EXAIR, Manufacturing Locally Equals Quick Customizations

Dryer with corn cob material

A manufacturing company contacted EXAIR about their metal tube processing. They made industrial precision tubes from start to finish. This would include turning, cutting, coating, washing and drying metal tubes to specific diameters and lengths.

For one specific problem area, they manufactured a tube with the dimensions of 1” (25.4mm) in diameter and 6” (152mm) in length. They would run a batch of 750 tubes through a wash cycle and then through a vibrating dryer with a drying material made from corn cobs. At the bottom of the vibrating dryer, the tubes would fall to an open mesh shaker table to transfer the tubes to Quality Control. The idea was to remove the excess cob material from the surface of the tubes before inspection and to recycle the drying material. But the problem was static.

When non-conductive materials slide, hit, peel, and vibrate; electrons from the surface can move from one atom to another; thus, creating static. The type of material and the amount of movement governs the positive and negative charges, and the amount of static forces.

The corn cob material is a non-conductive material, but what about the metal tubes? Since the metal tubes were coated for corrosion and abrasion protection, the surface is now a non-conductive area which will contain static. Since opposite charges attract each other, the cob material would cling to the outside surface of the metal tubes (reference photo below). Being a precision tube manufacturer, they did not want to send “dirty” tubes to their customers or allow the drying material to contaminate their measuring equipment. And, with the required quality control, the measurements had to be exact.

Tubes with cob material

The shaker table was 8 feet (2.4 meters) long and 2 feet (0.6 meter) wide with rigid walls. The top of the shaker table was covered with a canvas to allow for a vacuum system to collect the excess material and dust. About half way down, there was a 2” (51mm) drop to help jolt additional cob material off of the tubes as they landed. But the static forces were too strong to release the material. Thus, the static had to be removed from the surface, so they contacted EXAIR to see if we could find a solution.

They sent photos of their setup which always helps us to diagnose and find solutions. The target place that they suggested would be near the 2” (51mm) drop as the tubes would be suspended for just a moment. My recommendation was to use a Gen4 Super Ion Air Knife to blow ionized air around the tubes as they fell. By blowing air, we can use the non-contact force to remove the static and the cob material at the same time. But we had two issues to overcome. The width was fixed at 2 feet (0.6 meter), and the operation controls were 10 feet (3 meters) away from the mid-section of the shaker table.

Gen4 Super Ion Air Knives

EXAIR stocks many Gen4 Super Ion Air Knives ranging from 3” (76mm) to 108” (2.74meters) in incremental lengths for quick shipments. But our standard 24″ product was not able to fit inside that area nor was the five foot electrical cable long enough to reach the control panel. (As a note, it was important for the operator to be able to manually turn on and off the unit from the control panel.)

EXAIR uses an electromagnetically shielded cable to carry high voltage from our Gen4 Power Supply to our shockless, non-radioactive Gen4 Ionizing Bar. Our  stocked length for our armored cable is 5 feet (1.5 meter). After discussing the amount of movement with the table and the desired distance to the control panel, EXAIR could not use an item off the shelf. But not to worry… Since we are the manufacturer, we have the ability to make a special design for this customer.

Super Ion Air Knife Part Numbering System

I recommended a model 112220-10 special length Gen4 Super Ion Air Knife Kit. (Reference model numbering system above). Specials are non-returnable and non-cancelable, but for this customer, it was exactly what they needed. The Gen4 Super Ion Air Knives are engineered to efficiently blow ionized air to the target and remove static charge and debris.

For this special model, it was made to a specific width where the Super Air Knife was manufactured to a length of 20” (508mm), and the high voltage cable was lengthened to 10 feet (3 meters). The kit includes the Gen4 Power Supply to power the Ionizing Bar, a filter to clean the compressed air, a regulator to control the force, and a shim set to change force rates. This complete kit had everything required to begin operations to remove static and cob material from their precision tubes. The customer was able to mount the special length Gen4 Super Ion Air Knife within the shaker table and mount the power supply near the control panel.

Static can be an issue even with coated metal parts. For the customer above, EXAIR was able to make a special length Gen4 Super Ion Air Knife to work in their system. If you believe that static is causing issues, EXAIR has a great range of Gen4 Static Eliminators to remove that nuisance. You can discuss further with an Application Engineer as EXAIR for help; even if you need a custom product.

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

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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Eliminating Static in Industrial Processes

Ever wonder what causes that annoying shock you get when you go to grab a plastic or metal piece. That is a phenomenon caused by static electricity. This static is an electrical surface charge that is generated and when two surfaces come in contact with each other and generate an electrical charge from friction, separation, or simple contact. If the material in question is not grounded properly the electrical charge will continue to accumulate until it comes in contact with a proper ground or the path of least resistance to discharge the built up static and return to a neutral state.

