The Case For The Adjustable E-Vac Vacuum Generator

Vacuum generation is vital to many industrial processes:

*Pick-and-place. Vacuum cup systems are used to move metal sheets onto laser & plasma cutting beds, precisely place parts for assembly using end-of-arm robotic tooling, or moving awkward objects, like plates of glass, by hand.

The same Adjustable E-Vac Vacuum Generator can be used for a range of products, from the cinder bloc (left) to small pavers (right.)

*Bag/package opening.  When plastic bags come off a roll and are fed through an automated filler, vacuum cups can make quick work of opening them up, immediately before the filling operation.

*Vacuum filling.  A closed container can be easily filled, without a pump, by simply drawing a vacuum on it.  Same mechanism (and simplicity) as when you drink a beverage through a straw.

These are just a few of the typical uses for an EXAIR E-Vac Vacuum Generator…I’ve written before about how this is our most versatile product line (by number of different applications) but these in particular are the ones I want to use to make the case for the Adjustable E-Vacs.

EXAIR Adjustable E-Vac Vacuum Generators are available in four distinct models, depending on the needs of your application.  Performance is variable not only by regulating the air supply pressure (like any compressed air product) but also by threading the plug into the body, which changes the size of the annular gap that feeds the Venturi, changing the vacuum and flow levels.  This can be used to overcome vacuum loss due to material porosity or vacuum cup leakage in a pick-and place application, to accommodate different bag sizes or types in an opening application, or to change the rate at which a liquid is moved in a vacuum filling operation.

With four to choose from, EXAIR has an Adjustable E-Vac that will fit your vacuum generating needs.

Because of their larger throat diameter, they’re also better suited for situations where particulates or moisture may be entrained…they won’t clog or ‘stall out’ as is common with other Venturi-type products.  This is especially useful in vacuum chucking/clamping, or when contaminants from dirty environments can make their way into the system.

EXAIR E-Vacs provide instantaneous vacuum response, and are engineered for high efficiency to minimize air consumption.

Like EXAIR In-Line Vacuum Generators, they instantly develop rated vacuum as soon as compressed air is supplied, so they’re well suited for fast moving operations.  With no moving parts, they’re durable, effective, and if you feed them with clean, dry air, they’ll operate a good long time, virtually maintenance free.

If you have a vacuum generating application you’d like to discuss, please give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Custom Solution From Stock For A Pick And Place Application

Even if you’re just a casual, infrequent reader of our blogs, you likely know that EXAIR Corporation is proud of our abilities to customize solutions for “out of the box” compressed air product applications. Oftentimes, this is offered as a custom engineered product, developed from a user’s specifications when one of our stock products just won’t work for one reason or another. For instance, when an exotic material of construction is required for heat or corrosion concerns, a special length or size is needed for space constraints, etc.

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.

Other times, though, we can use a stock product for something other than what everyone else uses it for.  We’ve sold Air Amplifiers for use in vacuum chucking, and pick-and-place applications – those are normally the realm of our E-Vac Vacuum Generators.  Speaking of E-Vacs, they’ve been used to deflate basketballs.

And speaking of E-Vacs (still,) I had the pleasure of helping a long-time customer solve a new problem in their growing manufacturing business.  They put their consumer products in blister packages, and recently converted one of the lines that picks & places the plastic “blister” onto the cardboard “backer” from two at a time, to six at a time.  They were using a Model 810003M E-Vac High Vacuum Generator, which worked fine, every time, with two Model 900762 1″ x 1/2″ Oval Vacuum Cups, but when they put four more of those Vacuum Cups on, they weren’t able to pick all six “blisters” every time.

These plastic blisters are smooth and non-porous, so this a “textbook” application for a High Vacuum Generator.  They’re also VERY lightweight, and were picked in a horizontal motion, so the 27″Hg that the Model 810003M can generate wasn’t actually necessary.  By replacing it with a Model 800003M E-Vac Low Vacuum Generator, the extra vacuum flow solved the problem, with no increase in compressed air consumption, which was critical for this area of their operation.

EXAIR E-Vac Vacuum Generators and Vacuum Cups are a reliable, low cost solution for most any pick & place application.

EXAIR Intelligent Compressed Air Products can solve many of your industrial/commercial challenges.  Our catalog documents the ones they’re aimed at.  Others need to be addressed by knowledge and experience…and maybe a little theory to practice.  If that’s the case, call an EXAIR Application Engineer.  We’re here to help, and we’re pretty good at it.

How Versatile Are EXAIR Compressed Air Products?

I wish I could quantify that, but we keep finding more and more applications for them:

Vortex Tubes are used all the time for cooling applications, down to MINUS 40 degrees (Fahrenheit OR Celsius…that’s the point where they’re both the same; no math required.) They also produce a HOT air flow, which we usually call “exhaust,” but some users actually use IT for heating, and call the COLD flow the “exhaust.”

The EXAIR Vortex Tube. Cold air from one end; hot air from the other. Fully adjustable. You can use either...it's fine with us; whatever you need.
The EXAIR Vortex Tube. Cold air from one end; hot air from the other.  You can use either…it’s fine with us; whatever you need.

Our E-Vac Vacuum Generators are popular for “pick-and-place” jobs…hook one up to a Vacuum Cup and you can move parts around all day long. One time, though, I helped a

customer who needed to “pick-and-place” individual small pieces of woven fabric, a lot like a coffee filter. Even our smallest E-Vac, supplied from a Pressure Regulator cranked all the way down, was too much…it would still pick up most of the stack. We found they could use a Model 120020 3/4″ Super Air Amplifier just fine…the Pressure Regulator was still cranked all the way down, and it picked them up one at a time.

No matter what you need to pick-and-place, we've got you covered.
No matter what you need to pick-and-place, we’ve got you covered.

Our Super Air Knives are perfect for blow off, drying, and cooling applications…whether you’re trying to rid your product of dirt/debris, water, or heat, a laminar curtain of adjustable air flow is a “textbook” solution. But I recently had the pleasure of helping a customer who needed to KEEP SOMETHING IN PLACE and called to ask about an Air Knife. They had small cups running single-file down a conveyor belt, with an overhead brush roller pushing down on them at one point so they could be treated on one side. Without something holding them in place, the tooling would simply push them off the side of the conveyor. It required frequent adjustment because they run different sized cups…and they almost always lost some cups when they switched to a different size, while “dialing in” the brush tension. By installing a Model 110036 36″ Aluminum Super Air Knife in place of the brush, they can hold any size cup in place with the downward air flow “curtain.” No more lost product when they don’t get the brush adjustment just right!

Continuous, even, fully adjustable curtain of air...EXAIR Super Air Knives come in lengths from 3 inches to 9 feet.
Continuous, even, fully adjustable curtain of air…EXAIR Super Air Knives come in lengths from 3 inches to 9 feet, in stock.

If you have a compressed air application you’d like to discuss, give me a call.  Perhaps we’ll find the next level of versatility!

Russ Bowman
Application Engineer
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E-Vac Vacuum Generators- For More Than Just Pick and Place

A textbook application for vacuum generators is the ‘pick and place’ function.  With ever increasing automation and robotic cells, more and more opportunities present themselves to utilize the E-Vac Vacuum Generator as a part of the system to ‘pick up’ an object and ‘place’ it in a new position. But the E-Vac’s can be used for many more types of applications.

evac_models (2)
In-Line E-Vac

Another popular usage is to hold something in place. One of our customers uses an array of Adjustable E-Vacs to pull a vacuum and hold down various sizes of Styrofoam sheets during a machining operation. The previous system was a 1 hp blower type, and did not offer any flexibility for handling different size sheets. Sheets would slip and produce off quality results. After installing the new design, the system was able to handle any size sheet, and scrap levels went down dramatically.

adjustable_evacs (2)
Adjustable E-Vac

A unique implication that was solved with an E-Vac was to deflate sporting balls.  The customer printed custom logos, and preferred the items to be flat for the printing operation. Using a commercial grade electric shop vac didn’t completely deflate the balls, and motors burned out often.  Using a low vacuum In-Line E-Vac with a quiet Straight Through Muffler, the customer can now quickly and quietly, fully deflate the balls.

Another popular use for the E-Vac is to pull a vacuum for drawing up liquids or gases. A customer that manufactures automotive seats was having issues with the process, where the expanding foam was producing a gas, and the gas would produce pockets and voids in the foam after setting.  The customer used a model 800017 In-Line E-Vac to create a vacuum inside the mold and draw off the gas, eliminating the pockets and the voids in the final product.

Lastly, as I am big fan of recycling, anything and everything, we worked with a customer that recycles the old CRT style of computer monitor  (remember those?) The housing would be sawed in half, so that access to the internal components could be made. Because of the variability in the size and shape of the monitors, the customer was using an adjustable chuck system, which took time to set-up for every monitor, each being a bit different. To speed up the process, an EXAIR In-Line E-Vac and 5″ Suction Cup was implemented, and the monitor held in place by the screen, which was was very consistent in shape from monitor to monitor. This change reduced the set-up time required.

These and other Applications for the E-VACs and all other EXAIR products can be found on the EXAIR website on the Products page, under the Related Info section toward the bottom of each page.

If you have questions regarding E-Vac Vacuum Generators or 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.

Brian Bergmann
Application Engineer

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Video Blog: The EXAIR Ultrasonic Leak Detector Works for Vacuum Leaks?

 

A brief video showcasing the EXAIR model 9061, Ultrasonic Leak Detector’s, performance on vacuum leaks.  For more information or questions on what else the ULD can be used for, contact an Application Engineer!

