Ion Air Jet Applications

While writing my blog last week on all of the features & benefits of the Gen4 Ion Air Jet, I couldn’t help but think of some of the very interesting and successful uses I’ve seen in my nine years (as of this past Monday) as an Application Engineer at EXAIR Corporation.  In honor of my workaversary, this week’s edition is Russ’ Top 9 Ion Air Jet applications:

  1. A medical device manufacturer uses Ion Air Jets to remove dust from plastic extrusion as it goes through a puller belt.  The small diameter (0.05″ to 0.10″) made the Ion Air Jet a more efficient fit than the Super Ion Air Wipe, which is commonly used for extrusions like this, but is most effective for larger diameters.
  2. A maker of large scale automated machinery has provided Ion Air Jets (as well as other EXAIR quiet, efficient, and safe compressed air products) on machines they’ve been selling their customers for years.  When they started machining their own plastic parts, the Ion Air Jet was their first thought for a solution when plastic chips started sticking to their drill bits.
  3. A commercial printer makes displays, signs, etc. from a variety of static-prone materials such as acrylic, polycarbonate, and styrene.  They use CNC routers to cut them to size & shape, form the edges, and add dimensional detail.  Ion Air Jets blow the dust & shavings away, and keep them away, greatly reducing the prep time between routing and assembly.
  4. A weather sealing/stripping manufacturer uses Ion Air Jets to remove statically charged dust from their rubber & foam product extrusions, allowing for increased line speeds and better cuts for the products they cut for specific seal packages for the residential & commercial door and automotive industries, among others.
  5. A major provider of electrical and electronic contactors uses Ion Air Jets to blow off contact strip as it rolls off large reels to remove protective film and static.
  6. A manufacturer of wire marking machinery installs Ion Air Jets on their machines that are used to print on products with especially static-prone jackets, to ensure clean and crisp markings
  7. A cable manufacturer that caters to the computer & electronic industries uses Ion Air Jets to remove static & dust as foil is applied to PVC coated wire.  This eliminates the static charge that was causing inconsistencies when the adhesive was heated to activate.
  8. A wholesale food equipment distributor uses Ion Air Jets to blow out bottles during the sterilization process, prior to filling.
  9. A maker of specialty polymers uses Ion Air Jets to keep fine powders from accumulating in the entries into their hoppers.
Some applications call for a fixed-in-place solution, like the (above, from left) Super Ion Air Knife, Super Ion Air Wipe, Ion Air Jet, and Ion Air Cannon.) Others are best suited to the hand-held convenience of the Ion Air Gun.  Whatever your static problem is, though, EXAIR has a solution for you!

If you have a problem with static, the Ion Air Jet is just one of the solutions EXAIR Corporation can provide.  If you’d like to find out more about how we can help, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Static Eliminators: Ion Air Jet

Static charge causes a variety of problems & challenges in industrial applications:

  • It “zaps” operators who have to handle statically charged materials.
  • It makes sheets and films cling to each other.
  • It can cause tearing or jamming of those sheets and films as well.
  • Objects with high static charges can cause sensors or sensitive electronics to malfunction, and it the charge is high enough, even damage them.
  • It makes dust cling to parts and material that you want to keep clean.
  • It can lead to uneven or spotty coverage if the statically charged piece is to be painted, coated, printed on, etc.

Good news is, static charge is pretty easy to dissipate, and EXAIR Corporation offers a number of solutions that are simple to install and easy to operate.  Among them is the Gen4 Ion Air Jet.

The Gen4 Ion Air Jet generates a concentrated flow of ionized air, which is ideal when you need to focus on a specific spot without disturbing anything in the surrounding area.  They’re quiet, efficient, and OSHA compliant.  They are also available with a number of options to further simply installation & operation:

If you can hard plumb an air pipe directly, the Gen4 Ion Air Jet is ready to go, right out of the box.

Ion Air Jet

The Gen4 Stay Set Ion Air Jet includes a Magnetic Base and 12″ Stay Set Hose, for quick setup and easy aiming of the ionized air flow, exactly where you want it.

The Magnetic Base and Stay Set Hose make it a breeze to mount & aim your Ion Air Jet.

The Gen4 Instant Static Elimination Station adds a foot pedal and two 10ft compressed air hoses, perfect for hands-free on/off operation.

For a total hands-free solution, look no further than the Model 8910 Instant Static Elimination Station.

The Gen4 Deluxe Stay Set Ion Air Jet Kit adds an Automatic Drain Filter Separator and Pressure Regulator so you can keep your air supply clean & moisture free, and dial in the flow & force of the ionized air stream, from a breeze to a blast, or anywhere in between, depending on the needs of your application.

The Model 8495-9362 Deluxe Stay Set Ion Air Jet Kit has everything you need, right out of the box.

We offer two Power Supply options: the Model 7960 has two ports, which will operate any two EXAIR Static Eliminator Products, and the Model 7961 has four ports, to operate up to four Static Eliminators.  They’re switchable for operation with either 115VAC or 230VAC, and come with both cables for your convenience.

Model 7960 Gen4 Power Supply (top) has two ports; Model 7961 (bottom) has four, depending on how many Static Eliminators you wish to operate from the same Power Supply

The Gen4 Ion Air Jet is just one of EXAIR Corporation’s eight distinct lines of Static Eliminator Products.  If you’ve got a problem with static charge, we can help.  Give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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EXAIR Displays Benefits of Ion Air Gun Static Eliminators

EXAIR manufactures a range of Static Eliminator products that are all efficient, effective, and easy to use…none more so than the Gen4 Ion Air Gun. Consider:

  • It’s “plug and play,” all the way.  Connect the cable to the Power Supply, and hook it up to your compressed air system, and you’re ready to go.
  • It’s efficient and quiet.  The high velocity jet entrains an enormous amount of air from the surrounding environment, where it’s ionized and ready to eliminate static charge quickly and effectively.
  • Instant static dissipation, at your fingertips (literally) – squeeze the trigger to blow ionized air, anywhere you want (well, within the reach of the 10 foot cable, anyway.)
Model 8493 Gen4 Ion Air Gun Kit comes with everything you need, right out of the box. Just add compressed air.

Again, the Gen4 Ion Air Gun is just one of our Static Eliminator products.  How do you know if it’s the right one?  The selection of many EXAIR Intelligent Compressed Air Products comes down to the size & shape of the air flow that will solve the application.  Static Eliminators are no different.

  • If you need to treat a large surface, you might be looking for a Gen4 Super Ion Air Knife.  They come in lengths from 3 inches to 9 feet long, and blow a laminar, even curtain of ionized air that’s extremely effective and fast at static elimination, even at very low supply pressures.
  • Gen4 Super Ion Air Wipes blow a 360° ionized airstream for pipes, cables, extruded shapes, etc.
  • Gen4 Ion Air Cannons and Gen4 Ion Air Jets are made to mount in place, and blow a focused, conical flow of ionized air.

If you’ve got large areas, multiple surfaces, or complex geometries to contend with, one (or an array) of these products might be the solution.  For a simple, straightforward, hand held static elimination solution, though, it just doesn’t get any easier than the EXAIR Gen4 Ion Air Gun.  Call me to find out how you can get one today.

***Order any qualifying EXAIR Static Eliminator by February 28, 2019, and we will include a FREE AC Sensor.  Click here for details.***

Russ Bowman
Application Engineer
EXAIR Corporation
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Video Tutorial on Cleaning the Gen4 Static Eliminator

It has been over two years since EXAIR first brought our Gen4 Static Eliminators to market with improved performance, materials and durability.  The new design features continue to provide our customers with reliable, rugged and problem solving static eliminators.

More recently our Gen4 product line was completed by integrating these same beneficial features in the Gen4 Ionizing Bars, Gen4 Super Ion Air Knives, and Gen4 Standard Ion Air Knives.

There are two common ways that a Static Eliminator will start to underperform; contamination buildup and point degradation.  To create ions from a metal point, a high voltage is needed.  With 5,000 volts forcing its way into a confined area, the energy behind making an ion creates a corona field.  Any contamination near or around that point will produce a small amount of charred material.  The more contamination in the surrounding area, the faster the buildup will occur. Once a sharp point is coated, the ion production begins to decrease.

The other issue is with metal point degradation.  With the cycle of heating and cooling, the material will start to lose the sharpness of the point over time.  Like a wick used in a candle, you lose a little bit each time.  For both methods above, once the point sharpness is reduced, the dissipation time to remove static starts to increase.

For any “forensics” analysis with the Static Eliminators, you should have a model 7905 Static Meter.  Besides viewing the ion points, the Static Meter can help determine the severity of the function of the ion points.  If cleaning is required, you can use a soft-bristled brush to remove any charred contamination from the point and the base area.  Make sure that the power is turned off before cleaning.  For resistor-based Static Eliminators, the metal ion pins are replaceable.  This is model 901188.  This added feature makes a cost-effective way to keeping the points sharp, and the Static Eliminators like new.  The video below shows how to clean and replace the ion points.

Contact any of our Application Engineers if you have any additional questions about cleaning, about a new application or about potential solutions to static related problems.

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

Basics of Static Electricity

Here in the Northern Hemisphere, we are in the middle of winter and that means extremely dry air, and frequent shocks when reaching for a door knob after walking across a carpeted surface.  While a shock is mildly uncomfortable and can be annoying to us, the presence of static electricity in an industrial manufacturing process can be much more problematic.

Problems that static cause range from operator discomfort to increased downtime to quality issues.  Dust can cling to product, product can cling to itself, rollers, frames, or conveyors. Materials may tear, jam, curl and sheet fed items can stick and mis-feed. Hazardous sparks and shocks can occur, possibly damaging sensitive electronics.

EXAIR has put together a useful tool, the Basics of Static Electricity white paper with Interactive Regions to help a person learn more about static.

