EXAIR Products Are No Strangers To The Assembly Line

Although most folks think of Henry Ford as the inventor of the assembly line, there’s evidence that “division of labor” was practiced in ancient China, where metal products were mass produced by skilled workers performing a specific evolution and then passing it on to another person for the next step. In fact, Oldsmobile’s assembly line actually predates Ford’s by a few years, but a host of innovations by Henry Ford and his team of engineers reduced the assembly time of a Model T from a day and a half, to an hour and a half. Maybe that’s why he gets so much credit for it.

Through the 20th Century, technological advances continued to revolutionize the process. Automation and robotics have allowed a combination of speed & precision that would have impressed even Henry Ford. The guy was a genius, so he would have caught on pretty quick, I’m sure. If you hadn’t guessed, it, yeah; I’m a big fan.

In addition to all the technological marvels on display, our visit to The Henry Ford museum also allowed my brother and me a cool photo-op with our all-time favorite vehicle.

EXAIR products are used for a variety of applications on assembly lines…blow off, static elimination, painting/coating, and even cleanup. I had the pleasure of assisting a user with that last one recently.

Turns out, they make automobile windows, and in the process of handling the glass windows, the metal & plastic frame pieces, the rubber seals, the protective tape, etc., they end up with a LOT of scrap as these parts go down their assembly conveyor. According to this caller, it looked like “New Year’s Eve at the end of every shift” when they stopped to clean up. By installing EXAIR Model 130200 2″ Light Duty Line Vacs at strategic locations, they’re able to pick up almost all of the debris from the whole process.

EXAIR Light Duty Line Vacs come in sizes from 3/4″ to 6″ to accommodate a wide variety of conveyance needs.

If you’d like to find out more about how EXAIR Intelligent Compressed Air Products can make an impact in your facility…safety, noise, efficiency, or otherwise…give us a call.

Russ Bowman
Application Engineer
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Getting A Little More Vacuum and Flow

Last week, a customer called and indicated that he was a long time user of the model 6013 High Velocity Air Jet.

6013

Model 6013 High Velocity Air Jet

The customer was using the Air Jet to remove light trim scrap from a manufacturing process. The Air Jets utilize the Coanda effect (wall attachment of a high velocity fluid) to produce air motion in their surroundings.  A small amount of compressed air to the Air Jet is throttled through an internal ring nozzle at speeds above sonic velocity.  In the above image, this produces a vacuum at the left side, pulling in large volumes of surrounding air. By utilizing this vacuum pull and ducting the right side exhaust, air and scrap stream to a collection area. The customer assembled a small, efficient, and inexpensive scrap removal system.

The reason the customer had called in was there were some recent changes to the manufacturing process and needed a bit more vacuum force and flow to handle larger scrap and longer travel. We explored using a larger shim, but they were already using the largest size (0.015″.) We talked about the other products that EXAIR offers (Air Amplifiers, Line Vacs) that are used for scrap removal and conveyance.  But with any change, there are usually other modifications and approvals that must be dealt with in order to proceed. So we hit upon the Adjustable Air Jet, which is an adjustable version of the model 6013.

6019

Model 6019 Adjustable Air Jet

The model 6019 Adjustable Air Jet utilizes an adjustable air gap in place of the fixed shim thickness.  This allows for greater air flow, which results in greater vacuum and conveyance distances. As is the case for many customers, we gathered some additional data to help this customer make a decision. We set up each of the units and tested them at maximum capabilities, and the model 6019 was shown to deliver upwards of 50% greater flow.  The customer felt certain this level of performance would handle what the changed process would require, and best of all, no modifications to any part of the set-up would be required, simply install the 6019 where the 6013 was currently placed.

The High Velocity Air Jet is also part of the model 1909 Blowoff Kit, and is also used in the model 8193 Ion Air Gun and model 8194 Ion Air Jet, for Static Elimination applications. Of course, each can be purchased as an individual item.

To discuss your application and how an EXAIR Intelligent Compressed Air Product can make your process better, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Removing Chips from a Plastic CNC Router

These CNC routers needed a viable solution to remove and collect plastic chips and debris created during machine operation.

