Super Air Amplifiers vs. Fans – Why are Amplifiers More Effective at Cooling & Drying?

Super Air Amplifier

Super Air Amplifiers entrain ambient air at a rate of 25:1!!

When seeking a suitable solution for cooling or drying your parts, you may be tempted to try out a low-cost fan to get the job done. While fans do a great job of keeping you cool during the warmer months, they’re not the best choice for cooling or drying parts. Have you ever noticed that when standing in front of a fan the flow pattern is not consistent? This is due to the nature in which the fan blades create that air flow by “slapping” the air as they spin rapidly. The air flow that exits from the fan is turbulent and is not as effective as the laminar air flow pattern that is produced by EXAIR’s Super Air Amplifier. The Super Air Amplifier utilizes a patented shim design that maintains a critical position of the air gap and creates a laminar air flow pattern that will exit the outlet of the unit.

fan data2

In addition to providing laminar air flow more conducive for cooling and drying, the Super Air Amplifier provides much more air that can be directed at the target. A standard 2.36” x 2.36” DC operated fan provides anywhere from 12-27 CFM at the outlet, depending on the model. For comparison, a Model 120022 2” Super Air Amplifier will provide 341 SCFM at the outlet when operated at 80 psig. At just 6” away from the outlet, this value increases to 1,023 SCFM!! When compared to the fan outlet air flow, the Super Air Amplifier produces more than an 1,100% increase in air volume!

When replacing a fan with a Super Air Amplifier, the process time can be dramatically reduced. The increase in air volume significantly reduces the contact time that your part will need to be exposed to the air flow, allowing you to increase your line speed and decrease the overall production cost of the part. This is achieved due to the nature in which a Super Air Amplifier draws in air from the ambient environment. At amplification ratios as great as 25:1, the Super Air Amplifier is the best way to move a lot of air volume across the part with very little compressed air supplied to it. Check out the video below for a good representation of the air entrainment of a Super Air Amplifier.

In addition to providing laminar airflow and increasing the volume of air, the Super Air Amplifier is also infinitely adjustable through one of two ways. Each size Super Air Amplifier has a shim set that can be purchased. Swapping out the stock shim for a thinner shim will reduce the compressed air consumption, force, and flow. Installing a thicker shim will increase it. Additionally, the force and flow can also be adjusted by regulating the input supply pressure through the use of a pressure regulator. With sizes ranges from ¾” up to 8”, there’s a Super Air Amplifier for all applications. Give us a call today to see how you can optimize your process by replacing your fans with one or more Super Air Amplifiers.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@Exair.com
Twitter: @EXAIR_TD

Air Amplifiers – What is an Amplification Ratio?

On Friday my colleague, Russ, blogged about the Super Air Amplifier (see that BLOG here, including a video demo)  In discussing the Air Amplifiers, the topic of amplification was mentioned. Today, I’d like to expand a bit further the amplification aspect of the Air Amplifier performance.

As the name of the device implies, the compressed air used by the Air Amplifier is added to, and thus ‘amplified’, the total output flow of the unit. Depending on the size and type of Air Amplifier, the amplification ratio starts at 12:1 and goes up to 25:1, with the ratio being the output flow to the compressed air usage.

AirAmplifiers.jpg

Super Air Amplifier and Adjustable Air Amplifier

EXAIR offers (2) types- the Super Air Amplifier and the Adjustable Air Amplifier.  The Super Air Amplifier uses a patented shim technology to maintain a precise gap, which controls the compressed air flow and expansion through the unit.  As the expanded air flows along the Coanda profile, a low pressure area is created at the center which induces a high volume flow of surrounding air into the primary air-stream.  The combined flow of primary and surrounding air exhausts from the Air Amplifier in a high volume, high velocity flow.  The larger diameter units have a greater cross sectional area with larger low pressure areas, resulting in greater amplification ratios.

The Below table shows the amplification ratios.

SuperAirAmplifierPerformance

The Adjustable Air Amplifier does not use a shim, but rather has an infinitely adjustable gap, allowing for fine adjustment of performance.  Force and flow is changed by turning the exhaust end to adjust the gap, and is then locked into place. The method of the amplification is the same as for the Super Air Amplifier, and the amplification ratios are similar and shown below.

AdjustableAirAmplifierPerformance

The Super Air Amplifiers and Adjustable Air Amplifiers are ideal for use in applications and processes that require cooling, drying and/or cleaning of parts, or the ventilation of confined areas or weld smoke or the exhausting of tank fumes.

If you have questions regarding the Air Amplifier, or would like to talk about any EXAIR Intelligent 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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What’s So “Super” About The Super Air Amplifier?

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of free air from the surrounding environment.

“Free air” from the surrounding environment?  You might think it’s too good to be true, and if you think you’re getting something for nothing, you’re right.  If you consider, though, that it’s oftentimes preferable to work smarter, not harder, then the use of engineered compressed air products is too good NOT to be true.  Case in point: the Super Air Amplifier.

The Coanda Effect is the “work smarter, not harder” part of the Super Air Amplifier

Simple and low cost, (hey, “engineered” doesn’t necessarily mean “complex and expensive”) the EXAIR Super Air Amplifier uses a small amount of compressed air to generate a tremendous amount of air flow through entrainment.  How much do they pull in?  Depending on the model, they entrain air at rates of 12:1 (for the 3/4″ Model 120020) to 25:1 (4″ & 8″ Models 120024 & 120028, respectively.)  The larger diameters mean there’s more cross sectional area to entrain air, so there is indeed efficiency to scale, size-wise.  There are a couple of great visuals in this video, if you want to see the entrainment in action (1:50) or the difference that the entrainment makes (1:30):

 

Where can you use a Super Air Amplifier?  The easy answer is, anyplace you want a consistent, reliable air flow.  The pressure supply can be regulated from a “blast to a breeze,” depending on the needs of your application.  The patented shim can be replaced for even higher performance, while maintaining the efficiency that makes it so valuable.  The balanced flow makes for incredibly quiet operation…no more noisy fans, blowers, or open-end compressed air pipes.  The body (3/4″ to 4″ sizes) is cast with a 2-hole flange for ease of installation.

When can you use a Super Air Amplifier?  Another easy answer: anytime you want.  If you need a continuous air flow, there are no moving parts to wear or electrical components to burn out.  Supply them clean, dry air, and they’ll run darn near indefinitely, maintenance free.

Alternately, if you need intermittent air flow, starting & stopping operation is as simple as opening & closing a valve in the compressed air supply line.  They produce rated flow immediately, and cut it off just as fast.

Some of the more popular applications are ventilation/exhaust, cooling, drying, cleaning, and dust collection.  There are five distinct models to choose from, and they’re all in stock.  We’re also happy to discuss special requirements that might lead to a custom product too.  Our Application Engineers work with Design & Production all the time to meet specific needs of particular situations.

If you’d like to find out more about letting the Super Air Amplifier, or any of EXAIR’s Intelligent Compressed Air Products work smarter for you, give me a call.

Russ Bowman
Application Engineer
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Air Amplifiers – Vent, Exhaust, Cool, Dry, Clean – With No Moving Parts!

As an Application Engineer, one of the interesting aspects of working with customers on applications is the varied types of solutions an EXAIR product can provide.  The Air Amplifier family – Super Air Amplifier, Adjustable Air Amplifier, and the special High Temperature Air Amplifier can be used in a wide variety of process and applications.  Below highlights several of those from past experiences.

A defense contractor was performing maintenance service on a Navy ship, and the ventilation system had to be shut down.  To keep the personnel cool and safe, an auxiliary ventilation was to be supplied.  Rather than use a cumbersome blower assembly, which has to mounted on the top deck, and ducted down to the lower decks, they chose to utilize (2) 4″ Super Air Amplifiers.  They are very portable and can be set up in minutes.  This solution provided the necessary air flow, providing a safe environment for the maintenance crew.

Super Air Amplifier

EXAIR Air Amplifiers use a small amount of compressed air to create a tremendous amount of air flow.

A light bulb manufacturer needed a better solution for a cooling operation.  During manufacturing of a mercury lamp, the bulb must be cooled from 700°C to 600°C in just 15 seconds.  The current method, an open brass pipe, was working but the noise level was too high (95 dBA.) The goal was to maintain the 15 second cooling time, but reduce sound levels to 85 dBA.  By utilizing (2) of 3/4″ Adjustable Air Amplifiers, the customer was able to maintain the cooling rate, and reduce the noise level down to 80 dBA, a 15 dBA reduction.

adjustable Air Amplifier

Adjustable Air Amplifier

A garbage collector presented a problem that needed a solution.  The garbage was incinerated and when the furnaces were first started up, there tended to be issues with getting the flue to draft properly.  Using the High Temperature Air Amplifier, the high velocity air flow and draw provided the needed draft until the stack warmed up and the natural draft would be established.  Since the unit is capable of handling temperatures up to 700°F, it was able to withstand the heat of the process after the compressed air was turned off.

These and other Applications for the Air Amplifiers and all other EXAIR products can be found on the EXAIR website on the Products page, under the Related Info section toward the bottom of each page.

If you have questions regarding Air Amplifiers or any EXAIR Intelligent 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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83% Cyle Time Improvement with EXAIR Super Air Amplifiers

EXAIR Super Air Amplifier – an easy way to quickly move large air volumes

 

At a shipyard in Finland, our distributor found an application using blowers which needed a more viable solution.  The application was to dry the interior of large tanks after coating, and the original solution was to use a blower mounted to a 12” opening on top of the tank.  The airflow from the blower was forced into the tank in an effort to dry the coating but often ended up without any drying effect at all.

This problem was due to vapors (non-combustible vapors) produced by the coating process which are more dense than the ambient air, causing them to collect on the bottom of the tank.  The airflow produced by the blower was not sufficient to force these vapors from the tank, causing a long drying cycle for the coating process or no drying at all.

But, these same tanks feature a 3” diameter plug in the bottom of the tank to allow for draining if needed.  And, this opening is almost perfectly sized for a 2” EXAIR Super Air Amplifier model 120022.  (Model 120022 has an outer diameter of 2.95” at the side which provides incoming ambient air.)  By removing the plug in the bottom of the tank and installing a 2” Super Air Amplifier, this tank can be fully dried in a fraction of the time required for an electric blower setup.  The end user estimated an 83% reduction in drying times (from one hour per tank to ~10 minutes), and gained confidence that the tanks would be 100% dry and free of vapor when using the EXAIR solution.

One additional benefit of this Super Air Amplifier solution was increased reliability.  The electrical supply to this shipyard is unstable, resulting in blackouts and surges which shut down electric blowers.  But because the Air Amplifiers do not rely on electricity and sufficient storage capacity was available for compressed air, these units are unaffected by electrical supply problems.

If you have a similar application or would like to discuss a problem currently present in your production facilities, contact an EXAIR Application Engineer.  We’re here to help.

Lee Evans
Application Engineer

LeeEvans@EXAIR.com
@EXAIR_LE

Super Air Amplifiers for Cooling Injection Mold

When working with a cooling application, many customers will immediately look to the Vortex Tube and Cold Gun product lines. While this may be the best solution for some applications with smaller areas to cool, cold air from a Vortex tube based solution is not the best method for large parts or larger areas that exceed a footprint of approximately 2″ x 2″. For larger areas, we have other options for many cooling applications. EXAIR’s Super Air Amplifiers and Super Air Knives are also very effective at reducing the temperature of a part without requiring cold air.

Cooling is a relative concept based on the starting and finishing temperature. What feels “cool” to a human being does not necessarily mean the same thing as “cooling” a part or material. Due to the ability of the Super Air Knives and Super Air Amplifiers to entrain large amounts of ambient temperature air, we can move a lot of air volume across the surface of the target part and quickly lower the temperature.

