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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Cooling Punch Points with a Super Air Knife

A stamping facility had a high speed perforating operation. The idea was to punch holes into a matrix at a fast feed rate.  In their operation, they started to see issues with the punched holes, and they also noticed that the punch points were prematurely failing.  With a tight punch-to-matrix clearance, heat was building up from the friction.  This effect was galling the material and affecting the hole appearance and dimensions.  They also noticed heat damage to the punch points.  They either had to slow their process down, or find a way to cool the punch points.  They contacted EXAIR to see if we could help.

To remove heat, you need to have a fluid moving across the material to carry the heat away. For this customer, the fluid would be air.  Just like a hot cup of coffee, you can cool it by blowing across the top of it.  In this instance, EXAIR can blow a lot of air with using very little amount of compressed air.  Because of the gap opening of the tool die was narrow, I suggested the Super Air Knife.  It has a compact design and can blow nicely between the upper and lower die.  With slight modifications, they were able to mount the Super Air Knives right into the base set.  Because the tool die was a “bowl” type design, I suggested that they should use two pieces of the model 110206 Super Air Knife.  They could mount one to each side to make sure to hit all the punch points.  (Reference the picture below).

Punch Press with a Super Air Knife

Punch Press with a Super Air Knife installed

EXAIR Super Air Knives are the most efficient compressed air knives in the market. It is designed to have a 40:1 amplification ratio.  That means for every one part of compressed air, it will entrain 40 parts of the free ambient air.  As with the coffee reference above, the more air that you can blow, the better the cooling effect.  With the Super Air Knife, we can reach a velocity of 11,800 feet per minute at 80 PSI.  After the customer installed the Super Air Knives, they were able to increase production by 10%.  Also, they found that the punch points were lasting twice as long.  They were so impressed with the effectiveness of the Super Air Knives, they mounted them to all their punch press machines.

Super Air Knife

Super Air Knife

If you find that heat is affecting your process, EXAIR could have a product to help you. We have a variety of efficient air movers to cool your parts.  As for this customer above, we were able to increase production and extend the life of their tools.

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

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

Super Air Knife Shim Design Reduces Operation Costs

A customer of ours had an application where they needed to cool and dry parts on two conveyors that ran side by side.  A single 36″ Super Air Knife was chosen to provide coverage over the full width and to simplify the air plumbing and installation.  As we learned more about the application, it was discovered that there was 10″ section in the center where the the two conveyors butted up, where no parts would pass through, and hence no air was needed.

Fortunately, the EXAIR Super Air Knives can be supplied with custom shim designs to match the air flow requirements of the application.  These shims can be of various thicknesses to increase/decrease the air flow, of alternate materials such as a stainless steel shim in an aluminum air knife to increase the temperature range, or as in this case, designed to provide specific air flow patterns.

By utilizing the special shim design, it is estimated to save $865 per shift per year in compressed air costs versus the standard configuration.  That is a significant savings, and using less compressed air is high on everyone’s priority list.

Check out the video below to learn more about the EXAIR Air Knives.

akvideo

EXAIR manufactures 3 different types of air knives, in 4 different materials, up to 108″ in length.

To discuss your application and see how an 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

Send me an email
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Twitter: @EXAIR_BB

 

 

 

EXAIR Cabinet Cooler Systems – Reliable Protection For Vital Equipment

It’s November, and I’ve had to scrape ice from my windshield three times this week. I’m not complaining – I surrendered the right to complain about the cold when I moved from Florida to Ohio, on purpose, some 25 years ago…this month, in fact. I’m just making an observation. And noting that it’s 73 degrees & sunny in Cocoa Beach right now.

But it is a noteworthy time to be getting urgent calls about cooling applications, like the one I got just the other day.  A manufacturing facility had just suffered the loss of a VERY expensive installation of Variable Frequency Drives (VFD’s) because of a failure of the refrigerant-based cooling system that had come, pre-installed, on the panel.  This machinery, being critical to their process, needed to be brought back on line, RIGHT NOW, and they were the better part of a week away from getting a service technician to look at their current coolers.  They had much better luck with the VFD’s; thanks to a good relationship with a prompt repair service provider, they were going to be operational the next day.  But obviously, they wouldn’t be in operation for very long without proper cooling.

Enter the EXAIR Cabinet Cooler System.  Now, we LOVE to calculate the heat load from the operating conditions of an existing system, but since this one wasn’t running, we were left with estimating the heat load, based on the power requirements of the VFD’s – which did indeed line up with the capacity of the failed A/C system, so we offered a Model 4870 NEMA 4 Cabinet Cooler System – 4,800 Btu/hr – with Thermostat Control.  As a stock catalog product, it was available for same-day shipment, allowing them to resume operation just as quickly as the VFD’s could be restored. The EXAIR Cabinet Cooler product line is available in NEMA 12, 4, and 4X – and also a NEMA 4X in 316SS option for those harsher, more corrosive environments.

