Vortex Tubes can be Customized to Suit Your Application

Vortex tube

EXAIR’s Vortex Tubes are a low-cost, reliable, and maintenance-free solution to a variety of industrial spot cooling problems. With just an ordinary supply of compressed air, the Vortex Tube produces two streams of air: one hot and one cold. This is achieved without any moving parts or refrigerants!!

The Vortex Tube is capable of achieving a temperature drop/rise from your compressed air supply ranging from -50°F to +260°F (-46°C to +127°C). Flow rates range from 1-150 SCFM (28-4,248 SLPM) and refrigeration of up to 10,200 Btu/hr. With all Vortex Tubes constructed of stainless steel, they’re resistant to corrosion and oxidation ensuring you years of reliable, maintenance-free operation.

How A Vortex Tube Works

In addition to providing a range of different Vortex Tubes available to ship same-day from stock, EXAIR also has a few options available for cases where a stock Vortex Tube may not be the right solution. The standard Vortex Tube is suitable for use in environments with ambient temperatures up to 125°F (52°C) due to the plastic generator and Buna o-rings. For more extreme environments and ambient temperatures up to 200°F (93°C), we install a brass generator and replace the Buna o-rings with Viton seals.

All standard Vortex Tubes are adjustable. A small valve is located at the hot air exhaust end of the tube. Using a flat-tipped screwdriver, you can adjust the amount of air that is permitted to exhaust from the hot end. As more air is allowed to escape, the temperature at the cold end of the tube drops even further. The volume of air at the cold end as the temperature drops will also decrease. The percentage of air exhausting from the cold end relative to the total air consumption is referred to as the cold fraction percentage. Lower cold fractions will produce lower temperatures, but there won’t be as much volume. Finding the proper setting for your Vortex Tube can take some adjusting.

HT3240

As we all know, if there’s a knob to turn, button to press, or adjustment that can be made an operator is inevitably going to tinker with it. Day shift will blame the night shift, night shift blames the day shift, and it can present a problem when the Vortex Tube has been specifically tested and set to achieve the desired cold fraction. If you know the cold fraction you need, but would prefer to prevent it from being able to be adjusted, EXAIR can install a precisely drilled hot plug to set the cold fraction percentage to your specifications and eliminate any potential for it to be changed.

If you’d still prefer to keep the adjustability, but don’t have the capabilities to measure and set it yourself, we can also set any Vortex Tube to the desired cold fraction with the adjustable valve and send it to you ready to be installed. We’ll provide you with a special model number so you can rest assured that any time you need another it’ll come set to your specification.

At EXAIR, we’re committed to providing you with the best solution possible for your application. Sometimes that isn’t going to be achievable with a standard stock product. Just because you don’t see it in the catalog or on our website, doesn’t mean we can’t do it. If you have a unique application and would like more information on getting a special Vortex Tube, contact an Application Engineer today.

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

EXAIR Super Air Knives: Customized for You

In a recent blog “EXAIR Super Air Knives: Overview”, I shared the features and benefits that puts the “Super” in the Super Air Knives.  But, let’s not define ourselves by our widest range of lengths and materials that we stock.  EXAIR can also customize the Super Air Knives to fit your requirements.  Many manufacturers like to make their standard items and expect the customers to adapt to their design.  But at EXAIR, customer service is our primary focus.

EXAIR manufactures our products at one location in Cincinnati, Ohio.  So, this gives us the flexibility to do many things like making adaptive configurations with our Super Air Knives.  Here are some examples that our customers requested.

  • Special lengths: EXAIR stocks standard incremental lengths from 3” (76mm) up to 108” (2.74 meters) in aluminum, 303SS, and 316SS materials; or 3” (76mm) to 54” (1,372mm) for PDVF Super Air Knives. But sometimes, the Super Air Knife has to fit into a specific area where a standard length will not work.  This is where EXAIR exceeds, and we can make any length metric or imperial between the ranges above.

    PVC Super Air Knife
  • Other materials: There isn’t a single material that is inert to all chemicals. In some rare cases, the environment can chemically attack our Stainless Steel or PVDF Super Air Knives.  So, a different material may have to be used.  For the customer above, they required a PVC material for a phosphorous environment.

    Curved and Thin Super Air Knives
  • Critical Dimensions: When the Super Air Knives have to adapt inside machines or in tight areas, we can modify the profile.  We have two special applications (reference above) that needed a design change for fit and function.  A curved Super Air Knife was used to hold tubes on a rotary table; and a thin Super Air Knife that was only 11/16” (17.5mm) thick cleaned a mold for circuit chips.

    Super Air Knife special mounting
  • Add-ons: EXAIR understands the importance of connecting to our Super Air Knives to get the greatest performance.  Our stock product has ¼” NPT inlet air ports along the bottom and one at each end.  We have ¼” – 20 threaded holes for mounting along the bottom as well.  But if you want threaded holes in a specific location for mounting or need the inlet air ports to be metric threads, EXAIR can accommodate these features.

