Last year I worked with a power company that was having issues with Position Feedback Sensors overheating causing erroneous readings and early failures. The sensors were located above a steam turbine, and the ambient temperatures reached 128°F with spikes to 140-150°F. The customer had called in looking for a way to keep the sensors cool, using minimal compressed air, and in a robust package. After reviewing the details, we recommended the High Temperature Vortex Tube, model HT3210. While using just 10 SCFM of 100 PSIG compressed air, the HT3210 provides 8 SCFM of cold air at a temperature drop of 54°F from the supply air temperature. Bathing the sensor with this cool air keeps prevents it from heating up and has eliminated the bad readings and prevented the early failures.
The customer recently implemented the same fix for another set of sensors.
The High Temperature Vortex Tube is a special Vortex Tube offering from EXAIR that utilizes a brass generator and hi-temp seal for use in ambient temperatures up to 200°F. Simply supply clean, dry compressed air, and get cold air starting at 50-54°F lower than the supply air temperature. With sizes ranging from 2 to 150 SCFM, there is a Vortex Tube that will meet most applications.
If you have questions about the Vortex Tubes, or would like to talk about any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
I had the pleasure of discussing a spot cooling application with a customer this morning. He wanted to get more flow from his Adjustable Spot Cooler, but still keep the temperature very low. He machines small plastic parts, and he’s got enough cold flow to properly cool the tooling (preventing melting of the plastic & shape deformation) but he wasn’t getting every last little chip or piece of debris off the part or the tool.
After determining that he had sufficient compressed air capacity, we found that he was using the 15 SCFM Generator. The Adjustable Spot Cooler comes with three Generators…any of the three will produce cold air at a specific temperature drop; this is determined only by the supply pressure (the higher your pressure, the colder your air) and the Cold Fraction (the percentage of the air supply that’s directed to the cold end…the lower the Cold Fraction, the colder the air.)
Anyway, the 15 SCFM Generator is the lowest capacity of the three, producing 1,000 Btu/hr of cooling. The other two are rated for 25 and 30 SCFM (1,700 and 2,000 Btu/hr, respectively.)
He decided to try and replace the 15 SCFM Generator with the 30 SCFM one…his thought was “go big or go home” – and found that he could get twice the flow, with the same temperature drop, as long as he maintained 100psig compressed air pressure at the inlet port. This was more than enough to blow the part & tool clean, while keeping the cutting tool cool, and preventing the plastic part from melting.
If you’d like to find out how to get the most from a Vortex Tube Spot Cooling Product, give me a call.
EXAIR will be giving away a free Soft Grip Safety Air Gun with the purchase of any EXAIR Super Air Knife from November 1st through December 31st, 2017. This special promotion will apply to all Super Air Knife orders, whether aluminum, stainless steel, or PVDF. Use the promotional model number during the promotional period and receive a free model 1210, a value of $81.00! The Soft Grip Safety Air Gun is a Top Pick, and provides the ideal combination of forceful flow, quiet noise level and low compressed air usage. To get the special promotional item, use the special part numbers as detailed in the link below.
The Super Air Knife is the latest generation of the EXAIR engineered air knives with dramatically reduced compressed air usage and noise compared to other types of blowoffs. The Super Air Knife is truly a more efficient tool for cleaning, drying or cooling parts, webs, or conveyors. The air flow is a uniform sheet of laminar air across the entire length with a hard-hitting force.
Replacing a noisy blowoff with a Super Air Knife results is a significant reduction in sound. Operation at a high pressure of 80 PSIG (5.5 Bar) leads to a sound level of just 69 dBA for most applications. Air amplification ratios (entrained air to compressed air) of 40:1 is produced. It also meets OSHA maximum dead-end pressure and noise requirements, for safe operation in the vicinity of plant personnel.
Typical applications for use include-
Post wash part drying
Sheet cleaning in strip mills
Part or component cooling
Web drying or cleaning
Environmental separation (air curtain)
Pre-paint blowoff and cleaning
Bag opening/filling operations
Scrap removal on converting operations
Take advantage of the Promotional Offering by clicking on the link at the top of the page. Qualified orders receive the free model 1210 Soft Grip Safety Air Guns as shown below.
If you have questions about Super Air Knives, Safety Air Guns, or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
Albert Einstein famously said, “Nothing happens until something moves.” And unless it’s in a perfect vacuum when it moves, there’s gonna be friction. Especially if it’s in contact with something else besides air. And where there’s friction, there’s heat. This pretty much applies to almost every single evolution in the manufacture of…well, just about everything.
I’m probably not telling you anything you don’t already know, but heat can be a BIG problem. It can:
Shorten tool life. Not only do worn tools take longer to cut, they can also present safety issues. You can get hurt WAY worse by a dull blade than a sharp one.
Cause thermal expansion. If you’re machining something to a precise tolerance, and friction heat causes it to grow, it won’t be the same size when it cools down.
Melt plastics. And even softer metals. This isn’t good for the part…or the tool, either.