 

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

What’s In A Name?

Well, a lot, actually…if that name is EXAIR. I wrote a blog just last week about how a set of Super Air Knives solved a MAJOR problem with a brand new aluminum sawing application – the company got those Super Air Knives on the recommendation of the Maintenance Supervisor, who had used them, with great success, at a previous company.

Even more recently, I had the pleasure of helping a caller from an engineering firm that specifies a wide range of our products for use in their OEM machinery:

*Air Knives & Nozzles for automated blow offs.
*Cabinet Cooler Systems for electrical/electronics heat protection.
*E-Vac Vacuum Generators for end-of-arm robotics “pick & place.”

Turns out, they use a good amount of compressed air in their manufacturing facility and (did I mention they’re an engineering firm?) they’re interested in implementing a facilities resource management program. For one part of this, they want to know how much compressed air they’re using, when they’re using it, and what they’re using it for. And when presented with a question about compressed air, they thought about EXAIR…and wanted to know more about the Digital Flowmeter.

EXAIR's Digital Flowmeter w/ USB Data Logger
EXAIR’s Digital Flowmeter w/ USB Data Logger

We discussed everything from theory of operation, to best practices for installation (location, position, etc.,) to accuracy, to getting the flow data…and we’ve got a few options for that:

*The Digital Flowmeter itself can output a 4-20mA signal, or there’s an optional RS-485 output board available.
*The USB Data Logger connects directly to the Digital Flowmeter and records flow rate data – about 9 hours’ worth if measured once a second; 2 years’ worth if measured every 12 hours. When removed from the Digital Flowmeter and plugged into your computer, you can use its software, or Microsoft Excel, to view & analyze the data.
*The Summing Remote Display offers instant indication of current flow rate, previous 24 hours’ air consumption, and cumulative total usage, all at the push of a button.

EXAIR's Remote Summing Display - see current flow rate, previous 24 hours' consumption, or total cumulative usage, at the push of a button!
EXAIR’s Summing Remote Display – see current flow rate, previous 24 hours’ consumption, or total cumulative usage, at the push of a button!

The latter turned out to be the best fit for my caller – the main supply header runs right past his office, and, if he can sell his facilities folks on it, he can install the Summing Remote Display on the wall, right next to his desk.  Easy as that.

EXAIR’s Intelligent Compressed Air Products have made a name for themselves in many places like this. Here at the factory, we’re all dedicated to spreading, and reinforcing, that reputation for excellence. If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
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Help with Choosing an E-Vac Vacuum Generator

This is a pretty common question when it comes to Vacuum Generator use in pick-and-place application, and although we can’t boil it down to a simple table & formula based on mass (like we can with the Vacuum Cups themselves,) we can usually hone right in on it, if we have enough details of the situation. And, if questions remain, we can always test one to find out…we’ve got an Efficiency Lab.

That’s what I did, first thing this morning. I had the pleasure of speaking with a robotics instructor at a vocational school yesterday…his class was building a robot to enter in a competition, and one of the operations it needs to accomplish is picking up a golf ball and carrying it a certain distance.  This sounded like a great application for a small E-Vac Vacuum Generator, and, considering the potential leakage at the Vacuum Cup face from the dimples on the golf ball, my first instinct was to consider our Model 810002M E-Vac Low Vacuum (Porous Duty) Generator w/Muffler, and a Model 900766 Bellow Style Vacuum Cup, with a 0.73″ diameter face…our smallest, and ideally sized for a golf ball.  They, however, have a VERY limited supply of compressed air, so the difference between the Model 810002M’s compressed air consumption (2.3 SCFM @80psig) and the Model 800001M E-Vac High Vacuum (Non-Porous Duty) Generator w/Muffler (1.5 SCFM @80psig) was worth considering.  Also, we figured that they might be able to use a Model 900804 Check Valve, so the only time they’d need to supply air was to pick it up, and, possibly intermittently to maintain the vacuum.  So, golf ball in hand, off to the Efficiency Lab I went.  I also took our trusty video camera:

As you can see, it locked on to the golf ball instantly, and the Check Valve allowed the Vacuum Cup to hold the ball for over 13 seconds with no air flow to the E-Vac, proving that there isn’t much leakage at all past those dimples.  I suspect we’ll be seeing this robotics class team in the winner’s circle at the competition.

In most cases, the difference between 1.5 SCFM and 2.3 SCFM consumption may go unnoticed when picking a short-duration pick-and place vacuum generator.  The higher usage product’s supply pressure can always be regulated down to reduce compressed air consumption and use only what’s necessary to do the task…we, in fact, recommend that on ANY compressed air application.  In this case, though, it was worth finding out.

If you have a pick-and-place application that you’d like help with in selecting the right system, give me a call.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
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