Safety Air Gun Improves Aluminum Extruding Machining Process

I was doing some work around the house Saturday when I heard my wife shouting out from our laundry room….”Something is wrong with our dryer. This is the 3rd time I’ve restarted it and the clothes are still wet!”. Now having been in this situation before, I knew this meant that the exhaust was probably clogged with lint (again).

See, our laundry room runs parallel to our family room and the exhaust ducting goes up and then across the laundry room, across the family room and then exhausts on the side of the house. (I would like to find the person who thought this was a good idea!). I have thought about re-routing the ducting but the only other option would be to have the exhaust on the front of the house which will “never happen” (per my wife). So I usually end up taking my vacuum and attaching as many extensions as possible to reach as much of the ducting as I can. I have tried a few other methods with no success – like taking my leaf blower and, from the outside of the house, blow the lint back towards the laundry room and into a garbage can. (hint: make SURE your wife is not in the laundry room when attempting this…. They don’t react too well when they get covered in lint!)

This made me think of an application I worked on last week with an aluminum extrusion company. The customer cuts lengths of aluminum siding from 1’ up to 10’ in length and, standing at one end of the material, are using a standard blow gun to try and blow out the chips but are unsuccessful. They reviewed our website but were still unsure what product may fit their needs best, so they gave us a call.

We discussed their application and the customer was able to email pictures. After reviewing the pictures I recommended using one of our Soft Grip Safety Air Guns with our Model # HP1125, 2” Flat High Power Super Air Nozzle and a 72” extension.  The Soft Grip Safety Air Gun is constructed of cast aluminum and includes a hook for hanging in a convenient location. The Model # HP1125, 2” High Power Flat Super Air Nozzle, produces 2.2 lbs. of force @ 80 PSIG and utilizes 37 SCFM with a sound level of 83 dBA. This would also meet or exceed the OSHA standards for safety, per Standard 1910.242(b) for 30 psi dead end pressure, and allowable noise exposure per Standard 29 CFR – 1910.95(a).

HP1230

An EXAIR model HP1230 Soft Grip Safety Air Gun

To discuss your application or help with selecting the right product, contact an application engineer.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Dirty Compressed Air Consequences Are Avoidable

I would like to discuss the importance of clean and dry filtered air.  This all comes from some discussions I have had with customers over my time here at EXAIR, as well as from my time in the machine tool industry. It is notable to state that we simply ask for clean/dry air to run through our products, not “instrument” or “process” air which is typically held at a different pressure, temperature, or volume and can be more expensive to generate. All of EXAIR’s products use general plant air and can be cleaned up with simple point of use filters.

Clean and dry compressed air is essential for ensuring a long and easy life of almost any compressed air product.   One product in particular that I have some data on is the EXAIR Line Vac.  The pictures below show the inside wall of a Stainless Steel Line Vac.  This unit was used in a harsh outdoor environment.   The compressor was not maintained and did not have any form of filtration on the lines feeding the Line Vac unit. The first picture shows where all the dirt and particulate were impacting the internal generator wall as it entered the air chamber.

Damaged Generator

The two dark grey marks are actually the impact points on the unit.   There is only one air inlet on the Line Vac, this means that the unit was taken apart during the two months and actually inspected then put back together and the generator was rotated slightly during this process.  These spots are similar to what sandblasting does to metal, just to illustrate how much particulate was in the air stream. Since the air has not yet reached its full velocity within the Line Vac, it has left only those visible surface blemishes.

As the air begins to exit the array of small generator holes it begins to rapidly increase in velocity while it is trying to expand to atmospheric conditions.  Because of this increased velocity, the wear the generator holes experience is greater and as seen below it is causing some extreme wear.

Worn Generator Holes

To give you an idea of what a new generator should look like is below. Here you can see uniform holes that go precisely through the generator.

IMG_4283

To prevent a disaster like this from happening to your end-use compressed air products, all you need are some simple, low maintenance filters.   EXAIR offers dirt / water filter separators that will filter your compressed down to 5 micron particulate size.   The will catch the good majority of rust, water, and dirt within your compressed air system.   Then you can also install an oil removal filter which will filter all oils and particulate out of your compressed air system down to 0.03 micron particulate level.

Each of these units are great point of use filtration to keep any of your processes from experiencing what this Line Vac experienced.   If you have any questions about the quality of your compressed air or why you are seeing failures in product on your compressed air system, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Excellent Customer Service Is The Only Way To Live

I have recently had a few dealings with other companies recently which has left me with two reactions: 1) How they are still in business? and 2) They really have their customer service running well.  The first company was, of course, a large conglomerate that provides our home internet service. The second company was a web-based company providing clothes dryer repair parts.

bad-customer-service

So the first company, it is a local supplier of internet service.   I called to try and upgrade my service to higher speeds and see when I could get it changed.   I have had their service for over 8 years and haven’t had a whole lot of issues with them, everything has been pretty good.   That is until I tried to use their live chat feature on the website where I was told one price for the service, I then questioned why that price didn’t match the one on their site and was told in order to get that price I would need to call a certain number and speak with a representative.   I thanked the person and made the call.  It took me about 15 minutes or so to get to an actual human and then ended up the price still wasn’t the same and got a little run around on features, so I decided I would look at competitive service.

I spoke to their competitor in my area, which was very straightforward with pricing and answered every question I had directly and gave me a very speedy installation date of the next day, but were about 5 dollars more expensive.  So I called my current provider back and got yet another different price but did finally get some straight answers… and then we got to the installation date – 3 weeks out.   I asked if the fact I was a long-standing customer that was upgrading mattered and found out that is actually hurt my installation date.   Since I was merely an upgrade it was extremely low ranking, but if I signed up for additional services then I would get someone to install it within 3 days. When I expressed my concern for this practice I was greeted with silence and sorry that is just how it is followed by when would you like me to schedule this.

So, needless to say, I contacted their competitor, laid everything out and got the service installed the next day, today I call to cancel my existing service and will hopefully never have to look back.   The moral of the story here is, even though I was a long-standing customer the provider saw no merit in that and actually ranked me even lower than a new account.   They were very cumbersome in how they answered questions which left me feeling uncomfortable and I couldn’t get even the same bad answer from the three different people I spoke with.   Ultimately I left them as a customer and am glad to be with another provider.

As for the second instance, I needed to fix the clothes dryer because it was making some funny noises.   So I took a few pieces off, moved stuff around, didn’t see a whole lot wrong and put it back together.   It started making the noise again so I gave it “The Fonz” treatment (hit it hard) and all was good.   The next time I went to dry something my wife then accused me of not starting the dryer because everything was still wet.   I took a look into it yet again and this time I took the dryer all the way apart thanks to an informal video from the manufacturer. The problem seemed to be some bad preventative maintenance on my part and hair/lint wrapping around a roller guide which cause the  roller to stop and the drum to start going slower, as well as a lot of burnt crud around the heating element. So then the parts search began.   I found a company online whose site was easy to navigate, had lots of pictures, even used their live chat which I got quick responses from, and even found videos of how to fix the exact problem I was having.  So I ordered the parts late at night on Monday, their site showed in stock and shipping the next day.   Tuesday I end up getting a confirmation that the parts will be shipped.  Wednesday I received the parts as well as a follow-up e-mail confirming that the parts had been delivered.

20140720_214053

The moral of this interaction as a customer is that I experienced what I hope our customers at EXAIR experience everyday.   All the information I needed was in one place and easy to find,  all the parts were in stock, I got quick responses that were truthful, and in the end even after I ordered the part  I still got great customer service.  Needless to say I have bookmarked their site and will be returning.

Here at EXAIR, you don’t get greeted by a robot when you call during business hours, you get greeted by a human.  We do our best to ensure all information you need is accessible from our site, as well as back that support up with our Application Engineering staff being available by phone, e-mail, chat, fax, visits to EXAIR, and even mail if need be.   Then if you decide to order something from us, if it is standard stock, we ship it same day as long as we get the order by 3 PM EST and are shipping within the United States.  Then, we offer helpful videos, as well as support after you have made your purchase.  On top of all that, we stand behind our products with a 30 day guarantee and a 5 year built to last warranty.

30 Day Guarantee

So no matter how small a project you have, or if you are having any issues with your existing supplier for compressed air products, contact us and see if you notice a difference.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

 

Ion Cannon Eliminates Static in Electronics Application

Ion Cannon

EXAIR has a direct customer overseas who I occasionally have the pleasure in helping to solve various process problems. Our customer is involved in manufacturing user interfaces for products such as car heating and cooling systems, radio remote controls and control panels for various white goods.

Their most recent project involved the elimination of static on a rubber mat which has a PCB embedded within. Given the propensity for static charges to build on the rubber surface, the customer did not want to take any chances of possible discharge to the PCB board, they installed an Ion Air Cannon at the final assembly bench where the mat and PCB board were put together and tested before moving on to be applied to another part of sub-assembly for the product.

The compact nature of the Ion Air Cannon is what made it a perfect candidate for this kind of application. In the past, similar applications in which the Ion Air Cannon proved equally effective were blowing into the sub-assemblies for heat lamp and tail lamps before the reflectors and lenses were assembled. Another great application was to discharge the padding and molded carpet that is installed into vehicles prior to handling to keep operators from receiving static discharge. Finally, blowing out gauge clusters to remove dust and debris before assembly of the clear cover was another significant source of improvement for an assembly process.

Cannon gauge cluster

If your company is into the business of providing such sub-assemblies for automotive or perhaps “white goods” type products and you have issues with dissipating static on the assembly line, give our Application Engineers a call. The Ion Air Cannon is only one solution is a complete family of Static Elimination products that we manufacture for just such situations as these above.

Neal Raker, Application Engineer
nealraker@exair.com

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