Video Blog: Gen4 Super Ion Air Knife Conversion

The video below provides details on the simple conversion to the new Gen4 style Super Ion Air Knife from the previous style or the addition of a Gen4 Ionizing Bar to an existing Super Air Knife to add static elimination to an existing blow off.

If you have questions about the Gen4 Super Ion Air Knife or any of the 16 different EXAIR 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.

Brian Bergmann
Application Engineer
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Standard Ion Air Knife Keeps Viewing Cover Clean

A manufacturer of high speed industrial machinery makes a sorting machine for seeds.  There’s a clear plastic cover for operators to see the seeds as they pass through the machine.  Many seeds are dense enough to move right on through, but some lower density seeds (canola, lettuce, and flax seed, specifically) bounce around a bit, and even the slight static charge that builds up as they move through causes them to cling to the inside of that viewing window.

This was a great fit for our Model 8406 6″ Gen4 Standard Ion Air Knife Kit…”fit” being the operative word.  While the Super Ion Air Knives are more efficient and quieter, there simply wasn’t very much room at all for mounting inside, so the smaller profile of the Standard Ion Air Knife made all the difference in the world.  Also, since they just need static dissipation of such a small area, and not much flow at all is required to blow off these lightweight seeds, the differences in compressed air consumption and sound level were not very much at all.

Profile-wise, a Gen4 Standard Ion Air Knife takes up less than half the space of a Gen4 Super Ion Air Knife.

For performance, efficiency, and dependability, look no further than EXAIR’s Gen4 Static Eliminator Products.  If you have a problem with static, we’ve got a solution.  Give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Video Tutorial on Cleaning the Gen4 Static Eliminator

It has been over two years since EXAIR first brought our Gen4 Static Eliminators to market with improved performance, materials and durability.  The new design features continue to provide our customers with reliable, rugged and problem solving static eliminators.

More recently our Gen4 product line was completed by integrating these same beneficial features in the Gen4 Ionizing Bars, Gen4 Super Ion Air Knives, and Gen4 Standard Ion Air Knives.

There are two common ways that a Static Eliminator will start to underperform; contamination buildup and point degradation.  To create ions from a metal point, a high voltage is needed.  With 5,000 volts forcing its way into a confined area, the energy behind making an ion creates a corona field.  Any contamination near or around that point will produce a small amount of charred material.  The more contamination in the surrounding area, the faster the buildup will occur. Once a sharp point is coated, the ion production begins to decrease.

The other issue is with metal point degradation.  With the cycle of heating and cooling, the material will start to lose the sharpness of the point over time.  Like a wick used in a candle, you lose a little bit each time.  For both methods above, once the point sharpness is reduced, the dissipation time to remove static starts to increase.

For any “forensics” analysis with the Static Eliminators, you should have a model 7905 Static Meter.  Besides viewing the ion points, the Static Meter can help determine the severity of the function of the ion points.  If cleaning is required, you can use a soft-bristled brush to remove any charred contamination from the point and the base area.  Make sure that the power is turned off before cleaning.  For resistor-based Static Eliminators, the metal ion pins are replaceable.  This is model 901188.  This added feature makes a cost-effective way to keeping the points sharp, and the Static Eliminators like new.  The video below shows how to clean and replace the ion points.

Contact any of our Application Engineers if you have any additional questions about cleaning, about a new application or about potential solutions to static related problems.

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

A Tale of Two Super Ion Air Knives

A manufacturer of plastic bottles had a problem with static charge. Right after the bottles are extruded and cooled, they have an apparatus that “unscrambles” them and places them, single file, onto a conveyor. It does so with some fabric belts and plastic rollers. If you know anything of static electricity, dear reader, you probably recognize that there aren’t too many better ways to generate a static charge than to rub plastic against plastic, or (even worse) plastic & fabric together.  Here’s a prime example of the kind of static charge you can get, just from unrolling plastic film.

The separation of the non-conductive surfaces (like when this plastic film is unrolled) is capable of generating an incredible amount of static charge.

Now, the bottle makers didn’t have a static meter, but they didn’t need one to know they had issues:  the bottles that the “unscrambler” was putting on the belt were still very much “scrambled.”  They installed a Model 112209 9″ GEN4 Super Ion Air Knife Kit, to blow ionized air up from under the bottles as they entered the belt conveyor, and they did see what they’d call an improvement, but not quite what they’d call a solution.

Unfortunately, dissipating the static from just about half of the surface area of the bottle was still leaving them with half a problem.  However, by adding a Model 112009 9″ GEN4 Super Ion Air Knife (the 112209 Kit’s Power Supply has two outlets, and its Filter Separator & Pressure Regulator are capable of handling the flow to two 9″ Air Knives,) they were able to blow ionized air down from the other side, and up from where the first one was installed.  A soft “breeze” was all it took…a stronger air flow would have worked against the “unscrambler” anyway…because even at very low supply pressures, the Super Ion Air Knives produce an extremely fast static dissipation rate.

Even with a 5psig supply…which makes for just a “whisper” of air flow, the EXAIR GEN4 Super Ion Air Knife eliminates a 5kV charge in under half a second.