Our distributor in Poland recently emailed me about an application in need of a method to collect plastic chips from the CNC router tables shown above.  These machines are used for precision cutting, but face a problem when the cutting edge of the machine comes into contact with the chips and debris created during normal use.

The end user had considered a blow off device such as a nozzle or Air Knife, but this raised concerns with material collection.  Ideally, the customer wanted to be able to capture the chips and debris for recycling.

So, we looked into a method of removing the chips with a Line Vac, conveying the debris to a stationary drum for collection and recycling.  This type of solution has proven to be effective many times in the past, as shown in the image below. A Line Vac can be mounted at the cutting head to vacuum chips and debris as they are created by the cutting process.

This Line Vac provides vacuum to a drill head to remove debris.

Using the model 6081 Line Vac we can remove the plastic debris from the plotter as it is generated, and convey it to a drum located within the workspace.  And, to facilitate collection of the plastics for recycling, we can use our model 6850 drum cover to separate the conveyed chips from the air used to move the materials.

By providing a dynamic solution for this application, the Line Vac is able to lessen the workload of machine operators, allowing them more time to perform value added tasks rather than cleaning.  And, the solution is easy to install, requires little to no maintenance, and provides instantaneous vacuum only when needed.

If you have a similar application or would like to discuss problems facing your facilities, contact an EXAIR Application Engineer.  We’re available by phone, email, and online chat.

Lee Evans
Application Engineer

LeeEvans@EXAIR.com
@EXAIR_LE

Another Unique Solution in an Aluminum Processing Plant

Fine dust particles needed to be removed from this belt on the underside of a conveyor

A few months back I wrote about the impact of installing Super Air Knives in an aluminum processing plant.  Those Super Air Knives solved a recurring problem with cleaning alumina dust around conveyors and reduced costs for the end user by over $80k.

That same customer has also found a method to remove fine dust from the underside of the conveyor belt in an application area not suitable for an Air Knife.  In this application there was no dust collection system in place to carry away the fines as they are blown off of the belt, so a different type of solution was needed.

Model 150200 Heavy Duty Line Vac provides the vacuum needed to remove the dust fines.

That solution was to install a Heavy Duty Line Vac affixed to a vacuum hood to remove fines from the belt and convey them back to the head chute.  The only problem with this setup was that the 2” Heavy Duty Line Vac produced a bit too much vacuum flow than what was really needed in the application.  So, a pressure regulator was installed to allow for adjustment and fine tuning of the vacuum solution.  The customer was able to adjust the operating conditions for the Line Vac and minimize compressed air use while maximizing the vacuuming effect on the fines stuck to the conveyor.

The Line Vac used in this application quickly and easily solved a chronic problem plaguing this manufacturer.  By installing this vacuum solution they were able to prevent build-up of dust and debris underneath the conveyor which originally required shutting down the line to clean.  This improved process uptime, reduced cleaning costs, and increased throughput in the application.

If you have an application in need of a vacuum solution, consider an EXAIR Line Vac.  And, if you have any questions, contact an EXAIR Application Engineer.  We’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

New! In Stock! Sanitary Flange 316 Stainless Steel Line Vacs

Just released, we are now stocking four different pipe sizes of Sanitary Flange 316 Stainless Steel Line Vacs. We are offering these in the following sizes, 1-1/2″, 2″, 2-1/2″, and 3″ Sanitary Flange.   The performance is the same as our Stainless Steel Line Vacs,  but now it is even easier to install in sanitary flanged piping systems.  No need to get adapters or have specialty shops weld flanges on.

Model 161200-316 - 316 Stainless Steel Sanitary Flange Line Vac

Model 161200-316 – 316 Stainless Steel Sanitary Flange Line Vac

The new Line Vacs are available for purchase on their own or in a kit which includes the Line Vac, a mounting bracket for the Line Vac, pressure regulator and filter separator. The only parts you provide are the clamps, gaskets and compressed air supply.

With a wide range of sizes and materials of construction, we've got your solution. Call us.