A simple example I like to use is blowing on a hot cup of coffee just as its been brewed. The temperature of the air coming from your mouth is around 98.6°F, the same as your body temperature. Coffee can be as hot as 185°F when fresh. Due to the temperature differential between your breath and the hot coffee, we’re able to achieve a reasonable amount of cooling just by simply blowing across the surface. Typically, when the target temperature of the part or material needs to be around ambient temperature or higher; the best solution for cooling is going to be either a Super Air Amplifier or Super Air Knife.

Rob's I phone 877

EXAIR 5015 Cold Gun

To illustrate the above concept even more, recently I was working with a customer that needed to cool a silicon injection mold. The mold had two sides and the customer was looking for a method of cooling it down between cycles. The mold cavity surface was approximately 400°F and they wanted to get it down to around 150°F. They were familiar with the EXAIR Cold Gun as they use them across their facility in various secondary or post-molding drilling operations. They had a spare and decided to hook it up and blow the cold air across the face of the mold to see what happens. The volume of air from the Cold Gun was not enough to sufficiently cool the entire mold, so he reached out to EXAIR for assistance.

Based on the dimensions of the mold and understanding the target temperature to be 150°F, we settled on a system of (2) 120224 4” Super Air Amplifier Kits. One was placed above each side of the mold. As soon as the mold opened, they activated the Super Air Amplifiers and were able to pull the surface temperature of the mold down to an acceptable level. Time is money in any manufacturing operation. Companies that produce injection molded parts will look for any way to improve their process. By implementing a procedure to cool the mold more quickly, they are able to boost their productivity gains and become more profitable.

The Super Air Amplifier Kit comes with an Auto-Drain Filter to keep the air clean and dry, a pressure regulator to allow you to dial in the precise level of airflow, and a shim set that allows you to make gross adjustments to the flow. The Super Air Amplifier is available in (5) different sizes with ¾” up to 8” diameter outlets and flow rates from 219 SCFM to 9,000 SCFM 6″ from the outlet. They are capable of achieving an amplification ratio of up to 25:1 from the compressed air supply. The laminar airflow from the unit minimizes wind shear to produce sound levels that are typically three times quieter than other air movers. If you have an application that requires a similar type of cooling, give us a call. We’ll walk you through the process of selecting the most suitable solution.

Tyler Daniel
Application Engineer

E-mail: Tylerdaniel@exair.com
Twitter: @EXAIR_TD

EXAIR Super Air Amplifiers: Saving Air, Saving Lives

 

superairamp(2)

(2) Model 120021 Super Air Amplifiers

 

I have recently had the pleasure of working with a customer developing a method of delivering air to trapped miners during a multi-man mine rescue mission. The federal government mandates that in the event of an explosion, miners must have a safe place to retreat for a minimum of 96 hours. This system will provide them with a supply of air during that period of time. In the initial stages, they had tried using some old venturis left over from a previous project. While this did work, they weren’t as effective or efficient as they needed. Through a little bit of research, they found EXAIR.

Instead of using compressed air as the source, they’re using cryogenic liquid air. That air passes through a series of cold plates and heat exchangers and gets to the Super Air Amplifier at about 70°F. This air is then carried into the chamber, giving the miners a source of clean air.

superairamp(1)

Model 120021 in prototype

 

EXAIR Super Air Amplifiers utilize a patented shim design that allows the unit to entrain ambient air at a rate of up to 25:1 from the compressed air supply. This balanced outlet airflow minimizes wind shear, producing sound levels that are typically three times quieter than other air movers. The Super Air Amplifiers are supplied with a .003” slotted air gap and can be adjusted by replacing the shim with a thicker .006” or .009” shim.

Do you have a cooling or drying application that could benefit from a Super Air Amplifier? Contact an Application Engineer today to find out how EXAIR can help you save compressed air in your application!

Tyler Daniel, Application Engineer
Tylerdaniel@exair.com
@EXAIR_TD

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