    Double-sided Super Air Knife
  • Situational Applications:  Super Air Knives can have complex or simple changes depending on the application.  As an example, EXAIR created a design for a double-sided Super Air Knife to blow a laminar stream of air 180 degrees apart (reference photo above).   A simpler proposal was to replace the cap screws in a 316SS Super Air Knife with hygienic screws for food applications to remove crevices for bacterial growth.
  • OE Protection: In today’s market, it is important to protect your business.  At EXAIR, we can make a special Super Air Knife to blow, dry, or cool in your custom machines.  With a unique model number, EXAIR can help support and protect your business for future and replacement business.

Remember, your imagination is the beginning of creation.  If you cannot find a specific design to be used in your compressed air application, don’t give up.  Contact an Application Engineer at EXAIR to see if we can help you.  We have a team of engineers that can evaluate the fit and function to create a “Super” blow-off solution.  For the customers above, we were able to propose a unique Super Air Knife to work in their application; not the other way around.

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

EXAIR Manufactures Custom Solutions with Precision and Speed

Customs
An Air Amplifier with a PTFE plug (left,) a curved Super Air Knife (center,) and a flanged Line Vac are just a few ways EXAIR has provided custom solutions.

Because EXAIR designs and manufactures our own products here in Cincinnati, we can take advantage of the speed, control, and flexibility that comes with full service manufacturing. If you need a customization of a current production product or if you would like to start a compressed air application from scratch, we can probably help. This is true throughout our entire product line, the following custom examples are of our Super Air Knife products.

Do you have an application that may not be best served by one of our stock Super Air Knife products? While we have quite a variety of both materials, sizes, and connection types sometimes a special application requires a special solution. For this reason,  EXAIR manufactures special Super Air Knives suited EXACTLY for the type of application or environment that it’ll be operating in.

Unique applications are fairly common, and the Super Air Knife provides a great solution to many of them.  Consider these situations:

  • A machine builder had to fit an air knife in a 43″ channel.  We had it covered: we made them a custom (non-stock) 43″ 303SS Super Air Knife and shipped it in three days.
  • A user needed 15″ (and only 15″) of air flow.  A Model 110018 18″ Aluminum Super Air Knife, off the shelf, would provide an “overflow” which would disturb product in the vicinity of the blow off.  We had it covered…a custom shim can be made to provide 15″ (and only 15″) of air flow out of an 18″ Super Air Knife.  It only takes a couple of days to get the special shim. We can make shims to center the airflow, keep it all on one side of the knife, have it come out two separate areas etc.
  • Our customer needed the lightweight of the aluminum air knife, but the ambient air temp was causing the stock plastic shim to melt and cause leaks. So we made a custom 4″ Super Air Knife and installed a Stainless Steel Shim.
custom air knives
If your application is more challenging than a custom shim, we’ve also made Air Knives with (left to right) curved radius, special material (glass filled PEEK shown here,) flat, double-sided, and even one with end-mount threaded holes.

We’ve also made a variety of special Air Knives, when more than just length is a consideration.  So, even if your application is “Unique” it’s very likely that we still have you Covered. Give us a call and we can prove it to you!

Jordan Shouse
Application Engineer
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Twitter: @EXAIR_JS

Custom Products Designed Just for Your Application

Because EXAIR designs and manufactures our own products, if you need something a little different we can probably help. This is true throughout our entire product line, the following examples are of our Line Vac products.

Do you have an application that may not be best served by one of our stock Line Vac products? While we have quite a variety of both materials, sizes, and connection types sometimes a special application requires a special solution. For this reason,  EXAIR manufactures special Line Vacs suited EXACTLY for the type of application or environment that it’ll be operating in.

This special Miniature Line Vac was manufactured with barb fittings and designed for a manufacturer of integrated circuit chips. It was used to remove microscopic debris during the chip making process. It’s small overall footprint makes it ideal for applications requiring tight mounting conditions. It has also been used by other manufacturers to vacuum liquid and chips from small drilled holes. While the Line Vac isn’t typically suitable for liquids, the higher vacuum level associated with the smaller Line Vacs makes it a possibility.

ldlvspec1

This next special Line Vac was used to convey fine powders or granulated materials from a hopper. While this is a pretty straight-forward application for a standard Line Vac, their material could sometimes be moist which would pack the tube and restrict the flow of material. The funnel-shaped design created a suction on the existing tube that permitted a continuous product flow.

ldlvspec5

This flanged Line Vac was used to retrofit existing machinery to remove acidic vapors resulting from surface etching of a silicon wafer. Where this would typically be a nice fit for a Stainless Steel Air Amplifier, the existing exhaust piping was lengthy with many bends that would have caused back pressure on any Air Amplifiers. In this case, they needed the high velocity airflow from the directed nozzles of the Line Vac to overcome this downstream resistance.

ldlvspec3

In addition to making Line Vacs in different shapes and sizes, we can also use special materials. In this instance, the special flanged Line Vac was manufactured out of PVDF (Polyvinylidene Flouride) due to its superior corrosive resistance. The Line Vac would be regularly exposed to a chloride wash that would corrode even stainless steel. It was also manufactured with special QF flanges to allow for easy assembly and removal of the conveying hoses for cleaning purposes.

ldlvspec4

As you can see the sky is the limit when it comes to potential styles of Line Vacs. Don’t think just because you don’t find something you need in the catalog that EXAIR can’t do it! We’ll create special manufactured products for just about anything that you can find in the catalog, not just the Line Vacs. Whether it’s custom-length Super Air Knives or special Air Amplifiers we can make it happen. Reach out to an Application Engineer today for help designing a solution, just for YOU!

