Like many companies, here at EXAIR we generally always have a promotional offering. These rotate throughout the months and this month is no different. The current offering involves the EXAIR Cold Gun Aircoolant Systems.
These systems help to reduce cutting fluid use, increase production speeds, increase tool life, and has helped more customers than I know. One customer in particular is a maintenance worker from a welded tube manufacturer. This facility had very little amount of downtime permitted due to the high efficiency and high volume of orders. When a machine went down the maintenance team were in like a trauma team to determine the cause of failure and get it remedied to get the line back up and running. One of the biggest problems they would have is when they would have to dry machine a quick part to get the machine back up and running, this would either ruin tools or they would have to slow down the machining time to get the surface finish and dimensions they truly needed. After talking with us the team ordered a Single Point Cold Gun Aircoolant System as these parts were generally smaller shafts or machine dogs.
They received the system in and sure enough a machine went down. The crew went to work and once the part needed was found they got to work on their lathe trying to make a new piece. The Cold Gun held itself straight to the headstock thanks to the integrated magnet and the flexible single point hose kit routed the cold air straight to the cutting point. They didn’t have to fill up the liquid tank or setup the mist system on the lathe, they simply turned on the compressed air and let the lathe do the work. They were able to take what had recently been around a three hour machine job with heavy wear on tooling to a two hour job, no finish pass was needed on the part, and their tools weren’t completely spent by the end of the job.
They got the part back into the machine, made adjustments, and then went to work getting the machine back into production.
Right now, if you would like to try out a Cold Gun Aircoolant System you can order before 12/31/2019 and use the link to order through our promotion in order to receive a free Dual Point Hose Kit with your qualified purchase.
On January 2, 1960 Little Anthony & The Imperials appeared on The Dick Clark Saturday Night Beech-Nut Show to sing Shimmy Shimmy Ko Ko Bop. While I wasn’t around at that time, I have heard the song quite a few times and get it stuck in my head more than I have heard it. What does that song and EXAIR have to do with each other? Well, we shimmy shimmy Super Air Knives to dramatically increase or decrease their flow and force.
The stock shim that is assembled in every Super Air Knife is a .002″ (0.05mm) thick. This sets a continuous opening the full length of the knife that drives the performance of the knife. The shim sets the gap height between the cap and the body of the Super Air Knife. If we evaluate a 24″ Super Air Knife with the stock shim installed we could calculate the airflow opening of the knife as the surface area of a rectangle. To obtain the surface area we take the length of the air knife times the thickness of the shim. See the example below.
As you can see with the stock .002″ thick shim installed we are actually operating at a surface area opening of 0.048 square inches. If we were to install the .004″ thick shim into the knife then we would double the height which in turn doubles the surface area, shown below.
This doubling effect will increase the force out of the Super Air Knife when applications require more power. Thinning out the shim will have the exact opposite effect, if the shim thickness is reduced to .001″ thick then the air consumption and force will be reduced.
Changing the shims out of the Super Air Knives is a fairly simple task as shown in the video below. Installing a different thickness of shim is a coarse adjustment to the volumetric flow needed for your application. Then a pressure regulator can be used to fine tune the needed force and flow for the ideal setting to meet your needs, and operate at maximum efficiency for the application.
If you would like to discuss this further or even see what kind of custom thicknesses we can offer on the shims to truly make a tailor fit Super Air Knife for your application, please contact us.
Little Anthony & The Imperials “Shimmy Shimmy Ko Ko Bop” – [Merlin] XelonEntertainment, WMG (on behalf of Turntable Recordings LTD); ARESA, LatinAutor, União Brasileira de Compositores, Spirit Music Publishing, UNIAO BRASILEIRA DE EDITORAS DE MUSICA – UBEM, Abramus Digital, BMI – Broadcast Music Inc., and 4 Music Rights Societies – https://www.youtube.com/watch?v=5mLjZRAXRRA
Safety should always be a serious concern within industrial environments. Walk through any production facility and you should see all kinds of steps taken to give a safe workplace to the operators, contractors, and other team members. Whether this is through a sign showing PPE required to enter an area, an emergency exit sign, a safe walkway, or machine guards. Safety has become a standard that should never be lowered and there is good reason for that.
EXAIR designs all of our products to be safe and they meet or exceed OSHA standards that are directed toward compressed air safety. The first is to ensure that an operator or maintenance worker will not be injured through air impinging their skin should they come into contact with an EXAIR product. This OSHA standard is 29 CFR1910.242(b) claiming that all point of use compressed air products must be regulated to have less than 30 psig of dead end pressure. This directive is critical for worker safety and the way many blowoffs skirt by is to cross drill holes in the end of the blowoff.
Cross drilled holes may satisfy the dead end pressure standard but it does not address OSHA’s next important compressed air standard about noise exposure, OSHA standard 29CFR1910.95(a). The allowable noise level standard combined with 30 psig dead end pressure will render many home made or retail nozzles near useless because few, if any, meet both standards. Again, EXAIR has engineered and designed our Super Air Nozzles to permit 80 psig inlet pressure and still meet or exceed both of these OSHA standards so that the work can still be done by the operators while remaining safe and retaining their hearing.
For a better explanation and demonstration of how our nozzles meet these standards please see the video below.
While I use nozzles and cross drilled pipes as examples within this blog these safety features are designed into every product that EXAIR offers. This is due to the fact that OSHA, NIOSH, and the CDC do not delineate between a blow gun, blow off within a machine, or even a Cabinet Cooler System. If the device is powered by compressed air then the two key OSHA standard are in effect due to the inherit dangers of compressed air.
I encourage you now to walk through your facility and try to listen or spot compressed air points of use within your facility. Then, I ask you to call, chat, e-mail, or tweet an Application Engineer here at EXAIR and let us help you determine the most efficient and safest product to get the work done.
EXAIR currently offers a multitude of configurations when it comes to the Line Vac – air operated conveyors product line. One of the easiest to install and best suited for food, pharmaceutical, chemical or other sanitary environments is the Sanitary Flange Line Vac¯.
These are offered in four standard pipe sizes, 1-1/2″, 2″, 2-1/2″ and 3″. The models are only available from stock in 316 stainless steel. The sanitary flange is designed to be compatible with ISO 2852. These can easily be used with a “Tri-Clover” clamp and gaskets of varying materials to fit your needs. They have no internal moving parts and offer a compact, high throughput, quiet conveyance for parts, gases or ingredients.
With the sanitary flange design installation or removal are simplified in order to remove the unit for cleaning or reversing. If you would like to discuss just how easy these are to upgrade your existing system or to install into a new system, please contact an Application Engineer.
I recently spoke with a customer who is a casting / machining manufacturer. They had an automated cell that was finish machining a feature on a cast aluminum part then placing it on a conveyor belt for an operator to pick up and continue processing.
The parts were placed 3 pieces wide per row and the conveyor would index with every three parts. The operator would pick three pieces up and transfer them to another station during the machining time. These parts were carrying residual machining coolant and debris onto the outbound conveyor.
The operator would blow them off with a handheld blow gun and all the coolant and chips would generally end up on the floor in the area causing a slip hazard. The focus of the project is to eliminate the safety hazards and leave the parts as clean as possible for the inspection and further process.
The metal parts were positioned similar to the parts I placed in the mock up picture below. The conveyor the customer has is an open mesh conveyor so the process will work better than if it was a solid belt like in the mock up.
The bulk of the concern from the customer was the outside of the part and they stated that anything to blow out the internal is a bonus. The objective is to get as much coolant off as possible. For that we recommended they span the conveyor with a Super Air Knife Kit to blow all the parts off at once. This is mounted closely in the mock up because the customer had space restrictions.
Then, because the parts are always placed in the same location with the same orientation we can locate the ID hole with a Mini Super Air Nozzle on a Stay Set Hose of varying length to reach each set of parts as they come through. Once I had the idea and the products in place I delivered the customer a quote and dimensional CAD file for each part.
Another recommendation was to use a regulator and filter to control just the knife then operate the three nozzles off their own regulator and filter so that the forces between the two can be varied and the performance of the other is not effected. Accompanying the models were installation sheets for each item as well. Followed by the pictures of this mock up for their application.
Needless to say the customer was amazed that we would go to such lengths just to give them more assurance than our 30 day guarantee. They were extremely thankful and are pleased we shipped from stock and met their installation window.
If you are looking for a creative solution, next level customer service, same day product availability, or just a nice human to talk to about compressed air, contact us.
Sound Power… When I hear that term all I can think of is the classic commercial Maxell®Sound made in 1983. I was only a year old when that commercial graced the presence of everyone’s TV. I did see it throughout the years and recall recording Casey Kasem’s Top 40 on Maxell cassettes. Then, in college it was a classic poster you would see around the dorms.
1(Maxell / Retrontario, 2009)
Needless to say, this does show sound power and sound pressure which is the point of this blog. This video however is not an industrial environment that most of us are accustomed to when worrying about the sound power / sound pressure within an environment.
If you observe the video above the speakers and the driver of the speakers is the generator of sound power. That is the energy rate emitted by a source. This power then begins to fill a space which is equivalent to the sound intensity. This is because the sound energy has a direction that is given to it, think of the speaker. The speaker gives the sound energy a vector to travel. Then when the vector hits surfaces that is the sound intensity.
This sound intensity can then be interpreted as the sound power transfer per unit of surrounding surface at a distance. This will then give the information needed to convert the information to the Sound Pressure level. This is the force of a sound on a surface area perpendicular to the direction of the sound.
With this information we can then observe the logarithmic unit (or value) used to describe the ratio of sound power, pressure, and intensity, the decibel. The decibel is what all industrial hygienists and safety personnel are concerned with. In the end, all of this is started at the point of power generation, when observing compressed air blowoffs, this is the exit point of air from the device. If you optimize the point of use device to use the least amount of compressed air and be the most efficient then the amount of sound power being generated and eventually being measured as decibels at an operator’s work station, then the result will be lower ambient noise levels.
If you have ever walked into a manufacturing facility and heard the hiss or even worse the banshee scream of compressed air being exhausted to ambient, whether it be from a cylinder discharge, a timed drain going off, or a bypass valve being activated, they all could be hushed with a muffler. A muffler for compressed air comes in several shapes and sizes. EXAIR offers four separate types from stock to help attenuate the noise disruption within your facility.
The OSHA standard for allowable noise exposure is 29 CFR-1910.95(a) and outlines the number of hours per day any individual can be exposed to a particular noise level. These noise levels are expressed in decibels (dbA).
The first type I would like to showcase are the Reclassifying Mufflers. These are ideal for cylinder exhausts or valves which commonly contain an oil mist within the air stream which can easily contaminate the surrounding area. The patented design of the removable element separates oil from the exhausted air so virtually no atomized oil is released into the environment. They also attenuate the exhaust noise level up to 35 decibels. The filter element helps the exhaust to meet the OSHA Standard 29 CFR 1910.1000, a worker’s cumulative exposure to oil mist must not exceed 5 mg/m³ by volume in any eight hour shift of a forty hour work week.
The chart below helps to properly size the Reclassifying Muffler for a pneumatic cylinder. One key to proper installation of these mufflers is they must be installed vertically in order to properly trap and drain the oil.
The next type of muffler to discuss are the Sintered Bronze Mufflers that are offered in ten different sizes. These are an excellent low cost solution which easily install into new or existing ports. Each size is designed to provide minimal back pressure and restriction for the individual port size. The quick pick chart below helps to easily select the correct size for attenuating the exhaust of a pneumatic cylinder. One key difference between these and the Reclassifying Mufflers is, these do not have to be oriented vertically as they do not collect the oil out of the exhaust air.
If the process air needs to be directed or plumbed away from the operator then the Straight Through Mufflers are the ideal selection as they offer an NPT threaded inlet and exhaust. They are available in three standard NPT sizes from stock. These mufflers can be installed in any orientation and work well with our Vortex Tubes to help pass the cold air through while lowering the operating sound level of the tube. The average noise reduction of the Straight-Through Mufflers is 20 dB. This can easily reduce the noise level of an operation to below the OSHA standard requiring hearing protection for operators in the area.
The final option for mufflers from EXAIR are the Heavy Duty Mufflers. These are available in two sizes from stock and are constructed of corrosion-resistant aluminum with a stainless steel internal screen. These can be installed in any orientation and are ideal for protecting exhaust ports from contaminants that may clog or damage the device they are attached to. The typical noise reduction from installation is 14 dB with these mufflers.
These are available in two sizes from stock and are constructed of corrosion-resistant aluminum with a stainless steel internal screen. These can be installed in any orientation and are ideal for protecting exhaust ports from contaminants that may clog or damage the device they are attached to. The typical noise reduction from installation is 14 dB with these mufflers.
To summarize, EXAIR offers a multitude of options when it comes to lowering sound levels in operation areas that are caused by exhausted compressed air. Each of the mufflers discussed above are shipped same day from stock to meet your immediate need. If you are unsure of which muffler to use for your application, feel free to contact an Application Engineer.