Stories From The Field: Automotive Plant Tour

Throughout my years I have been in many manufacturing facilities. Oddly enough, I have seen nearly every part of a passenger car manufactured and then fully assembled. The amount of compressed air applications in automotive supplier and manufacturing facilities are tremendous. Here are some stories from just a few we have encountered over the years, and all of them can be found in our Application Database.

Air Wipe – How it works
  1. A component manufacturer, specifically a steering and transmission component manufacturer was having issues with machined parts coming out of a CNC machine with too much oil based cutting fluid on them and not passing inspection process because the oil would throw off the automated measuring system. The part was a splined shaft that the high surface tension oil stayed in the splines. The part was removed from the machine via robotic loader and set onto a fixture. The path to the fixture was outfitted with a Super Air Wipe so the robotic loader could move the part into and out of the air wipes’s airflow and remove the oil. The converging airflow of the Super Air Wipe was ideal to keep the peaks and valleys of the shaft clean of oil and they were able to direct oil back into the cutting machine so no separate collection system was needed.
Robotic Welder fitted with EXAIR Super Air Wipe

2. A seat bracket manufacturer had issues protecting the lenses on their vision systems from welding spatter. They were again able to reduce the replacement / repair downtime by installing a 9″ Super Air Wipe in front of the robotic mounted lens and keep the spatter / fumes from ever making it to the lens, resulting in expanded run times between repair / downtime.

Cooling with Air Amplifiers

3. A forging company manufacturing the pistons was having issues reducing the temperature of the pistons as they were assembled to the connecting rods. The solution for them was to install a series of Super Air Amplifiers over the fixtured, indexing line and at each dwell station a Super Air Amplifier would activate and cool down the assembly by moving large volumes of ambient air mixed with small amounts of compressed air onto the surfaces.

4. An automotive manufacturer had issues with stamping shavings and welding debris staying on the surface of parts and fixtures resulting in rework and defective parts. Implementing a series of Super Air Nozzles, and Super Air Knives resulted in debris removal that saved tooling rework as well as production reject parts.

5. Another automotive / recreational vehicle manufacturer needed help with their torture test machine for suspension components. They were utilizing fans to try and keep shock sensors cool and replicate air movement. electric fans were not able to provide a focused airflow and so enter the Super Air Amplifiers. These have also been utilized on engine torture test machines.

1 – Chevrolet Corvette C7 2014 – LT1 Engine Testing on Dyno

These are just a select few of the actual applications that I have actually help with over the course of the years. As a whole, we have helped endless number of automotive industry applications. It doesn’t matter if you are in the automotive industry or just a garage tinkerer, contact and Application Engineer and let us help you with your point of use compressed air application today.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

1 – Autoblog_gr; Chevrolet Corvette C7 2014 – LT1 Engine Testing on Dyno – retrieved from https://www.youtube.com/watch?v=N3h8imnOPwU on 8/31/2022

Application Database : Success Stories in Foundries

EXAIR products are used in countless applications across all facets of industry, we have been working to compile some in a easy to read Application Database on EXAIR.COM!

Today I wanted to cover a few application successes from within Foundries.

The first example is from a company who manufactures flux for aluminum processing. They were experiencing conveyor belt jam ups because not all the material would fall off at the tail end of the belt. What adhered to the belt would be carried over on the return, fell off due to gravity and vibration, and was causing build up underneath and jamming the belt. The Model 110036 36″ (914mm) Super Air Knife was installed on the end of the conveyor blowing off any tramp material as the belt came around the head pulley. This consolidated the debris to one area where they could easily reach it for removal. This all but eliminated maintenance and downtime.

Super Air Knife installed

A manufacturer of aluminum rods was having problems with removing drawing die lubricant from aluminum bar being cut to length. The lubricant was causing the bar to slip in the grippers, causing the bars to be cut short. Passing the bar through a Model 2402 2″ (51mm) Super Air Wipe effectively removed the lubricant, and eliminated grip slippage.

Super Air Wipe

The last customer operates an aluminum foundry. A small actuating cylinder’s seals were failing frequently, due to the heat from a nearby furnace. Using a Model 3230 Medium Vortex Tube, they are able to direct a flow of cold air onto the cylinder, keeping the elastomer seals cool, which greatly extends their life.

Cooling or Heating with the Vortex Tube

If you have questions about any of the quiet 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.

Jordan Shouse
Application Engineer
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Twitter: @EXAIR_JS

Check Out EXAIR’s Knowledge Base for All Your Compressed Air Needs

At EXAIR, we want to ensure our customers have access to as much technical data and information as possible. This helps to assist in identifying solutions to common industrial problems and provide you with the resources necessary to make an informed purchase. A big part of that effort is displayed here on the EXAIR Blog. But, did you know that our website is home to a wealth of information ranging from Case Studies, Videos, Webinars, Installation Guides, Catalog Sections, CAD Models and much, much more?

Once you’ve registered for an account on the website, you’re able to access all of the content housed in our Knowledge Base, including 3D models and CAD drawings, case studies, application examples, webinars, and .pdf file downloads of installation and maintenance guides or catalog sections. Have a question on a particular product? Check out the FAQ section, created by our Application Engineers, the FAQ section contains a variety of commonly asked questions from customers.

Misplaced your installation sheet? No problem! All installation and maintenance guides, in addition to product catalog sections, can be found in .pdf format for download under “PDF Library”.

With 15 different product lines, EXAIR has products capable of addressing a wide range of industrial process issues. Not sure where in your facility you may have an opportunity to improve? EXAIR’s Application Search Library allows you to narrow down your search. Categorized both by specific process or by industry, we’ve highlighted a variety of different specific applications that our products can serve.

EXAIR hosts a yearly Free Webinar covering a variety of topics related to industry and compressed air. After the webinar has been sent out to all registrants, we include a recorded video of the webinar as well.

It doesn’t just stop there. The Knowledge Base also contains calculators and general compressed air related data in addition to PowerPoint presentations for each product line. Click here to register for the website and begin accessing all of this valuable content!

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