With a wide range of sizes and materials of construction, we’ve got your solution. Call us.

These are the latest four additions to our already extensive line of in-line pneumatic conveyors.   If we do not offer a stock Line Vac that will fit your needs, we also offer custom Line Vacs to fit virtually any need you may have, just contact us and we will help you determine what will work!

Custom PVDF Line Vac

Custom PVDF Line Vac

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

Conveying Plastic Bucket Handles With A Line Vac Saves Time

A packaging company was looking to convey the plastic handle grips commonly found on plastic buckets (see below pic for reference). The grips are roughly 3″ long and about a 1/2″ in diameter and they currently have an operator manually load the hopper on their vibratory feeder which is located on the 2nd floor, about 12′ away from the receiving area. The hopper is level controlled and the machine uses 3 grips per minute so as the level dropped,  the operator would have to stop the process, go down and load the parts in a box, then go back up the stairs and dump the box into the hopper. This was a very tedious process, which wasted a lot of time so they reached out to EXAIR for a more effective way to get the job done.

yellow-bucket

The plastic handles are similar to the black handle shown here.

After further discussion, I recommended our 1-1/4″ Line Vac Kit  for the application as this unit has a 1″ inside throat diameter that would easily pass 1/2″ diameter parts and deliver them to the overhead hopper. Since they were only needing to load a few parts at a time, I proposed they have the operator simply feed the parts in to the Line Vac suction line to avoid any potential blockages. Additionally, I suggested they incorporate our Model# 9040 foot valve into the process to simplify the operation and provide additional control so they are only using their compressed air supply when needed to move the parts. The foot pedal will allow the operator to activate the Line Vac each time they feed parts moving in to the hopper. Among the items this kit includes is a pressure regulator which would allow them to adjust the supply pressure to the unit, providing control over the conveyance rate and velocity at which the parts are ejected.

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The Line Vac Air Operated Conveyors are available with smooth or NPT threaded ends in aluminum, 303ss, 316ss or hardened alloy construction to meet the demand of a wide variety of material transfer needs.

 

EXAIR’s Line Vac Air Operated Conveyors are able to convey light materials,  like plastic pellets,  to more abrasive materials like steel shot blasting media. To see how a Line Vac might fit into your process or for help selecting the best EXAIR product for your needs, give me a call, I’d be glad to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

yellow bucket image courtesy of sammydavisdog via Creative Commons license

Creative Uses for the Line Vac Air Operated Conveyors

Last week a customer called in looking for some help in solving a minor issue in the plant. The customer is a specialist in the filament winding business making all types of products from many types of fibers, such as Polyester, Nylon, Nomex®, PTFE and Kevlar®.

At the end of a run, there will be a small amount of thread left on several bobbins.   There is not enough thread to save for a future run, and so the customer has to strip the remaining thread off, to be able to reuse the bobbin.

I remembered that an EXAIR Application Engineer had done some testing on thread, using a Line Vac to pull and unwind a spool. See here for that demonstration.

The customer sent me the below photo, helping us to visualize the application better, and then went even further by shipping a couple of sample bobbins with some thread still remaining.

After running a few tests, it was determined that the smallest Line Vac available , the model 6078 – 3/8″ Aluminum Line Vac, produced the fastest results due to the narrow throat diameter in conjunction with the thin thread.  A brief demonstration of the test can be found below.

Using just 5.6 SCFM at 80 PSIG of compressed air, the Line Vac quickly unwound the bobbin, providing a simple, cost-effective way to automate what had been a tedious manual process.

The Line Vac conveyor are ideal for moving large volumes of material over long distances, using a small amount of compressed air. The material flow rate is easily controlled by use of a pressure regulator.  No moving parts or electricity assures maintenance free operation.  EXAIR offers the Line Vac in sizes from 3/8″ up to 5″ in diameter, in materials including aluminum, Type 303 and Type 316 Stainless Steels, and a Heavy Duty model with hardened alloy construction.

To discuss your application and how a Line Vac or another EXAIR Intelligent Compressed Air Product can help your process, feel free to contact EXAIR and one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Twitter: @EXAIR_BB

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