At EXAIR, we know compressed air, and we’ve been helping customers around the world get the most out of their compressed air systems since 1983. It was only logical that, about ten years ago, we got into using compressed air for liquid atomization. If you’re looking to spray a liquid in a fine mist with a controllable pattern & flow rate, there are many advantages to using compressed air to atomize it:
Optimal, efficient consumption
Small droplet size
Since their introduction, EXAIR has come to offer 142 distinct models of Air Atomizing Spray Nozzles, and, along the way, we leveraged our engineering, machining, and manufacturing prowess to gain position as an industry leader in liquid spraying. So much so, that, earlier this year, we introduced a spraying product line that doesn’t require compressed air: the FullStream Cone Liquid Atomizing Nozzles. Instead of using the energy of compressed air to effect atomization, these use the energy of the liquid’s pressure and flow to change the continuous stream of liquid flow entering the nozzle into a conical spray as it exits to atmospheric pressure. Here’s how it works:
While Air Atomizing Spray Nozzles maintain their advantage of a smaller droplet size (ours consistently make droplets under 100 microns in size,) there are clear benefits in certain applications to the FullStream Cone Liquid Atomizing Nozzles:
Higher liquid flow rates
Increased liquid coverage
More compact design
These are all important in applications like quenching, cooling, foam breaking, lubricating, degreasing, and sanitizing. All stainless steel construction means they’ll stand up to a variety of chemicals…both in what’s being sprayed, and in the environment in which they’re installed.
EXAIR manufactures a variety of Air Nozzles and Jets . Back Blow Air Nozzles can help reduce cost, clean hard to get to areas in small diameters, pipes, tubes, channels and holes. These nozzles are designed to remove debris from pipes, blind holes, and other areas where it is difficult be effective. Sometimes it is a bad idea to blow debris all the way through a pipe because there may be personnel on the other end or it is simply too long or it may be sealed on an end.
Model 1004SS: This is a M4 x 0.5 and delivers the smallest, most effective airflow for cleaning out small diameter tubes, pipes, channels or holes for diameters between 1/4″ up to 1″. Extension pipes available from 6″ up to 36″ in length.
Model 1006SS: The 1/4 NPT Back Blow Nozzle recommended for a wide range of diameters from 7/8″ up too 4″. Extension pipes available from 12″ up to 72″ in length.
Model 1008SS: 1 NPT female and the largest Back Blow Nozzle in stock for diameters from 2″ up to 16″ with pip extensions available from 12″ up to 72″ long.
These nozzles can also be assembled to our VariBlast, Soft Grip, Heavy Duty and Super Blast Safety Air Guns. EXAIR safety air gun options include chip shields and pipe extensions up to 72″ long. EXAIR has the products and accessories you need to make any job more efficient saving you time and money. Give us call at 800.903.9247 and ask for any of our qualified Application Engineers to help you. Most items are stock and can be shipped the same day if we receive and enter your order by 3:00PM EDT.
I had a customer wanting to reject a container off a conveyor belt. The container held yogurt, and when an optic detected a reject, they wanted to operate a solenoid to have a nozzle blow the container into a reject bin. They had a range that went from 4 oz. (113 grams) for the small containers to 27 oz (766 grams) for the large. He wanted me to suggest one nozzle for all sizes, as they would automatically regulate the pressure for the full range of products. In looking at the largest size, this container will need the most force to blow off the conveyor. The two factors that affects the force in this type of application is weight and friction. When it comes to friction, it is generally an unknown for customers. So, I was able to help with a couple of things to determine the friction force.
Friction is a dimensionless number that represents the resistance created between two surfaces. We have two types; static friction, ms, and kinetic friction, mk. Static friction is the maximum amount of resistance before the object begins to move or slide. Kinetic friction is the amount of resistance that is created when the object is moving or sliding. So, Static friction is always greater than kinetic friction, ms > mk. For this application, we will use an air nozzle to “shoot” horizontally to hit the rejected product.
Let’s take look at our customer’s application. We have a system to reject a non-conforming part with air. The conveyor has a urethane belt. The container is plastic. For the largest container, they have a weight of 27 oz. (766 grams). Being that the conveyor belt is only 12” (30.5 cm) wide, we can determine that if we get the part moving, it will continue off the belt and into the reject bin. The equation for the maximum amount of force required to move a container is below as Equation 1.
Fs = ms * W
Fs – Static Force in ounces (grams)
ms – Static Friction
W – Weight in ounces (grams)
One way to determine the amount of force is to use a scale similar to a fish scale. The scale should have a maximum indicator to help capture the maximum amount of force. You will have to place the object on the same belt material because different types of materials will create different static forces. Keep the scale perpendicular to the object, and slowly pull on the scale. Once the part begins to move, record the scale reading. For the exercise above, it showed 9.6 oz. (271 grams) of force to move the 27 oz. (766 gram) object.
Another way would be to calculate the static friction, ms. Static friction can be found by the angle at which an object starts to move. By placing the container on a section of supported urethane conveyor belt, you can lift one end until the object starts to slide. The height of the lift can be measured as an angle. As an example, we take 3 feet (0.9 meter) of supported urethane conveyor belt, and we lifted one end to a height of 1 foot (0.3 meters) before the 27 oz (766 gram) container moved. To determine static friction, it is the tangent of that angle that you lifted. With some right triangle trigonometry equations, we get an angle of 19.5o. Thus, ms = tanq or ms = tan(19.5o) = 0.354. If we plug this into Equation 1, we get the following:
Imperial UnitsSI Units
Fs = ms * W Fs = ms * W
= 0.354 * 27 oz. = 0.354 * 766 grams
= 9.6 oz. of force = 271 grams of force
Now that we have the static force, we want to be slightly higher than that. In looking at the force requirements that are published in the EXAIR catalog, it shows that the model 1126 1” Super Flat Air Nozzle has a 9.8 oz. (278 grams) of force at 80 PSIG (5.5 Bar). This force is measured at a 12” (30.5 cm) distance with a patented .015” (0.38mm) shim. So, this nozzle will be able to slide the largest container into the reject bin.
To expand on the benefits in using the EXAIR Flat Super Air Nozzles, the force can be changed easily with a regulator or with a Shim Set. This is a unique feature as most competitive flat nozzles do not allow you to do this. The patented shims control the force rating in a wide range with lower air consumption and lower noise levels; making them safe and efficient. So, if this manufacturer decided to produce other sizes in the future, then they could change the shim to target even larger containers. The flexibility of using the EXAIR Flat Super Air Nozzles allow you to increase or decrease the force by just removing two screws and changing the thickness of the shim inside. EXAIR does offer a pack of shims with different thicknesses which are called a Shim Set.
With air pressure or shim manipulation, the customer could use the same nozzle for the yogurt containers. If you have any applications that need products to be rejected quickly, an Application Engineers at EXAIR will be happy to help you with a solution.
Some applications such as blowing chips or debris out of a pipe or blind hole, it may not be possible to blow forward. The pipe may be too long, making it impossible to push the debris all the way down the pipe or the other end of the pipe may not be open. In either of these scenarios, the Back Blow Nozzle is the right tool for the job. An array of holes around the diameter of the Back Blow Nozzles provides a powerful 360° airflow pattern that will clear out any leftover coolant or chips from the machining process.
EXAIR has three different size Back Blow Nozzles; the 1004SS (M4 x .5), the 1006SS (1/4 NPT), and the 1008SS (1” NPT). The 1004SS is recommended for use on pipes as small as ¼” and up to 1”. The 1006SS can be used for a wide range of pipe sizes, from 7/8” up to 4”. The 1008SS nozzle offers the greatest overall force for stubborn or sticky materials stuck to the inside diameter of the pipe. This nozzle is suitable for use in pipes ranging from 2”-16”. As the Back Blow Nozzle will be blowing chips and debris back out of the pipe towards the operator, it is always recommended that a Chip Shield is used. The strong polycarbonate Chip Shield will keep them safe from flying debris and keep you in compliance with OSHA directive 1910.242(b).
All of EXAIR’s Back Blow Nozzles are available with extensions. For the 1004SS we have extensions from 6”-36”, and from 12”-72” for the 1006SS and 1008SS. The Back Blow Nozzle can also be installed on our VariBlast, Soft Grip, Heavy Duty, and Super Blast Safety Air Guns. With such a wide range of available sizes and configurations, we can tackle just about any internal pipe cleaning application. If you have a process in your facility that may benefit from the use of one of these nozzles, give us a call and get one on order today!