Small, Precise Blowoff at Your Fingertips

For many blowoff applications, stronger isn’t necessarily better.  For applications and processes where a light, but effective blast of air is needed for cleaning and drying, the VariBlast Compact Safety Air Gun with the Atto, Pico, or Nano nozzle fits the bill. The smallest of the EXAIR engineered Super Air Nozzle family, the Atto, Pico, and Nano have been designed to provide the smallest, most precise blowoff possible. The focused airflow pattern allows for very accurate control and placement of the air stream.  The nozzles are available in both Type 316 Stainless Steel and PEEK plastic (useful for harsh environments, and is non-marring)

img_7480.jpg
The Atto, Pico, and Nano Super Air Nozzles (Scale is in Inches)

The new VariBlast Compact Safety Air Gun is a great choice for putting the power and performance of the nozzle into a small and lightweight air gun. Designed with a variable flow trigger, the airflow can be throttled from a whisper to full force, simply by varying the trigger pull distance.

1698SS
VariBlast Model 1698SS, with Stainless Steel Nano Super Air Nozzle

The Atto, Pico, and Nano nozzles use very little compressed air and are extremely quiet, easily meeting OSHA Standard 29 CFR 1910.95(a) for Noise Exposure.  The design incorporates engineered solutions for safety and can be supplied with higher pressure compressed air and meet OSHA Standard 29 CFR 1910.242(b), relating to dead end pressure requirements.

The table below provides performance data, including the compressed air consumption, force, and sound level for the various configurations.

VariBlast With Small Nozzles

Note that the VariBlast air guns can be had with extensions from 6″ to 72″ and chip shields to meet the performance and safety needs of any application.

The Atto, Pico and Nano Nozzles can also be configured to work with the Soft Grip style of Safety Air Gun.  Consult an Application Engineer for assistance in choosing.

If you have any questions about the Atto, Pico, or Nano nozzles, the VariBlast Compact Safety Air Gun, or any EXAIR 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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An Ultrasonic Leak Detector Helps with a Pressure Decay Leak Detector

Ultrasonic Leak Detector

A manufacturing company had a pressure decay leak system to check for leaks in compressed air housings.  Their detector was able to find leaks as small as 0.02 cc/min.  The leak program was designed for recording each housing with a batch/lot number and the corresponding leak data.  If the housing reached or surpassed the leak limit, the part would be marked and quarantined.  The pressure decay leak detector was a sensitive instrument, but it could not tell the operator where the leak was occurring.

How the pressure decay leak detector worked was by pressurizing the housing to a target pressure.  The flow valves would shut, isolating the housing.  After the pressure stabilized, the sensitive pressure sensors would pick up any loss in pressure over time.  If the leak limit wasn’t reached, a green light would indicate a good leak test.  If the limit was reached, a red light would indicate a failed leak test, and the housing would have to be segregated.

Reference Filter Housing

The housing design used a head, a bowl, a drain, and a differential pressure gauge.  The leak paths were numerous.  It could be at the drain, between the drain and the bowl, between the head and bowl, at the differential pressure gauge, and even in the casting of the head.  The heads were made from a die-casted aluminum.  If the process was not done properly, porosity could occur in the head.  The leak detector was sensitive enough to find any voids that would allow air to pass through the head casting.  With these many areas of potential leaks, it could be problematic if the reject rate was high.

For the application above, it is important to find where the leaks are occurring in order to create a corrective action.  In order to find the leaks, they purchased a model 9061 Ultrasonic Leak Detector from EXAIR.  Instead of pressure decay, the Ultrasonic Leak Detector uses sound.  Whenever a leak occurs, it will generate an ultrasonic noise.  These noises have a range of frequencies from audible to inaudible.  The frequencies in the range of 20 Khz to 100 Khz are above human hearing, and the Ultrasonic Leak Detector can pick up these high frequencies, making the inaudible leaks, audible.  The model 9061 has three sensitivity ranges and a LED display; so, you can find very small leaks.  This unit comes with two attachments.  The parabola attachment can locate leaks up to 20 feet (6.1 meters) away.  And the tube attachment can define the exact location.  With this application, they used the tube attachment to locate the leaks.  After retesting the failed housings, they found that 80% of the rejects were from a sealing surface.  They were able to replace or repair the o-rings.  10% of the leaks were coming from the drain.  3% of the rejects were leaking at the differential pressure gage.  Both the drains and the pressure gages could be replaced with new units.  7% of the housings had a porosity problem in the head of the housing.  For these, they were shipped back for evaluation to create a modification for a better casting.  The production manager shared with me that an extra vent hole was required to reduce the void.  This was a huge savings for the die-caster and manufacturing plant.

EXAIR Ultrasonic Leak Detector is a great tool.  It can be used in a variety of applications including compressed air systems, bearing wear, circuit breakers, refrigerant leaks, and gas burners to name few.  For the company above, it was a great tool to improve their assembly and testing process for their housings.  If you have an application where you need to find an ultrasonic noise, you can speak with an Application Engineer to see if the model 9061 Ultrasonic Leak Detector could help.

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

Video Blog: EXAIR Atomizing Spray Nozzles Product Line

Want to learn more about EXAIR’s line of Atomizing Spray Nozzles?  This short video will familiarize you with their benefits, features, and capabilities.

Russ Bowman
Application Engineer
EXAIR Corporation
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EXAIR Super Air Wipe Greatly Increases Productivity & Saves Money!

Late last year I received a call from a customer that was using EXAIR Super Air Knives to create an air curtain that protected the lens on their Robotic Welders from weld spatter.  The EXAIR Super Air Knife accomplished this by virtue of its design to deliver a uniform sheet of laminar air flow across its entire length.  While this greatly improved the life of the welder lens and reduced maintenance time, further improvements were needed.

The event that triggered this was the challenge they received from their customer (one of the big 3 automobile manufacturers) to increase their output of welded seat frames by 50%.  While the EXAIR Super Air Knives greatly reduced lens maintenance the consensus was further improvements would facilitate the goal of increasing output 50% .

Super Air Knife laser application
Using the Super Air Knife to protect the welding lens

 

This started the discussion on the possibility of using the EXAIR Super Air Wipe, even though it is primarily used for drying/cleaning of long continuous flow products its airflow pattern (see illustration below) was able to direct the weld splatter down and away from the lens.  This ultimately proved to be more effective at protecting the lens than the laminar air curtain provided by the EXAIR Super Air Knife.

Air Wipe - how it works
Air Wipe – How it work

The installation of the EXAIR Super Air Wipes started on 12/16/2017 and was completed on 12/23/2017. The original production rate was 480 pair of SUV rear seat frames per day running 3 shifts 24/6.

Laser Above SAW Front
Robotic Welder fitted with EXAIR Super Air Wipe

After the Installation of the EXAIR Super Air Wipes, they had improved the production rate to 750 pair/day running 3 shifts 24/5 days per week.  That equates to a productivity increase of 156%, far exceeding the goal of 50%!

Before using the EXAIR Super Air Wipe their maintenance department would clean the Cover Slide on the Laser Welding Head – 3 times per day at approximately 20 min x 3x daily x 6 days / week 6 hours / week.  “With the EXAIR Super Air Wipe we found that we can weld for 10 days before cleaning the Cover Slide” says the customer.

Each Cover Slide costs $195 and those were being replaced weekly, it was a pleasant surprise to find out that only a small amount of dust collects on the Cover Slide now, which is cleaned off in less than a minute

In 10 weeks of Operation they have not replaced a single  Slide since the EXAIR Super Air Wipe has nearly eliminated pitting from the weld spatter.

Also, Cleaning of the Slides is now performed on Saturday’s at the leisure of the maintenance team and not under the strain of production time. The Labor Rate for Maintenance is $75/hour x 6 hours/week = $450 X 50 weeks/year $22,500 plus the cost of the replacement windows at $195 each x 25 weeks = $4,875 savings per year.  Total savings after implementing the EXAIR Super Air Wipe = $27,375 per welding machine!

With the maintenance & replacement cost savings alone it is an easy calculation to make on the purchase of the EXAIR Super Air Wipe’s. That figure is not counting the productivity increase of 156% which allowed them to meet their customers delivery schedule and reduce overtime!

If you would like to discuss increasing the efficiency of your compressed air usage, quieter compressed air products and/or any EXAIR product,  I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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What’s The Big Deal About Clean Air?

Compressed air isn’t called manufacturing’s “Fourth Utility” (the first three being electricity, water, and natural gas) for nothing. Pneumatic tools are popular because they’re often so much lighter than their electric counterparts. Compressed air can be stored in receiver tanks for use when other power supplies are unavailable or not feasible. Many compressed air operated products can be made to withstand environmental factors (high/low temperature, corrosive elements, atmospheric dust, oil, other contaminants, etc.,) that would make electric devices very expensive, unwieldy, or impractical.

One of the most valuable considerations, though, is that your compressed air system is, by and large, under your control.  The type and capacity of your air compressor can be determined by your specific operational needs.  The header pressure in your supply lines is based on the applications that your air-operated devices are used for.  And the performance & lifespan of every single component in your compressed air system is determined by the care you take in maintaining it.

I covered the importance of compressed air system maintenance in a blog a while back…today, I want to focus on clean air.  And, like the title (hopefully) makes you think, it’s a REALLY big deal.  Consider the effects of the following:

Debris: solid particulates can enter your air system through the compressor intake, during maintenance, or if lines are undone and remade.  If you have moisture in your air (more on that in a minute,) that can promote corrosion inside your pipes, and rust can flake off in there.  Almost all of your air operated products have moving parts, tight passages, or both…debris is just plain bad for them.  And if you use air for blow off (cleaning, drying, etc.,) keep in mind that anything in your compressed air system will almost certainly get on your product.

Your compressed air system may be equipped with a main filter at the compressor discharge.  This is fine, but since there is indeed potential for downstream ingress (as mentioned above,) point-of-use filtration is good engineering practice.  EXAIR recommends particulate filtration to 5 microns for most of our products.

Water: moisture is almost always a product of condensation, but it can also be introduced through faulty maintenance, or by failure of the compressor’s drying or cooling systems.  Any way it happens, it’s also easy to combat with point-of-use filtration.

EXAIR includes an Automatic Drain Filter Separator in our product kits to address both of these concerns.  A particulate filter element traps solids, and a centrifugal element “spins” any moisture out, collecting it in the bowl, which is periodically drained (automatically, as the name implies) by a float.

Point of use filtration is key to the performance of your compressed air products, and their effectiveness. Regardless of your application, EXAIR has Filter Separators to meet most any need.

Oil: many pneumatic tools require oil for proper operation, so, instead of removing it, there’s going to be a dedicated lubricator, putting oil in the air on purpose.  Optimally, this will be as close to the tool as possible, because not all of your compressed air loads need oil…especially your blow offs.  If, however, a blow off device is installed downstream of a lubricator (perhaps due to convenience or necessity,) you’ll want to do something about that oil. Remember, anything in your system will get blown onto your product.

If this is the case, or you just want to have the cleanest air possible (keep in mind there is no downside to that,) consider an EXAIR Oil Removal Filter.  They come in a range of capacities, up to 310 SCFM (8,773 SLPM,) and the coalescing element also offers additional particulate filtration to 0.03 microns.

In closing, here’s a video that shows you, up close and personal, the difference that proper filtration can make:

If you’d like to discuss or debate (spoiler alert: I’ll win) the importance of clean air, and how EXAIR can help, give me a call.

Russ Bowman
Application Engineer
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Turn The Pressure Down & Save Money

In the past your typical industrial air compressor was rated to run at 100 psi and it was not often that this pressure was exceeded.  Lately with modern advances pressures have slowly crept up and have surpassed this threshold.  Unfortunately this has proven costly to the industrial user of compressed air.

To clarify this point, if a compressed air system is set to maintain 102 psi it will cost the plant 1% more in electric costs than if the system ran at 100 psi.  Also noteworthy is that unregulated air demands consume about 1% more flow for every psi of additional pressure.

So why is the air pressure getting so high and what can you do about it?  Here are some possible causes and solutions:

Devices that do require more than 100 psi:  It may not be the pneumatic device at all. If these devices are connected with restrictive fittings or there are excessive leaks in the system this can cause up to a 30 psi increase in line pressure just to make up for the poor piping. If this can be corrected it is possible that the pressure can be reduced.

EXAIR offers the Ultrasonic Leak Detector to facilitate tracking down hard to find system leaks and a wide variety of Air KnivesAir Amplifiers, Super Air Wipes, Air Nozzles, Line Vacs, Vacuum Generators and all of them are engineered to provide peak performance at 80 psi and make efficient use of compressed air. Though it is not uncommon for these products to provide a solution at much less pressure.

9061
EXAIR 9061, Ultrasonic Leak Detector

Applications that are believed to be high pressure:  Plant workers sometimes think that a higher air pressure is required than actually necessary.  This can be caused by a lack of training or perhaps the trainers are simply repeating what they have been taught in error.  It is good practice to review all locations that are using a higher pressure to determine if it is really necessary.