Basics of Static Electricity

 

Topics covered include Electron Theory, Causes of Static Electricity, Triboelectric Series chart, and Types of Static Generation.  Also, the white paper covers the areas of How to Control Static Charge Buildup, Determining the Source of the Static Buildup, Eliminating or Minimizing the Source Causing the Buildup, and Treating Static Buildup.

The Treating Static Buildup is a comprehensive review of the EXAIR Static Elimination products and how each technology is best applied to different processes and applications.

To receive your copy of the Basics of Static Electricity white paper, click the photo above or the link here.

If you would like to talk about static electricity or any of the EXAIR Intelligent Compressed Air® Products, 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 Makes Things Easier Than An EXAIR Static Eliminator? Another EXAIR Static Eliminator!

A contract manufacturer, servicing the medical and biotechnology markets, is a long time user of our Ion Air Guns. They’ve had great success with them in keeping their products free from static & dust for years. These are mainly small, hand-held parts, so, when they need to get them clean and static-free during assembly and packaging, EXAIR’s Ion Air Gun is ideal, because it, too, is small and hand-held.

A new process, though, involves the operator needing both hands for assembly. This would mean picking up the Ion Air Gun, blowing off the part, putting it down, and then using both hands to complete the operation. They thought there had to be a better way. And they were right!

The Model 8910 Instant Static Elimination Station offers hands-free control of ionized air flow – a foot pedal turns an Ion Air Jet (whose performance is identical to the Ion Air Gun) on and off with…well, the press of a foot. The Magnetic Base and Stay Set Hose make it easy to install, and even easier to position.

Hand held convenience of the Ion Air Gun (easy) or no-hands convenience of the Ion Air Jet Station (easier.) Your call.
Hand held convenience of the Ion Air Gun (easy) or no-hands convenience of the Ion Air Jet Station (easier.) Your call.

For an even more automated approach, they are considering an EFC Electronic Flow Control. They’re ready to go, right out of the box…the photoelectric sensor will open and close a solenoid valve (installed in the compressed air supply line) based on the setting of the programmable timer unit. With a simple wave of the part in front of the sensor, the operator could activate a preset blow of a few seconds, which would be easy to determine, even easier to set, and…easiest of all…reliably repeat all day long. They’re going to try out the foot pedal first, and that’s just fine by me.  Perhaps there’s such as thing as “too easy,” but man, I hope not.

Even if you’re already using EXAIR products to make things easy, you can call me to see how much easier it might get.

Russ Bowman
Application Engineer
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Speaking of easy...get a FREE AC Sensor with a Static Eliminator order. Promotion ends 1/31/2017!
Speaking of easy…get a FREE AC Sensor with a Static Eliminator order. Promotion ends 1/31/2017!

Static Electricity – What is it?

Now that the air is cooling and the humidity is dropping, you may often experience the phenomena of static electricity, and the resultant shock when touching something metal. As a child, you may have learned about static electricity by rubbing a balloon on your head and then seeing it stick to the wall. What is the science behind static electricity?

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All materials are made up of atoms, which have a positively charged core called the nucleus surrounded by a cloud of negatively charged electrons.  Each material is different, and in some types of materials the positive nucleus has a very strong pull on the electrons while in other materials the pull is very weak.  If we were to put a strong  pull material in contact with a weaker pull material, atoms from the weak pull material will migrate, and when the materials are separated, additional electrons will remain with the strong pull material.  Due to the overall increase in electron quantity, the material becomes negatively charged and the other material becomes positively charged. If the materials are rubbed together, the opportunities for the electron migration increases, and thus more electrons are exchanged.

Electrons build up more easily in dry conditions. When the air has humidity, static build up is less common because a very thin layer of water molecules coat most surfaces, which allows the electrons to move more freely and make most materials conductive and static free.

In some cases, static electricity can be a good thing – laser printers and photocopiers use static electricity to transfer ink from the drum to the paper.  Also, some power plants and chemical factories use static electricity  to remove pollutants in a process that takes place within the smokestack.

But generally when EXAIR gets involved, it is because the static electricity is causing an unwanted build up of static charge that affects a manufacturing process. The results of a static charge imbalance can result in a shock to an operator, materials sticking together, poor print quality, sensor or counter malfunctions, bad surface finish, or any number of other problems.

EXAIR offers systems for total static control, such as the Super Ion Air Knife and Ionizing Bars for wide applications such as paper, film and plastic webs, the Super Ion Air Wipe for narrow, continuously moving materials such as wire, tube, or extrusions.  Also offered are the handheld Ion Air Gun for use on three dimensional parts prior to assembly, packaging painting or finishing. Other options include the Ion Air Cannon for limited space or remote mounting applications, Ion Air Jet for tight spaces and concentrated airflow, and the Ionizing Point to provide close distance and accurate static removal.

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Super Ion Air Wipe

To discuss your static elimination concerns , feel free to contact EXAIR and one our  Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Spark Photo Credit – Eric Skiff – via Creative Commons License