If you’ve got problems with static charge, we’ve not only got improvements; we’ve got solutions. Give me a call to find out how we can help.

Basics of Static Electricity

Here in the Northern Hemisphere, we are in the middle of winter and that means extremely dry air, and frequent shocks when reaching for a door knob after walking across a carpeted surface.  While a shock is mildly uncomfortable and can be annoying to us, the presence of static electricity in an industrial manufacturing process can be much more problematic.

Problems that static cause range from operator discomfort to increased downtime to quality issues.  Dust can cling to product, product can cling to itself, rollers, frames, or conveyors. Materials may tear, jam, curl and sheet fed items can stick and mis-feed. Hazardous sparks and shocks can occur, possibly damaging sensitive electronics.

EXAIR has put together a useful tool, the Basics of Static Electricity white paper with Interactive Regions to help a person learn more about static.

Basics of Static Electricity

 

Topics covered include Electron Theory, Causes of Static Electricity, Triboelectric Series chart, and Types of Static Generation.  Also, the white paper covers the areas of How to Control Static Charge Buildup, Determining the Source of the Static Buildup, Eliminating or Minimizing the Source Causing the Buildup, and Treating Static Buildup.

The Treating Static Buildup is a comprehensive review of the EXAIR Static Elimination products and how each technology is best applied to different processes and applications.

To receive your copy of the Basics of Static Electricity white paper, click the photo above or the link here.

If you would like to talk about static electricity or 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.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web 
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Twitter: @EXAIR_BB

Ion Bars Eliminate Jam In Fiberglass Production

Last week I worked with a specialty glass manufacturer who was experiencing a static issue in their fiberglass mat production. Their particular production cycle consists of a rotary spinning process where molten glass exits a furnace and goes into a cylinder with several holes that rotates at high speed, causing the glass to be “pushed” through the holes. Upon exiting the cylinder, the fibers are blown down on to a conveyor belt underneath, treated with a binder and pressed together, then sent to an oven to cure. After the sheets exit the oven, they are air cooled, cut to the desired length, then sent to a sorter that directs the material to collection bins, based on thickness and length. It is at this point that they were seeing the parts start to “bunch” up, which caused the system to be shut down so an operator could manually clear the jam and sort the mats. The customer has experienced static issues before in other parts of their plant and took some readings and were seeing a 4 kV charge on the surface of the mats.

After discussing the details of the application, I recommended they use our 24″ Ionizing Bar, the width of their widest mat. The Ionizing Bars produce a high concentration of positive and negative ions to eliminate the surface static of an object when mounted within 2″ of the surface of the material. At 2″ away, the units are capable of dissipating a 5kV charge in less than half a second. By placing a unit above and below the exit point of the sorter, they would effectively remove the surface charge and eliminate the potential jam.

Ionizing Bars Work
Ionizing Bars are effective up to 2″ away and require no compressed air to operate.

Our Ionizing Bars are available in lengths from 3″ up to 108″ for a variety of small or wide surface treatment applications. For assistance selecting the best product for your specific requirements, please contact one of our application engineers at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Ion Air Jet Improves Teflon Gasket Cutting

If your familiar with our blog, you may have noticed that a common theme lately has been static.  Take for example our recent blog titled  Static Can Become A Big Issue With Winter Approaching , details how static was negatively affecting an automobile instrumentation assembler’s production or another one titled Static Electricity – What is it? , providing a better general understanding of the phenomena. Here in Cincinnati we’ve had some relatively mild temperatures lately but this weekend it was just downright cold. Now that our furnace is running, the humidity in the house is starting to be removed which not only wreaks havoc on our hardwood floors, but in winter’s past, it seemed like every time one of us touched each other or something metal , we got “zapped” due to static. As many homeowners do, I’ve purchased several humidifiers and strategically placed them throughout the house which has helped immensely. While this is a good approach for a residence, it’s not as easy an alternative when dealing in an industrial setting.

I recently worked with a customer in the northeastern U. S. who manufacturers Teflon gaskets. As the Teflon tube exits the extruder, a blade passes by and cuts a very thin cross section of material which drops into a collection bin underneath. During the spring and summer months, the process was running seamlessly but over the past couple weeks, temperatures in the area have dropped, causing the company to turn on the large, gas heaters on the production floor. Now that the air is starting to dry out, they are beginning to see the gaskets cling to the blade and surrounding tooling which is not only causing damage to the part itself but it’s also resulting in production delays.

Since the area they are needing to treat is relatively small, I recommended they use our Ion Air Jet. The Ion Air Jet  provide a focused stream of ionized air to eliminate the surface static of a material or object. By incorporating a pressure regulator to operate at low pressure, they would be able to reduce the outlet force and velocity, allowing them to gently blow the airflow across the area as to not disrupt the collection of the parts.

NEW Ion Air Jet
Static can cause a variety of nuisances in industrial settings ranging from damage to sensitive electronics, machine jams, parts or sheets sticking together, and personnel shock just to name a few. If you need any help selecting the best EXAIR product for your needs, don’t hesitate to ask one of our application engineers for assistance. I’d be shocked if we couldn’t help. (I know, not punny).

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN