressed air stream at an angle. EXAIR manufacturers a product that can do just that, the Super Air Wipe. The design of the Super Air Wipe blows compressed air at a 30-degree angle toward the center in a 360-degree air pattern, just like a cone. It can be placed around the lens and still be able to create a “wall” of air to block any slag or debris from hitting the lens.

I recommended the model 2452SS, 2” Super Air Wipe Kit. This Super Air Wipe has the body, braided hose, hardware, and shims that is made from stainless steel. It can handle the high heat loads from the welding process as well as to allow for easy cleanup after a day of operating. The kit includes a filter, to keep the compressed air clean; a regulator, to finely tune the force requirement; and a shim set. The shim set includes two additional sets of shims that can be added to increase the force of protection if needed. With the kit, the customer can “dial” in the correct amount of force needed to keep the lens clean without using excessive amount of compressed air.

As an added benefit of saving compressed air, the Super Air Wipe uses the Coanda effect to maximize the entrainment of ambient air into the compressed air stream. This makes the unit very efficient and very powerful. The Super Air Wipe was mounted just behind the lens like the customer required (Reference mock picture below), and the sensor could examine the welds without any interference with the metal enclosure.

Laser Lens mock drawing

Visual inspections systems are highly accurate pieces of equipment, and a dirty lens will affect the performance. EXAIR has many ways to keep the lens clean with a non-contact invisible barrier to protect sensors, cameras, and lasers. If you have a similar application, you can contact an Application Engineer to determine the best way to keep the lens clean and your equipment functional. After mounting the Super Air Wipe, the customer above eliminated any false rejections, and dramatically decreased any downtime for cleaning or replacing the lens in his welding machine.

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

Super Air Knife Plumbing Kit Allows Installation In Tight Quarters

I recently had the pleasure of helping a long-time user of our Super Air Knives with a challenging application. They already use quite a few of our Model 110012SS 12″ Stainless Steel Super Air Knives to clean & dry their nonwoven material as it’s being rolled for packaging. They like them because they’re quiet and efficient, but also because they’re durable…this particular product off-gasses a mildly corrosive vapor, which used to corrode other equipment in the area. Not only does the Stainless Steel Super Air Knife resist corrosion itself, the air flow keeps these vapors contained. Two birds, one stone.

They have a new product…same kind of material, but much wider…that needed to be blown off, and the identified the Model 110060SS 60″ Stainless Steel Super Air Knife as a “no-brainer” solution. Thing is, it had to be a pretty even air flow across the length, and a 60″ Super Air Knife has to get air to four ports across its length for optimal performance. And, they wanted to install it at a point where it would serve not only as a blow off, but as a vapor barrier, just like the 12″ Super Air Knives they’re already so fond of. The space was a little limited, though, so they opted for the Model 110060SSPKI 60″ Stainless Steel Super Air Knife with Plumbing Kit Installed, which allowed them to simply run an air supply line to both ends.

EXAIR SS Super Air Knives can be ordered with a Plumbing Kit installed, or you can easily install a Plumbing Kit on your existing Super Air Knife.

If you want to find out more about an engineered solution for your compressed air application – cleaning, drying, vapor barrier, or all of the above – give me a call.

Russ Bowman
Application Engineer
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The Old One-Two: Super Air Knives And Super Air Nozzles

The EXAIR Super Air Knife is THE ideal, efficient, and quiet solution for most any blow off application. We know this for a fact; we’ve been making them for years, folks all around the world have been buying them for years, and they keep coming back for more. They’re popular enough that over the years, we’ve introduced Mounting Systems and Plumbing Kits for ease of installation, and when Coupling Kits (to join multiple Super Air Knives together for greater lengths) became big sellers, we “upped our game” and started making Super Air Knives up to nine feet (108″) long. And certain applications (I’m looking at YOU, lumber and paper industries) order multiples of THOSE, and our Coupling Kits. Quite literally, there’s no job too big for EXAIR Super Air Knives.

EXAIR Super Air Knifes come in a wide variety of lengths to suit a wide range of applications.

No matter how long they are, though, the laminar, high velocity curtain of air they generate only moves in one direction. So, if there are significant geometric features (holes, bosses, recesses, “nooks & crannies,” etc.) to be blown off, we’ll have to look at something supplemental.

Enter the EXAIR Blowoff Systems…it doesn’t get any easier than this: an EXAIR engineered Super Air Nozzle, attached to a flexible, repositionable Stay Set Hose, mounted to a Magnetic Base.  Put a hard hitting, high velocity, pointed flow of air right where you want it.  If the next piece is different, that’s no problem – just bend the hose to re-aim the air flow.