Loss due to undersize pipes:  If your plants compressed air supply lines are undersized for the volume demand, this can cause a significant restriction and raise the line pressure.  The EXAIR Digital Flow Meter can assist in recording how much demand is for a given point in time which will clarify usage.

9093
EXAIR Digital Flow Meter

 

Filter/Dryer restrictions:  If the Dryer or Filter/Separators are dirty and/or undersized the compressor operating pressure is typically raised to overcome these restrictions.  EXAIR has six sizes of Filter/Separators to ensure they are properly sized for the SCFM required by the devices that are connected to them.  Five of the models feature an automatic drain system and of course we carry the replacement filter elements and rebuild kits to keep them in top operating condition.

Temporary demands: There may be occasional peak compressed air demands in the plant that may be caused by a different or special compressed air process or machine. If the demand is greater than the supply, the pressure may be pulled down to unacceptably low levels.  In an attempt to make up for the increased demand a plant may raise the operating pressures.  The best way to cope with temporary demands is to install a receiver tank that stores compressed air that can be released when the demand calls for it.

receiver_tank
EXAIR 9500-60, 60 Gallon Receiver Tank

Factory default settings:  It is common for compressor manufacturers to set the air pressure at or very near the maximum pressure rating for that compressor.  There is no reason for this other than to verify that the air compressor will perform at its rated maximum pressure.  To save on air and maintenance costs the compressor should be set only as high as the maximum pressure for approved uses in the facility.

In the compressed air industry, EXAIR provides tools and products with quick payback times.

If you would like to discuss increasing the efficiency of your compressed air usage, quieter compressed air products and/or any EXAIR product,  I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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Super Air Knife with a Plumbing Kit Removes Gypsum from a Conveyor Belt

Plumbing Kits

A gypsum facility was having issues in losing powder from the tailings in their conveying system.  The conveyor moved gypsum from their processing plant to an outside silo bin location for loading and transportation.  The conveyor that they used was 60” wide.  As the conveyor went around the end to dump the gypsum powder, some of the material would stick to the belt and collect on the floor underneath.  Depending on production rates, they would have to stop the operation to clean up the floor which added additional hours for custodial work.  The customer sent a picture of the problem and wondered if EXAIR could help them with this application.

The facility did an annual cost projection to determine the loss of money from the gypsum material collecting under the conveyor.  The custodial cost to clean up the excess powder was roughly $45,000/year.  The unscheduled downtime was estimated at 115 hours per year.  (They did not share the loss of dollars in production to EXAIR.)  But it was large enough that they needed a solution from EXAIR.  (The photo below is similar to the same application as written by Lee Evans: “EXAIR Super Air Knives Improve Process in an Aluminum Rodding Shop“.)

Powder collecting under conveyor

I suggested a model 110260PKI Super Air Knife Kit for this application.  The Super Air Knife was 60” in length to cover the conveyor belt.  The kit included a filter, a regulator, and a shim set to “dial” in the minimum amount of force to remove the material.  This gives the customer the most flexibility when using an EXAIR Super Air Knife.  The “PKI” suffix at the end of the model number indicates our Plumbing Kit.  This kit which is Installed on the Super Air Knife allows for ease of installation to compressed air connections and it also allows for the proper airflow to get a consistent blow-off across the entire length of the Super Air Knife.

At EXAIR, we pride ourselves in energy efficiency.  Compressed air is expensive to make, so why not use it as efficiently as you can?  The Super Air Knife has a 40:1 amplification ratio which allows 40 parts of ambient “free” air for every 1 part of compressed air.  And, with the “dirty” environment at the gypsum facility, the Super Air Knife would not be affected as they do not require a motor that can fail or a maintenance program to perform.  After installing the model 110260PKI, the gypsum powder was no longer collecting on the floor underneath.  If we look at the cost of removing the hourly rate of the custodian, the Return on Investment, ROI, was only 27 days (and this did not include the increase in production rates).

Spillage is wasteful, costly, and time consuming to cleanup.  If you have excess waste from your conveying system, EXAIR will have the product to help you.  For the gypsum facility above, the Super Air Knife Kit made it possible to increase production efficiencies with a short ROI.  You can contact an Application Engineer to review your application and see if we can improve your conveying operation.

John Ball

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