Those are just a few of the problems heat causes in manufacturing operations, and they’ve been traditionally addressed with mist (liquid) coolants. And they work just fine…most of them are water-based, and if you want to get heat out of a solid piece of something, water will do the job VERY quickly. Other additives in the coolant provide a measure of lubricity, corrosion control, emulsion prevention, etc. It’s easy, well-known, and time-tested. There are some drawbacks, however:
It can be messy. When a part (or a tool) in motion gets sprayed down with liquid, it tends to fling that liquid all over the place. That’s why most machines fitted with mist coolant have spray shields.
Not only is it a hassle to clean up, if you don’t stay on top of the clean-up, it can lead to slip hazards.
Speaking of hazards, if you can smell that mist (and you know you can,) that means you’re breathing it in too. Remember the lubricants, corrosion inhibitors, emulsion preventers, etc., I mentioned above? Yeah…they’re not all what you might call “good for you.”
Recirculation systems are common, which means the coolant sump is gathering solids, so the lines and/or spray nozzles can clog and be rendered useless.
They incorporate EXAIR’s Vortex Tube technology to produce a stream of cold air.
They’re reliable. There are no moving parts; if you supply them with clean, dry air, they’ll run darn near indefinitely, maintenance free.
They’re quick & easy. With a built-in magnet for mounting and a flexible cold air hose, you can be be blowing cold air right where you want it as quickly as you can attach an air hose and open the valve.
Speaking of opening the valve, that’s all it takes to run a Cold Gun. They’re producing cold air at rated flow and temperature, right away. No “ramp up” time to get into operation.
They’re clean. That cold air stream just becomes…well, air. No mess. No slip. No clean up. No smell. No problem.
We’ve got four Models to choose from, depending on the nature of the application:
If you need to cool parts or tools down, and want it to be effective and clean, give me a call.
Today, I would like to focus on 2 specific Atomizing Nozzles – our No Drip Internal Mix Deflected Fan Nozzle and our Internal Mix 360° Hollow Circular Pattern Nozzle.
The No Drip Internal Mix Deflected Fan Atomizing Nozzle produces a flat fan of atomized liquid at a right angle to the nozzle’s orientation and is designed for use in pressured fed applications where the liquid doesn’t need to be controlled independently from the pressurized air. This nozzle is the perfect choice in processes where mounting space is limited like spraying solvent on conveyed parts inside a small chamber or coating the inside of an enclosure. The patented No Drip feature positively stops the liquid flow when the supply air pressure drops below 30 PSIG, eliminating the need for any additional valves or supply lines. This is especially beneficial in applications using expensive fluids or where drips can ruin a finished product. This nozzle is available with 1/4″ NPT inlets and flows as high as 6.9 gallons per hour.
Our Internal Mix 360° Hollow Circular Pattern Atomizing Nozzles produce a circular spray pattern, the ideal solution when trying to coat the inside of ductwork or where a broad mist of atomized liquid is necessary, like dust suppression or humidification. Available in 1/4″ NPT with flows as high as 14.7 GPH and spray diameters up to 53″ in diameter depending on air and liquid supply pressures. With the 1/2″ NPT, we can achieve up to 150 GPH with a spray diameter up to 156″. Our standard Atomizing Nozzles also feature an adjustment valve to provide control of the flow rate, making them easy to adapt to a specific requirement.
If you have an application requiring a fine mist of atomized liquid, please contact one of our application engineers and let us know how we can help in making the best product selection to fit your need.
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:
Considering the simplicity of the product itself, they can be used for a large variety of “typical” applications:
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:
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.
The Super Air Amplifier is a powerful, efficient, and quiet air mover. Applications currently in place include blowoff, drying, cooling, circulation and ventilation. Sizes from 3/4″ to 8″ are available to best match the air volume that is necessary to achieve the process goals. There are a couple of ways to change the performance of the Super Air Amplifier if either a small or large change to the output flow is required.
The chart below shows the Total Output Flow for each of the 6 models. As an example, the Model 120021 or 121021, when operated at 60 PSIG of compressed air supply, will have a total output flow of 120 SCFM. These same devices when operated at 80 PSIG will have a total flow of 146 SCFM. By simply using a pressure regulation device on the compressed air supply, the output performance can be tuned to match the desired outcome.
For those applications where much greater flow and/or force is needed, the option of installing a thicker shim is available. The Super Air Amplifiers are supplied with a 0.003″ shim installed (the 8″ model 120028, has a 0.009″ shim as standard) and can be fitted with shims of thicknesses of 0.006″ or 0.009″ (the 8″ model has an optional 0.015″ shim.) Installation of a thicker shim increases the slotted air gap, allowing for a greater amount of controlled air flow. As a general rule, doubling the shim thickness will double the air flow rates.
The Super Air Amplifier design provides for a constant, high velocity outlet flow across the entire cross sectional area,. The balanced outlet flow minimizes wind shear to produce sound levels that are typically three times quieter than other air movers. By regulating the compressed air supply pressure and use of the optional shims, adjustability and flexibility of the unit is wide ranging and sure to meet your process needs.
If you have questions regarding the Super Air Amplifier, or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.