You Might be Freezing, but Your Electronics Can Still Overheat

For those of us in the Northern Hemisphere it can be easy to be overrun by static elimination problems during these winter months.  But, colder outside temperatures don’t always mean cooler temperatures for the electronics used in production processes.

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This cabinet was facing unaddressed overheating issues before exploring a Cabinet Cooler solution

I received an email from one of our distributors this week describing two applications with failing electronics (shown above and below).  The root cause of failure for both applications was excessive heat inside the enclosures which house electronic devices, even though the ambient air temperatures weren’t abnormally high.  So, we used the Cabinet Cooler Sizing Guide to determine the heat load of each application and make recommendations for proper Cabinet Cooler model numbers.

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This cabinet was also overheating, causing problems in the processes controlled by the components inside the cabinet.

What we found was that the heat load in both cases was rather low, but in each case it was enough to cause the electronics to overheat.  When the temperature of the electronic devices exceeds their specified temperature range, they cease to operate, causing downtime of every device tied to the processes they control.  By installing a Cabinet Cooler onto each enclosure, the overheating problem will be quickly and easily solved.  And, because of the relatively low heat load in this application, a small NEMA 12 type Cabinet Cooler was the perfect solution.

If you have an overheating electrical enclosure, whether during the Winter, Spring, Summer, or Fall, contact an EXAIR Application Engineer.  We’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

What Makes Things Easier Than An EXAIR Static Eliminator? Another EXAIR Static Eliminator!

A contract manufacturer, servicing the medical and biotechnology markets, is a long time user of our Ion Air Guns. They’ve had great success with them in keeping their products free from static & dust for years. These are mainly small, hand-held parts, so, when they need to get them clean and static-free during assembly and packaging, EXAIR’s Ion Air Gun is ideal, because it, too, is small and hand-held.

A new process, though, involves the operator needing both hands for assembly. This would mean picking up the Ion Air Gun, blowing off the part, putting it down, and then using both hands to complete the operation. They thought there had to be a better way. And they were right!

The Model 8910 Instant Static Elimination Station offers hands-free control of ionized air flow – a foot pedal turns an Ion Air Jet (whose performance is identical to the Ion Air Gun) on and off with…well, the press of a foot. The Magnetic Base and Stay Set Hose make it easy to install, and even easier to position.

Hand held convenience of the Ion Air Gun (easy) or no-hands convenience of the Ion Air Jet Station (easier.) Your call.

Hand held convenience of the Ion Air Gun (easy) or no-hands convenience of the Ion Air Jet Station (easier.) Your call.

For an even more automated approach, they are considering an EFC Electronic Flow Control. They’re ready to go, right out of the box…the photoelectric sensor will open and close a solenoid valve (installed in the compressed air supply line) based on the setting of the programmable timer unit. With a simple wave of the part in front of the sensor, the operator could activate a preset blow of a few seconds, which would be easy to determine, even easier to set, and…easiest of all…reliably repeat all day long. They’re going to try out the foot pedal first, and that’s just fine by me.  Perhaps there’s such as thing as “too easy,” but man, I hope not.

Even if you’re already using EXAIR products to make things easy, you can call me to see how much easier it might get.

Russ Bowman
Application Engineer
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Speaking of easy...get a FREE AC Sensor with a Static Eliminator order. Promotion ends 1/31/2017!

Speaking of easy…get a FREE AC Sensor with a Static Eliminator order. Promotion ends 1/31/2017!

Solving a Printing Problem with EXAIR Static Eliminators

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Unrolling plastic into this machine created a static charge throughout the process

One of the most common sources of static electricity in automated processes is friction.  As two (or more) materials move against each other, static is produced due to the triboelectric effect.  By definition, the triboelectric effect is a type of contact electrification in which certain materials become electrically charged after they come into frictional contact with a different material.  If these materials are non-conductive, or if they are not grounded, the static charge will remain.  This was the case for the machine shown above.

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Multiple stations of this machine, all experiencing static problems

This machine is a Chesnut 150 Gravure Print Station.  It is used for printing, coating, laminating, and sometimes die cutting of paper, light paperboard, films, polyester, flexible packaging and aluminum foil.