Static

Static is generated on the atomic level from the exchange of valance electrons on each surface. The energy produced from the friction, separation or contact cause those valance electrons to enter an excited state; when in this excited state they begin to jump back and forth from atom to atom. When this happens, the atoms begin to accumulate either a positive charge if the atom lost electrons or a negative charge if the atom gained electrons. As the charge accumulates on the surface were the friction occurs if a ground source (i.e. piece of metal or a person) comes in close proximity to the charged surface an arc is generated between the two surfaces returning the originally charged surface to a neutral state.

Static can be harmful to both employees and product in an industrial environment. If a static arc is generated in the presence of either flammable, combustible, or explosive liquids or gasses the arc can cause an ignition of the material. Static can also cause the charged object to stick or cling to various surfaces causing clogs in pipes and issues when trying to separate the material one at a time. This phenomenon is called static cling.

Even though static is very easy to generate it can just as easily be dissipated; EXAIR’s line of static eliminating devices use a high voltage emitter point to generate a small zone of ions which consists of both positive and negative charges to dissipate the static build up on the surface. Also, when the various emitter points and ion bars are coupled with our compressed air products, the air carries the ions much farther and can dissipate static up to 20’ away. The best part is that about the line of our line of static eliminators is that they are shockless; this means that if somebody bumps into it, they won’t get shocked.

Gen 4 Super Ion Air Knife Eliminating Static with Ions

For more information on EXAIR’s Static Eliminators and any of EXAIR‘s Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Cody Biehle
Application Engineer
EXAIR Corporation
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Super Ion Air Wipes – Eliminate Static on Wire, Cable, Extrusions

Gen4 Super Ion Air Wipe

As the colder dryer months are upon us, static electricity will be more frequent and will become a real nuisance.  Machines will start jamming, alignments will be difficult, dirt will collect to surfaces, and hazardous sparks can shock personnel.  EXAIR manufactures a line of Gen4 Static Eliminators to remove this nuisance.

EXAIR manufactures eight different product lines in two different styles within our Gen4 Static Eliminators.  In this blog, I will be covering the Super Ion Air Wipe.  This product blows ionized air in a 360-degree pattern.  They are engineered to remove static and debris from the outside of hoses, plastic pipe, extrusions, and coated wires.  With a split design, the Gen4 Super Ion Air Wipe can easily mount around the product without having to re-thread.  EXAIR stocks two different sizes with a 2” (51mm) and 4” (102mm) inside diameter. The Super Ion Air Wipes give a fast static-decay, a shockless and non-radioactive design, variable flow and force, low air consumption and no moving parts.

8462 Super Ion Air Wipe Kit

The Gen4 Super Ion Air Wipe can be purchased as a kit which will include the power supply (required for ionization), a filter separator (to clean contamination from the compressed air), and a pressure regulator (to control the blowing force).  The filter and regulator are properly sized to avoid any air flow restrictions or loss of performance which can occur when using components which are not suited for the application.

Static

Generally speaking, static is generated from non-conductive surfaces being “rubbed”.  This could be from going over rollers on a conveyor, stacking product onto each other, sheet feeding, and even peeling away a backing material.  When non-conductive surfaces, or insulators, are moved or separated, electrons are “stripped” and redistribute on to different areas of the surface.  Static charges are typically measured in kilovolts (kV), or 1,000 volts, and they can be either positive or negative.  The higher the charge, the stronger the static force.  In reference, at 10 kilovolts, a spark can jump one inch (25 mm) from the surface.   EXAIR offers a Digital Static Meter, model 7905, to measure the amount of static voltage on a surface.  It is a great tool for finding problem areas in your process as well as determining the effectiveness of the treatment.

All EXAIR Gen4 Static Eliminators use one of two Power Supplies – your choice of the 2-port Model 7960, or the 4-port Model 7961.

These ionizers are powered by a 5,000V AC power supply.  The alternating current, AC, will create both negative ions and positive ions.  So, no matter the polarity of charge on the surface, the Gen4 Static Eliminators will be able to remove it.  The power supplies come in either a 2 port or 4 port design so you can power multiple Gen4 Static Eliminators with one power supply.  The input power is selectable from either 115VAC or 230VAC in both 50/60 Hz.   Two armored and electromagnetic shielded cables connect the Super Ion Air Wipe to the power supply. This will help to protect the cable from abrasions, cuts and splits which can be common in rugged industrial areas.

Static can be a real nuisance with shocking operators, “sticking” debris, and jamming processes.  If you run into these issues in your application, no matter the shape, EXAIR has a Gen4 Static Eliminator for you.  Even if you have cylindrical objects like tubes, pipes, hoses and extrusions; EXAIR can provide the Gen4 Super Ion Air Wipes in stock.  For more information, you can contact one of our Application Engineers at EXAIR.

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