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

 

Custom Shims – Literally A Breeze For EXAIR

As proud as we are of being able to ship most any catalog product, same day, from stock (99.9831% of the time for on-time shipping in 2017…22 years straight for 99.9% or better,) we take a certain amount of pride in our ability to offer custom solutions for challenging applications as well. Our Engineering and Production teams have a deep well of resources (knowledge, experience, and capability) to draw from, which allows us to meet those challenging applications head-on, in short order.

The one I’m writing about today isn’t exactly one of those challenging ones…

A machine fabricator had a special need for an Air Knife. It had to be Stainless Steel, and it had to be 30″ long. No problem so far…that’s a Model 110030SS 30″ Stainless Steel Air Knife, and it’s on the shelf. Thing is, they only needed 26″ worth of air flow; a full 30″ width was going to disturb, and maybe damage, the edges of the sheet of material that the air was being blown onto.

So we made a custom shim for the Air Knife.  Now, we make these all the time, in all kinds of configurations…hence the term “custom.”  Since this one was blowing onto a web where they didn’t want to disturb the material on the far edges, we made this shim to provide 26″ of flow, on center.  We could just as easily made it to provide 26″ of flow starting at one end or the other, or a specified distance from one end or the other.  Or 13″ of flow on both ends, with 4″ of no flow in the middle, for a total of 26″.

If your application is more challenging than a custom shim, we’ve also made Air Knives with (left to right) curved radius, special material (glass filled PEEK shown here,) flat, double-sided, and even one with end-mount threaded holes.

Regardless of how challenging (or not) your compressed air product application is, we’re here to discuss, any time you’re ready.  Call us.

 

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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EXAIR Manufactures Custom Vortex Tubes

EXAIR is based in Cincinnati, OH and it is where we design and manufacture our products. Since we are the manufacturer, we can design and build custom product when your application demands particular features. Vortex Tubes are the foundation of our cooling products and can be customized to suit your needs in many ways…

Vortex Family

The EXAIR Vortex Tube uses compressed air to generate a cold air stream at one end and a hot air stream at the other end.  This phenomenon in physics is also known as the Ranque-Hilsch tube.  It can generate very cold or very hot air without any moving parts, motors, or Freon.  Thus; making it low cost, reliable, and maintenance free.  The EXAIR Vortex Tube can generate

  • Air temperatures from -50 to +260 deg. F (-46 to +127 deg. C).
  • Flow rates from 1 to 150 SCFM (28 to 4,248 SLPM)
  • Refrigeration up to 10,200 BTU/hr (2,570 Kcal/hr)
Cooling or Heating with the Vortex Tube

With a wide range of cooling and heating applications, the EXAIR Vortex Tubes can be an ideal product for you.  They are used for cooling electronics, CCTV cameras, and soldered parts.  They are also useful for setting hot melts, gas sampling, and environmental chambers.  With its very compact and versatile design, it can be mounted in tight places to apply heated or cold air to your process.  The Vortex Tubes are used for improving process times in cooling, protecting equipment, or setting specific temperature requirements.  If you need a Vortex Tube to be more specific to your application, EXAIR can manufacture a proprietary product in the following ways:

Preset Vortex Tubes – the standard Vortex Tube has a screw on the hot end to adjust the cold and hot air temperatures.  To make the Vortex Tube tamper-resistant, EXAIR can replace the screw with a preset hot valve.  If you can supply the temperature and flow requirements for your application, EXAIR can determine the correct diameter hole to give you a consistent temperature and flow from the Vortex Tube.

Materials – The standard Vortex Tubes has a maximum temperature rating of 125 deg. F (52 deg. C).  For elevated ambient temperature, we offer a brass generator which will increase the temperature rating to 200 deg. F (93 deg. C).  If other materials are needed for food, pharmaceutical, or chemical exposure, we can also offer stainless steel for the hot plug, cold cap, and generator. I have seen Vortex Tubes made entirely from 316SS and even one made with a brass body. There are EXAIR Vortex Tubes with special material o-rings and hot valves or with customized muffler assemblies.

Fittings – Our standard units have threaded connections on the Vortex Tube to connect fittings and tubing.  In certain applications to improve mounting and assembly, special fittings may be required for ease of installation.  EXAIR can attach or modify these parts to the Vortex Tube to meet your requirements.

At EXAIR, we pride ourselves with excellent customer service and quality products.  To take this one step further, we offer specials to accommodate your applications.  As a manufacturer of the Vortex Tubes, we can work with our customers to generate a custom product with high quality, fast delivery, and a competitive price.  So, if you do need a special Vortex Tube to give you a specific temperature, ease of mounting, or a proprietary product for your OEM design, you can discuss your requirements with an Application Engineer.  We will be happy to help you.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb