Customizing Air Amplifiers

EXAIR’s line of Air Amplifiers can be found in a multitude of different applications across the world. They solve problems as simple as blowing debris off parts to exhausting fumes or circulating air. The Air Amplifier comes in two different styles either the Super Air Amplifier or the Adjustable Air Amplifier. Super Air Amplifiers come in a stock Aluminum Body with a diameter that ranges from ¾” to 8”. This differs from the Adjustable Air Amplifier which comes in either type 303 Stainless Steel or Aluminum and are Sized from ¾” to 4”.

The main difference between the Super Air Amplifier and the Adjustable Air Amplifier is the fact the Super Air Amplifier has a shim inside of it that sets the gap for the air flow. The standard shim thickness for the Super Air Amplifier in sizes of 3/4″ to the 4″ is 0.003” which is suitable for most applications. These shims can be exchanged for a thicker shim of thickness of either 0.006″ or 0.009″. The 8″ Super Air Amplifier is the only air amplifier that comes with a standard stock shim of 0.009″ and can be exchanged for a 0.015″ shim if needed.

Flanged Stainless Steel Adjustable Air Amplifier
Sanitary Flanged Adjustable Air Amplifier

Even though there is a wide variety of sizes and materials for the Stock Air Amplifiers they may not meet a customer’s specific application or need. Over the years EXAIR has produced many different custom Air Amplifiers for a customer’s specific need and the images throughout this blog are just a few of what we have done.

High Temp Air Amplifier

• Depending on the environment certain specific materials may be required like the food industry which requires specific Stainless Steel for various applications. One customer had a special PTFE plug made for the Adjustable Air Amplifier to help pull a sticky material through the process. The PTFE helped prevent the material form depositing on the Amplifier.
• For applications were mounting may be an issue, special attachments have been made to assist. For instances were an Amplifier may need to be mounted to a pipe a custom Stainless-Steel Adjustable Air Amplifier with a class 150 raised face flanges.
• Applications that are in a hot environment may require a special high temperature version which has be developed to operate in areas up to 700°F. The High Temperature Air Amplifier was so widely sought after that we turned it into a stock item. It is commonly used in large roto-molds and ovens to circulate air in order to maintain consistent temperatures.

Adjustable Air Amplifier with PTFE Plug Installed

No matter what your application needs are EXAIR will to work with you to create any custom Air Amplifier that fits your specific application needs.

If you have any questions about compressed air systems or want more information on any of EXAIR’s products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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Custom Products for Custom Applications

Here at EXAIR we pride ourselves on the number of problem solving products we have on the shelf that can ship same day if ordered by 3 PM Eastern Time. But some times a stock product doesn’t quite fit the bill for every application.

Since EXAIR manufactures our products at one location in Cincinnati, Ohio, this gives us the flexibility to do many things like making custom configurations with our Line Vac Systems.  Here is one example of a custom Line Vac and how the customer is using it!

IMG_8628
From Right to Left : Custom 1″ Line Vac with a custom threaded Out Let – 6081 Standard 1″ Line Vac  – Custom 1″ Line Vac with a custom threaded Out Let

The photo above shows two custom 1″ Aluminum Line Vacs with custom threaded outlets. This customer wanted to use the line vac to remove fumes from a welding application and wanted to attach one of their flame retardant filter bags to the outlet of the Line Vac! These custom threads allowed them to screw the filter bag directly onto the line vac with the added insurance of a threaded connection to prevent sparks from escaping the bag.  

No matter what your application is EXAIR is capable to work with you to create custom solutions for your application. Whether you need a different material, size or dimensions or design, EXAIR is able to meet your requirements. These Line Vacs represent only one of our many product lines that can be custom made to your specifications.

For more information on EXAIR’s Line Vacs or help with customizing any of EXAIR‘s Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer

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EXAIR, Manufacturing Locally Equals Quick Customizations

Dryer with corn cob material

A manufacturing company contacted EXAIR about their metal tube processing. They made industrial precision tubes from start to finish. This would include turning, cutting, coating, washing and drying metal tubes to specific diameters and lengths.

For one specific problem area, they manufactured a tube with the dimensions of 1” (25.4mm) in diameter and 6” (152mm) in length. They would run a batch of 750 tubes through a wash cycle and then through a vibrating dryer with a drying material made from corn cobs. At the bottom of the vibrating dryer, the tubes would fall to an open mesh shaker table to transfer the tubes to Quality Control. The idea was to remove the excess cob material from the surface of the tubes before inspection and to recycle the drying material. But the problem was static.

When non-conductive materials slide, hit, peel, and vibrate; electrons from the surface can move from one atom to another; thus, creating static. The type of material and the amount of movement governs the positive and negative charges, and the amount of static forces.

The corn cob material is a non-conductive material, but what about the metal tubes? Since the metal tubes were coated for corrosion and abrasion protection, the surface is now a non-conductive area which will contain static. Since opposite charges attract each other, the cob material would cling to the outside surface of the metal tubes (reference photo below). Being a precision tube manufacturer, they did not want to send “dirty” tubes to their customers or allow the drying material to contaminate their measuring equipment. And, with the required quality control, the measurements had to be exact.

Tubes with cob material

The shaker table was 8 feet (2.4 meters) long and 2 feet (0.6 meter) wide with rigid walls. The top of the shaker table was covered with a canvas to allow for a vacuum system to collect the excess material and dust. About half way down, there was a 2” (51mm) drop to help jolt additional cob material off of the tubes as they landed. But the static forces were too strong to release the material. Thus, the static had to be removed from the surface, so they contacted EXAIR to see if we could find a solution.

They sent photos of their setup which always helps us to diagnose and find solutions. The target place that they suggested would be near the 2” (51mm) drop as the tubes would be suspended for just a moment. My recommendation was to use a Gen4 Super Ion Air Knife to blow ionized air around the tubes as they fell. By blowing air, we can use the non-contact force to remove the static and the cob material at the same time. But we had two issues to overcome. The width was fixed at 2 feet (0.6 meter), and the operation controls were 10 feet (3 meters) away from the mid-section of the shaker table.

Gen4 Super Ion Air Knives

EXAIR stocks many Gen4 Super Ion Air Knives ranging from 3” (76mm) to 108” (2.74meters) in incremental lengths for quick shipments. But our standard 24″ product was not able to fit inside that area nor was the five foot electrical cable long enough to reach the control panel. (As a note, it was important for the operator to be able to manually turn on and off the unit from the control panel.)

EXAIR uses an electromagnetically shielded cable to carry high voltage from our Gen4 Power Supply to our shockless, non-radioactive Gen4 Ionizing Bar. Our  stocked length for our armored cable is 5 feet (1.5 meter). After discussing the amount of movement with the table and the desired distance to the control panel, EXAIR could not use an item off the shelf. But not to worry… Since we are the manufacturer, we have the ability to make a special design for this customer.

Super Ion Air Knife Part Numbering System

I recommended a model 112220-10 special length Gen4 Super Ion Air Knife Kit. (Reference model numbering system above). Specials are non-returnable and non-cancelable, but for this customer, it was exactly what they needed. The Gen4 Super Ion Air Knives are engineered to efficiently blow ionized air to the target and remove static charge and debris.

For this special model, it was made to a specific width where the Super Air Knife was manufactured to a length of 20” (508mm), and the high voltage cable was lengthened to 10 feet (3 meters). The kit includes the Gen4 Power Supply to power the Ionizing Bar, a filter to clean the compressed air, a regulator to control the force, and a shim set to change force rates. This complete kit had everything required to begin operations to remove static and cob material from their precision tubes. The customer was able to mount the special length Gen4 Super Ion Air Knife within the shaker table and mount the power supply near the control panel.

Static can be an issue even with coated metal parts. For the customer above, EXAIR was able to make a special length Gen4 Super Ion Air Knife to work in their system. If you believe that static is causing issues, EXAIR has a great range of Gen4 Static Eliminators to remove that nuisance. You can discuss further with an Application Engineer as EXAIR for help; even if you need a custom product.

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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