EXAIR Cabinet Cooler Systems offer reliable protection from heat, year-round

EXAIR Cabinet Cooler Systems offer reliable protection from heat, year-round.

No matter how cold it gets outside, there are lots of “hot spots” in many workplaces that just don’t care about the regional climate.  If you…or, more to the point, your critical electronics…are in one of those places, isn’t reliable protection a reasonable consideration?  Give me a call; let’s talk.

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Web: www.exair.com
Blog: http://blog.exair.com
Twitter: https://twitter.com/exair_rb
Facebook: http://www.facebook.com/exair

The Adjustable Spot Cooler Is Ideal For Small Parts Cooling

I recently worked with a customer who was trying to cool some small part housings after they leave a wash system. The parts are currently placed in a wash tray where they travel down a conveyor belt and into the washer where they are heated to around 160°F. As the parts exit the washer, the belt is stopped so the parts can be left to cool before an operator places the parts into their dryer system. This cooling process was taking about 15 minutes before the operator was able to safely handle the parts. This cooling delay was negatively affecting their production cycle. They were looking to eliminate the 15 minute cooling cycle by incorporating some type of air cooling system so the parts could be quickly processed to the dryer. They wanted to standardize on a single device as they manufacturer a variety of part shapes with the largest being a valve housing that measures close to 2″ x 2″.

The customer was able to send a few photos of their parts and after reviewing the information sent, I recommended they use our Model # 3925 Adjustable Spot Cooler System with dual point hose kit. Incorporating a Vortex Tube, the Adjustable Spot Cooler is able to produce cold air temperature as low as -30°F, based on ambient supply temperature. The unit features a temperature control valve that allows for simple adjustments of the temperature of the exhausting cold air as well as the volume of air being discharged.  The system includes 2 additional generators which provide more or less airflow volume through the device as well as cooling capacity (Btu/hr.) for even  more control. The dual hose kit separates the cold air into two separate airstreams to provide for a wider coverage area or in this particular case, the customer would be able to treat both sides of the housing for even cooling. The magnetic base makes for easy installation without having to make expensive modifications to their existing setup.

3925 Adjustable Spot Cooler

3925 Adjustable Spot Cooler System – for wider coverage areas with no moving parts to wear out or replace.

EXAIR offers a wide variety of spot cooling products for use in many industrial settings. For help selecting the best product to fit your needs, give me a call, I’d be glad to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

 

High Temperature Air Amplifier Cools High Tech Mirror Glass

We recently worked with a customer that manufactures mirrors for the automotive industry.  Today’s mirrors are evolving and becoming more and more complex, including functions such as auto-dimming, and navigation and backup camera display.

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Mirror manufacturing involves many steps, one step is the application of the reflective material.  Silver can be deposited chemically, but other materials such as aluminum and gold, and for scientific grade mirrors, silicon oxides and silicon nitrides are applied via an evaporative process within a vacuum chamber.  The metal is heated under the condition of vacuum until it vaporizes and is then deposited on the glass.  Many layers may be deposited depending on the mirror type and reflective properties desired.

Our customer came to us and said they were interested in utilizing the Super Air Amplifier technology in the glass cooling process. After reviewing all of the details of the application, including the ambient temperature conditions, we recommended the EXAIR High Temperature Air Amplifier, model 121021, as the right choice for the cooling application.

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Model 121021, High Temperature Air Amplifier

The  model 121021 High Temperature Air Amplifier was developed for moving hot air and to be able withstand high temperature ambient conditions. This special design is rated for environments up to 700°F and its surface is protected from heat stress by a mil-spec coating process developed for the aircraft industry. It uses just 8.1 SCFM of 80 PSIG compressed air, has an amplification ration of 18:1, and a sound level of only 72 dBA. This highly efficient and quiet air amplifier was the right choice, and the customer has reported back that they ‘have been working good’ in the application. They are also used to circulate hot air in ovens or keep even temperatures on large rotational molds. They also solve heat/cooling problems in glass manufacturing, primary metals, heat treating and power generation. They are the right choice for rugged, high temperature processes.

EXAIR makes other specialty Air Amplifiers, including models made for specific customer applications.  These include designs with flange mounting for exhausting flue gases from a  furnace and a design with a PTFE plug to help pull sticky material through a process while preventing the material from depositing on the Air Amplifier.

To discuss your application and how an Air Amplifier would help out, feel free to contact EXAIR and one our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
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Twitter: @EXAIR_BB

 

Mirror Photo Credit – Steve Damron – via Creative Commons Licensei

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