Mag Bases come with one or two outlets. Stay Set Hoses come in lengths from 6″ to 36″.

No matter what the requirements of your blow off application are, we have an efficient, quiet, and safe solution.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
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Custom Air Amplifiers To Meet Most Any Requirement

When I think of “special” in regard to Air Amplifiers, I’m more inclined to think of the applications they can be used in. I mean, the Air Amplifier itself is about as straight-forward as an engineered compressed air product can be:

Air Amplifiers use the Coanda Effect to generate high flow with low consumption.

Considering the simplicity of the product itself, they can be used for a large variety of “typical” applications:

  • Cooling
  • Drying
  • Cleaning
  • Ventilation
  • Fume Exhausting
  • Dust Collection

There are no shortage of “special” applications either.  They’re used successfully in Air Operated Conveyance applications (when the stronger vacuum head of a Line Vac isn’t required) and we’ve even got a customer who uses one instead of an E-Vac Vacuum Generator for a “pick & place” operation…they’re picking up small, porous fiber discs (sort of like a coffee filter) one at a time, and the E-Vac wanted to pick up a good part of the whole stack, no matter how low they turned the pressure.  And of course, I can’t think of anything more special about Air Amplifiers than this:

You have to read it to believe it.  Follow the link and click on “Case Study: Roaring Banana Breath”

With fifteen distinct models to choose from in a range of sizes (3/4″ to 8″,) materials (aluminum or Stainless Steel) and even a High Temperature model that’s rated to 700°F (374°C), we’ve still made a fair number of Custom Air Amplifiers too…thirty-four, to be exact, as of this writing.

I won’t bore you with all the details – I can’t, actually, because some of them are proprietary* – but here are some “regular” examples of “special” accommodations:

  • Connections: EXAIR Air Amplifiers have smooth bores on the inlet & outlet plenums that you can hose clamp a hose (or round duct) to if you need to get air flow from, or to, one place or another.  Sometimes, though, they’re going in to an existing system, so we’ve made them with flanges (150#RF and Sanitary Tri-Clamp, for example) or threads (NPT or BSPP.)  If you want to use something other than a standard hose or duct line, we can help.
  • Material of construction: Our durable, lightweight aluminum Super & Adjustable Air Amplifiers are just fine an awful lot of the time.  Our type 303 Stainless Steel Adjustable Air Amplifiers will hold up to heat and corrosives.  We’ve also in PTFE (Teflon™) as well as a range of metal alloys to meet specific corrosion or wear conditions.  If your environment calls for a little something extra, we can help.
  • Assembly: Super Air Amplifiers are fitted with a stock shim that gives you published performance.  We’ve got other thicknesses, though, if you need more (or less) flow, though.  Adjustable Air Amplifiers are, well, adjustable…you just thread the plug in/out of the body until you get the results you want.  Sometimes the user knows what shim they want in a Super Air Amplifier, or what gap their Adjustable Air Amplifier needs to be set to, and we can assemble it accordingly.  If you have a ‘tried-and-true’ performance setting and want it met right out of the box, we can help.
  • Assembly, part 2: Good engineering practices call for lubrication on O-rings and threaded connections, and we use high quality, general purpose compounds when assembling our Air Amplifiers.  These are detrimental, however, in certain situations (silicone exclusion areas, I’m looking at you.) If certain chemicals or compounds are prohibited by your application, we can help.

*Let’s say you’ve done the “heavy lifting” to call out one (or more) of these special design features.  If we make a custom product (and that’s not just Air Amplifiers, by the way) using directions based on your time and labor, we’ll treat that product as proprietary to you, and you alone.

EXAIR has 208 catalog pages worth of Intelligent Compressed Air Products on the shelf…8 of those pages are our Air Amplifiers.  If you want to talk about customizing one to meet your needs, give me a call.

Russ Bowman
Application Engineer
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Engineered Nozzles Replace Segmented Coolant Hose for Ink Drying Application

flat nozzle loc line comparison

Segmented Hose on the left and an HP1126 1″ Flat Nozzle on the right

A common item that can be found in a majority of machine shops is the blue or gray knuckle-jointed hose used to dispense coolant on lathes and CNC machines. EXAIR also uses this same hose with our Cold Guns and Adjustable Spot Coolers for applications that cannot or do not wish to use liquid coolant as a means of keeping the heat down on their tooling. Since the cold air discharges at atmospheric pressure, this is an acceptable application. Another application is using this style of hose as a compressed air blowoff. This is NOT a proper use of the hose and is not only a considerable waste of compressed air but can also pose a safety hazard. Using this method for compressed air blowoff is not compliant with OSHA 1910.242(b) (a directive we blog about).