In this application, a roll of plastic is dispensed, but a static charge is preventing proper printing on the plastic as it travels from roll to roll.  As the film is separated from the roll, a static charge is produced, and this charge is carried through the process at values ranging from 3,000 – 20,000 volts.  The manager for this production area contacted EXAIR to see if there’s a viable EXAIR solution to remove this static charge.  They were interested in a solution that could eliminate static on the full width of the plastic, could be mounted 200-300mm away from the rollers, and could be replicated at multiple places along the machine.

With this in mind, the best solution was to use a series of 18” Super Ion Air Knives installed periodically along the path of plastic within the machine.  Operating at a low pressure of 1-2 BARG (14.5 – 29 PSIG), the Super Ion Air Knives create an evenly dispersed, quiet airflow of static eliminating ions with a low compressed air consumption.  Using the laminar, static eliminating airflow from the Super Ion Air Knife, this solution can be mounted away from the static charge, allowing the ions to “rain” down on the affected areas.

For this application finding a solution meant finding a method to keep production on schedule.  Without static elimination this machine faced defects, downtime, and decreased efficiency.  Using EXAIR Super Ion Air Knives brought this application back up to optimal operating speeds, keeping the revenue generating process of this manufacturer ongoing.

Colder weather is here and static comes along with it.  If you’re experiencing a static related problem in your facility, contact one of our Application Engineers.  We’d love to help you find a solution.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

How To Solve A Problem with Compressed Air

In my (almost) six years as an EXAIR Application Engineer, I’ve learned a great many things about the capabilities of our products.  The way we do business sure does make it easy:

  • We readily share application information, as a team.  If you ask me a question, you’re asking all of us.  It does neither of us any good if I tell you something MIGHT work if one of my team knows it WON’T – or if someone knows what else DOES work.  If we can offer a solution, we will.
  • We’ll test your product, free of charge.  This is a popular way of finding out which Line Vac is best for conveying a particular product, for example.
  • If you’re considering a quiet, safe, and efficient EXAIR product as an upgrade, we’ll test your current product in our award winning Efficiency Lab, so you can compare accurate performance data and analyze the expected benefits…which can be dramatic.  Try us on that.
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Line Vac conveyance rate testing (left;) Efficiency Lab testing (right.)

 

  • We’ll let YOU test our product, risk-free.  All catalog products come with a 30 Day Unconditional Guarantee.  We invite you to put it through its paces for up to a month.  If it’s not working out, we’ll arrange return for full credit.
  • We’ll do the math.  But first, a disclaimer: strictly comparing the force or flow of an engineered product to an open-end blow off won’t always tell the tale.  Our Intelligent Compressed Air Products are creating a laminar flow which won’t generate as high of a force/thrust as open-end blowing (which is turbulent by nature,) but is MUCH more conducive to efficiency and noise reduction, as well as similar (if not improved) performance.  But back to the math: if you know the metrics you need to meet for spot cooling (like a Vortex Tube, Adjustable Spot Cooler, Cold Gun, etc.) or for liquid spraying (the liquid flow rate and/or pattern size & shape from an Atomizing Spray Nozzle, for instance,) or the heat load that a Cabinet Cooler System can handle, we’ll do the calculations and specify the appropriate product.

Regardless of the application, if it can be solved with compressed air, it’s very likely that we have a great solution.  Call me to find out how we can help.

Russ Bowman
Application Engineer
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High Temperature Capability

Last week, a customer called in to talk about their application.  After aluminum and steel machining operations, parts are run through a washer system. The drying portion utilized a Super Air Amplifier to dry the sides and a Super Air Knife to dry off the top. The wash temperature was running at 185°F.  The customer wanted to review the application and make sure the EXAIR products utilized in the process were rated to this temperature and to check on high the products could go, since the maximum possible temperature for the washer was listed as 250 °F.

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Drying Section – Utilizing EXAIR Air Amplifier (near top) and Super Air Knife

The Super Air Amplifier is rated to 275°, above the maximum possible condition.  The Super Air Knife was pre-installed with a stainless steel shim, enabling a maximum temperature rating of 400 °F. Both of the components are rated for temperatures in excess of the maximum possible washer temperature condition, and the customer felt confident with the system design.

EXAIR has several options in the Air Amplifier and Super Air Knife product families to allow for operation in high temperature applications.  For the Air Amplifier, the Super Air Amplifier and Aluminum Adjustable Air Amplifier have a maximum temperature rating of 275°F.  The Stainless Steel Adjustable Air Amplifier is rated to 400°F, and for the hottest of conditions, the High Temperature Air Amplifier is rated to 700°F.

Relating to Super Air Knife, the aluminum Super Air Knife is rated to 180°F.  With a stainless steel shim installed, the maximum increases to 400°F. The PVDF Super Air Knife, used in applications where chemical resistance is needed, can withstand temperatures up to 275°F. And for the most extreme temperature environments, the Type 303 and Type 316 Stainless Steel Super Air Knives are rated up to 800°F.

To discuss your application and how an Air Amplifier and Super Air Knife or any EXAIR Intelligent Compressed Air Product can help your process, feel free to contact EXAIR and one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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“(Stay) Set It And Forget It”

The Stay Set Hose is a popular, and practical, accessory for use with many of our blow-off products. Thread one end onto a compressed air supply connection, thread a Super Air Nozzle (or maybe even a small Air Amplifier or short Air Knife) onto the other end, and you’ve got an easily repositionable blow off…which will reliably hold its position.

That last part was of considerable importance to a caller I had the pleasure of assisting recently. Some of the CNC machines in their shop were fitted with flexible plastic tubing (commonly used for coolant & cutting fluid,) supplied with compressed air to blow off chips & debris from the tooling as the parts were being machined. They use our Super Air Knives in other blow off processes (where they used to use costly & loud open blow off devices,) and wanted to see if engineered products might reduce their compressed air consumption & noise levels in the machine shop too. (spoiler alert: Yes, they can.)

Thing is, they really needed the flexibility of the modular hose, but it’s not rated for the pressure supply required for a Super Air Nozzle. This is what makes our engineered products so efficient; they use the Coanda effect to amplify the compressed airflow..and they use the supply pressure to do that. So they can’t install a Super Air Nozzle on what they have now.

Enter the Stay Set Hoses: They’ll bend to direct the nozzles’ air flow right where you need it, and they’ll keep it there until you bend it again. Which (back to what’s most important to this caller) is exactly what they needed. With our efficient & quiet Super Air Nozzles, they’re saving compressed air and improving the conditions of their work environment. With the Stay Set Hoses, they’re able to quickly & easily rig the air flow before running a job, knowing they won’t have to worry about it until the job’s done.

EXAIR Stay Set Hoses hold their position as long as you need them to. All day, every day.

EXAIR Stay Set Hoses hold their position as long as you need them to. All day, every day.

“Set it and forget about it” is a benefit you can realize from many EXAIR Intelligent Compressed Air Products. If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
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Removing Debris from Jars Prior To Filling

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These PET jars needed a way to remove static dust prior to filling with product

Back in the spring of this year I had some interaction with a customer in India about a Vortex Tube application.  At the time, they were facing an overheating condition and needed some guidance as to which model would provide the best solution.

Fast forward to this week and this same customer reached out to me again, this time for a static problem.  The application in question was plagued with difficulty in removing small dust particles from the inside of PET jars (shown above).  The jars range from 220-260mm in height (8.6”-10.25”), 80-100mm (3.1”-4”) in diameter, and travel through the process at a speed of ~40 units per minute.

Due to static charge, the dust in this application would adhere to the inside of the jars, presenting a problem with filling during the next stage of the process.  What this customer needed was a way to remove the static, blow away the dust, and then pull a slight vacuum on the jars as a safeguard against any remaining dust.

The solution was to use the Stay Set Ion Air Jet to blow into the jars, removing the static and blowing away the dust, followed by a Super Air Amplifier to remove any dust particles which were not removed by the Ion Air Jet.

The customer was happy with this solution, but there was a bit of hesitation as to whether the Air Amplifier would be able to truly remove debris from the jars.  In an effort to visualize the effects of an Air Amplifier on this type of application I made the short video below.

This video shows paper pieces inside of a cylinder of comparable height to the jars in this application.  After the paper is placed in the cylinder the model 120021 Super Air Amplifier is used to pull the paper out of the cylinder, mimicking the effect it will have on residual dust in the customer’s application.  After seeing the video the customer was confident in the application solution.

Providing this type of assistance for our customers is nothing new for us at EXAIR.  We’re available via phone, online chat, or email for all of our customers, and commit to taking the time needed to really provide the assistance needed.  If you find yourself in need of solid engineering support for an application in your facility, contact an EXAIR Application Engineer.

 

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

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