A little while back, I was contacted by a customer who was looking for a way to clean chips and debris out of tapped holes in an engine block. They were familiar with our products, having used them in several different areas in their plant, and had done some early research into our Air Nozzles.
They were considering using our small M4 Back Blow Air Nozzle in the process. The Back Blow Air Nozzles produce a 360° airflow that blows away from the end of the nozzle and in many cases, are the ideal solution for treating the inside diameter of hose, pipe, machined holes, etc. These unique nozzles, eliminate the concern of forcing particulate further down into a machined hole or the safety issue of blowing material out of the opposite end of an open tube or pipe.
In this particular case, having the material blown out of the hole increased the risk of possible cross contamination somewhere else in the engine block so they were also thinking of incorporating some type of recovery system like our Chip Vac or one of our Line Vacs but were concerned with having to use two separate devices.
Once again, EXAIR has the perfect solution, the Deep Hole Vac-u-Gun. The Deep Hole Vac-u-Gun features a small blow tube (1/8″ OD) that provides a small blast of air to dislodge or loosen foreign material while simultaneously providing vacuum to carry the debris away.
If you have a similar application or would like to discuss how an EXAIR Intelligent Compressed Air Product can help solve a unique situation, contact an application engineer for assistance.
My hobby with cars is no secret. Most people who meet me come to know I’m a total gearhead. Case in point, on a recent trip to visit with our distributor in Finland, I was asked about the car I was working on when they last visited us just a few months ago. Since then, the aforementioned car (a blue BMW) has found a new home, and I’m gearing up to sell another.
So, when I received an email from a major auto manufacturer needing a solution to clean the top side of an engine block, I was intrigued. In addition to the photo above, I received the photo below with a short description of the current state in the application.
As it stands, coolant is accumulating on the top side of the engine block after they are fully cast, decked, and cleaned. In order to move on to the next step in the process, these engine blocks need to have all residual oil removed from the top side of the block.
The solution? A 9” (229mm) Super Air Knife installed above the engine blocks as they travel down the production line. The Super Air Knife will install at a 45° angle of attack, blowing off the residual coolant and allowing these parts to move on in the process without stopping. This prevents lost throughput due to stoppage of the production line, prevents increased costs due to personnel needing to treat each engine block by hand, and provides a uniform condition for the engine blocks when they arrive in the next step of this production process.
The best part of the interaction was that this auto manufacturer contacted EXAIR for a solution because they were able to solve previous problems with overheating electrical control panels using our Cabinet Coolers. So, when they needed another compressed air solution, they immediately knew who to call.
If you have an application in need of a compressed air solution, give us a call. We’ll be happy to help.
Above, you see a photo of what our customer calls an “air box”. It is aptly named as it consists of approximately 65 homemade nozzles, connected to a large plenum, which are able to be aimed in a variety of directions to blow out the numerous holes that are machined into the bottom of an aluminum engine block.
Each of the nozzles above were hand-made for the air box fixture with an internal hole diameter of 1.6 mm. and which produced a force of about 50 grams with 6 BARG inlet pressure. The goal of reviewing the application was to see what if any EXAIR nozzles could replace these custom-made units to produce an air savings and thus cost savings for operating their fixture.
The calculated air savings between the existing nozzle and the EXAIR Super Air Nozzle was about 34%. That’s a savings of 1.4 SCFM per nozzle. In terms of sheer air volume, that’s not a lot, BUT when you multiply that up over 65 nozzles, total air savings is 91 SCFM. That is close to saving the full output of a 25 HP air compressor!
And so, if you run out the cost to operate a 25 HP air compressor for a year’s worth of production, the savings becomes quite clear that by simply swapping out these homemade nozzles for an engineered solution with EXAIR Super Air Nozzles, the customer can achieve their goal for reduction in air use. Not to mention a significant reduction in the noise level for the application as well as enhanced safety with OSHA compliant nozzles.
Do you have a blowing application that could benefit from the same kind of simple, swapping of nozzles to bring your production costs down? Give us a call and let us know about your application. We would be happy to discuss with you and provide a similar comparison to determine how much air you could save!