I was recently contacted by a customer in Indonesia that was using an array of (6) of these knuckle-jointed hoses with a ¼” round nozzle attachment for a blowoff operation. The customer had a series of rubber pads used in the construction of a toy castle. The pads were brought along by an overhead conveyor and a design was printed on the head of the pad. The nozzles were used to dry the ink before the pad made it to the next part of the process. This was a new product line and the processes involved were being evaluated for potential places to save on compressed air rather than adding overall capacity to their system. After using a variety of EXAIR products for other blowoff applications, they came back for another engineered solution.

After testing both a 1009-9280 (Adjustable Air Nozzle w/ 30” Stay Set Hose) and an HP1126-9280 (1” High Power Flat Nozzle w/ 30” Stay Set Hose), the customer determined that the airflow pattern from the 1” Flat Nozzle was more conducive to drying the rubber pad and purchased the remaining units to replace their original method. The compressed air savings was noticed immediately!!

For the old operation, they had to regulate the pressure down on the hose to 25 psig so that the hose wouldn’t break apart. (1) This hose , with a ¼” round nozzle, will consume 52 scfm at 25 psig of supply pressure. With (6) of these they were consuming a whopping 312 scfm!! Since the HP1126 is compliant with OSHA directive 1910.242(b) and will not break apart at higher pressures, they were able to operate at 80 psig while only consuming 17.5 scfm. They saved more than enough air for their new process and are evaluating whether or not they can turn off one of their smaller 25 HP compressors.

The new setup with the EXAIR engineered solution was able to save them 207 scfm of compressed air. Assuming a cost of $.25/1000 scfm and a 40 hr work week, this translates to an overall savings of $6,458.40 per year off of their utility bill.

207 scfm x 60 minutes x 8 hrs/day x 5 shifts/week x 52 weeks/year =25,833,600 scf

25,833,600 scf x ($.25/1000 scf) = $6,458.40

If you’re using an inefficient compressed air blowoff in your facility, give us a call. An Application Engineer will be happy to evaluate your process and determine the safest and most efficient solution. With same day shipment for stock items on orders placed by 3:00 pm EDT, we can get a solution out to you by the following day!

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

Video Blog: The Monetary Benefits of an Engineered Solution

This video highlights the value and benefits of an engineered blow off solution.  We take a homemade open pipe blowoff and replace it with an EXAIR model 1100 Super Air Nozzle.  This air nozzle is then controlled through our Electronic Flow Controller, allowing for intermittent On/Off of the compressed air flow.  And, these solutions are wirelessly monitored via Zigbee network using our Wireless Digital Flowmeter.  Implementing these solutions results in a compressed air reduction of over 90%!!!

 

Full calculations along with supporting flow values (pulled from the same data shown in the video above) are shown below.

Screengrab of the flow values shown in the video above. Click for larger image.

The open pipe:

The first compressed air flow values to show up on the EXAIR Logger are for the open pipe blow off.  At 1 BAR operating pressure, this “solution” consumes 22.3 SCFM of compressed air.  At a cost of $0.25 for every 1,000 cubic feet of compressed air, this nozzle will cost $695.76 to operate 8 hours per day, 5 days per week, 52 weeks per year.

The engineered EXAIR Super Air Nozzle

Model 1100 EXAIR Super Air Nozzles consumes 4.7 SCFM at an operating pressure of 1 BAR – a reduction of 79% compared to the open pipe.  These savings prove out in terms of operating cost as well – $146.64 per year, compared to $695.76.

The engineered EXAIR Super Air Nozzle with Electronic Flow Control (EFC)

By controlling the “ON” time for this application with an EFC, we are only blowing for 32% of the time for each minute of operation which changes the required compressed air flow from 4.7 SCFM to a peak value of 1.5 SCFM. This control saves an additional 68% of compressed air flow.  And, these savings are compounded by eliminating the need for constant compressed air flow.  Total annual operating cost for the EXAIR 1100 Super Air Nozzle with Electronic Flow Control is just $46.80.

Implementing an engineered solution can have a TREMENDOUS impact on energy costs and operating costs in your facility.  Compressed air is the most expensive utility to produce and consume, making the impact of proper solutions of high value to any business.  Let us help you utilize engineered compressed air solutions in your facility by contacting an EXAIR Application Engineer today.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

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