Adjustable Air Amplifiers Aren’t Just About Adjustability

Adjustability is a key feature for a great many devices:

  • An adjustable wrench – or as I like to call it, the trusty “all 16ths” – is my go-to for work around the house involving anything with a hex…fittings under the sink when I’m cleaning out a drain, nuts & bolts on furniture or household items needing some tightening (or loosening,) etc.  I don’t get out my combination-end wrenches for much except automobile maintenance.
  • Speaking of sinks, my kitchen faucet lets me adjust water flow (and temperature) which is important because I use different flow rates (and temperatures) if I’m getting a tablespoon of water, or if I’m rinsing my hands, or if I’m filling the sink to do dishes.
  • Speaking of tablespoons, I’ve even got an adjustable measuring spoon that lets me get a full tablespoon, a half a teaspoon, or anywhere in between, by moving a lever block back & forth in the spoon head.

Adjustability is a key feature for several EXAIR Intelligent Compressed Air Products too…like our Adjustable Air Amplifiers.  The ‘adjustable’ part has to do with setting the air flow:

Just loosen the locking ring, and you can thread the plug out of, or in to, the body to increase, or decrease the flow and force of the developed flow.  There’s a hole in the plug (opposite the “EXAIR.com” stamp) so you can use a spanner wrench (another adjustable tool!) to thread the plug in or out.

You can get an amazing range of flow from a little twist*:

These are the performance values for a Model 6042 2″ Aluminum Adjustable Air Amplifier with a compressed air supply pressure of 80psig. Regulating the pressure can give you even lower…or higher…flows.                                              *0.002″ to 0.010″ is about 1/4 turn of the plug.

A gap of about 0.010″ is about the max for 80psig supply pressure.  Above that, the air flow overwhelms the Coanda profile, creating a turbulent ‘storm’ in the throat, hampering the efficiency and effectiveness.  The proper “adjustment” for that is to select the next larger Air Amplifier!

While the range of air flow is certainly impressive, their versatility is another major factor in their selection.  I reviewed our Application Database (registration required) for real-life details on Adjustable Air Amplifiers “in the field” and found a litany of other benefits that made them better suited to particular installations than a Super Air Amplifier:

  • A customer who builds automated equipment incorporates the Model 6031 1-1/4″ SS Adjustable Air Amplifier to blow open bags with a puff of air as they move into position on an automated filling machine. They use it because it’s available in stainless steel construction, and it’s still compact & lightweight.
  • A mattress manufacturer uses Model 6043 3″ Aluminum Adjustable Air Amplifiers to  cool mattress springs.  They’re lightweight, the perfect size to match the springs’ profile, and they can “dial them out” for high heat removal before putting springs on a rubber conveyor.
  • A tier 1 automotive supplier has Model 6234 4″ SS Adjustable Air Amplifier Kits installed on their robotic paint line to blow off moisture from parts to prevent water spotting between the wash cycle and the oven.  They use them because the stainless steel construction holds up to high heat due to the proximity to the ovens.
  • A food plant uses Model 6031 1-1/4″ SS Adjustable Air Amplifiers to improve the drying time of 3,000 liter mixers that must be washed between batches of different products.  The stainless steel construction holds up to the rigors of the frequent washdown in this area.
  • A bedding manufacturer replaced a regenerative blower with a Model 6041 1-1/4″ Aluminum Adjustable Air Amplifier for trim removal on stitched fabric at bedding manufacturer.  The blower was prone to failure from lint & dust; the Air Amplifier, with no moving parts, is not.  It’s also compact, lightweight, and virtually maintenance free.
  • A light bulb manufacturer installed Model 6030 3/4″ SS Adjustable Air Amplifiers on the ends of open pipes that were used to cool mercury lamp wicks.  This reduced noise levels significantly while providing the same cooling rate, and the stainless steel construction holds up to the heat of the operation.

Because of the simplicity of their design, Adjustable Air Amplifiers are also extremely adaptable to custom applications.  We’ve added threads or flanges to the inlets and outlets of several different sizes, to accommodate ease of mounting & installation:

Among other custom Air Amplifiers, we’ve put (left to right) threads on the outlet, ANSI flanges on the inlet/outlet, Sanitary flanges on the inlet/outlet, and Sanitary on the inlet/ANSI on the outlet. How are you installing your Air Amplifier?

Adjustable Air Amplifiers are available in both aluminum and 303SS construction, to meet most any environmental requirements…except extreme high heat.  In those cases, the Model 121021 High Temperature Air Amplifier is rated to 700°F (374°C) – significantly higher than the Aluminum – 275°F (135°C) or the Stainless Steel – 400°F (204°C).  They’re commonly used to circulate hot air inside furnaces, ovens, refractories, etc.

A Model 121021 1-1/4″ High Temp Air Amplifier directs hot air to a rotational mold cavity for uniform wall thickness of the plastic part.

Adjustability.  Versatility.  Durability.  If you’d like to know more about the Adjustable Air Amplifier, or any of EXAIR’s Intelligent Compressed Air Products, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Calculating Static Friction To Eject Parts with Air

2″ Flat Super Air Nozzle

In today’s fast-paced world, companies are always looking for ways to do things faster, cheaper, more efficiently without sacrificing safety.

A cereal company had a high-speed system to check the quality of each box of cereal.  When a box did not meet the quality criteria for visual and/or weight, the box would be rejected.  The rejection system that they used was a quick blast of compressed air to remove the box from the conveyor line into a non-conforming bin.  For their first attempt, they tried to use a ¼” copper tube with a solenoid valve attached to a reservoir tank.  When a “bad” box was detected, the solenoid would be triggered, and compressed air would “shoot” the box off the rubber conveyor belt.  The ¼” copper tube can be an inexpensive, common, and easy-to-use device; but they found that the copper tube was very loud (above OSHA limits for noise exposure) and not very effective.  As a note, this company had a safety committee, and they wanted to keep all blowing devices below 80 dBA in this department.  The ¼” copper tube was around 100 dBA.  So, they contacted EXAIR to get our expertise on this type of application.

The cereal company gave me some additional details of the operation.  The box weighed 26 oz. (740 grams) with a dimension of 7.5″  wide by  11″ tall by  2 3/4″ deep (19 cm X 28 cm X 7 cm respectively).  The issue with the ¼” copper tube was the small target area compared to the area of the box.  With any slight variation in the timing sequence, the force would miss the center of mass of the box.  The box could then spin and remain on the conveyor belt.  This would cause stoppage and disruption in the system.  They asked if EXAIR had a better way to remove the defective boxes.

I recommended a model 1122, 2” Flat Super Air Nozzle.  The reason for this style of nozzle was for a variety of reasons.  First, we needed a larger area to “hit” the box.  This Flat Super Air Nozzle has a width of 2” versus the ¼” copper tube.  This increased the target area by 8 times.  So, any small variations in time, we could still hit the center of mass and remove the box.  The second reason was the force rating.  The model 1122 has a force of 22 oz. (624 grams) at 80 PSIG (5.5 bar).  This is slightly under the 26 oz. (740 grams) weight of the cereal box, but we are just sliding the box and not lifting it.  If we can overcome the static friction, then the box can be easily removed.  With Equation 1, we can calculate the required force.

Equation 1:

Fs = ms * W

Fs – Static Force (grams)

m– Static Friction

W – Weight (grams)

From the “Engineering Toolbox”, the static friction between rubber and cardboard is between 0.5 to 0.8.  If I take the worse case condition, I can calculate the static force between the belt and cereal box using Equation 1:

Fs = 0.8 * 740 grams

Fs = 592 grams

The model 1122 has a force of 22 oz. (624 grams), so plenty enough force to move the box from the rubber conveyor belt.

The third reason for this nozzle is the noise level.  The noise level of the model 1122 is 77 dBA, well below the safety requirement for this company.  Noise levels are very important in industries to protect operators from hearing loss, and the model 1122 was able to easily meet that requirement.  I added an additional reason for recommending the 2” Flat Super Air Nozzle; compressed air savings.  Companies sometimes overlook the cost when using compressed air for blow-off devices.  In this comparison, the ¼” copper tube will use 33 SCFM (934 SLPM) at 80 PSIG (5.5 bar) while the model 1122 will only use 21.8 SCFM (622 SLPM).  This is a 33% reduction in compressed air; saving them money.

At the intro, I mentioned that companies are looking to do things faster, cheaper, more effective without sacrificing safety.  For this company, we were able to increase production rates by removing every cereal box from the conveyor belt.  We also saved them money by reducing the compressed air requirement as well as keeping it safe by reducing noise.

If you have an application that needs products to be moved by air, you can contact an Application Engineer at EXAIR to help you with a solution.

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

General Good Ideas For The Compressor Room

When considering your compressor room all too often the phrase applies “out of sight and out of mind”.  Of course, we all know that is not a good approach to the compressor room or really anything in life.  Unfortunately, many of us take for granted that very system that delivers the power to keep our machines, equipment and tools operating.

Air Compressor
Compressor Room Located Outdoors

So, what can we do keep the ‘lungs” of our plants performing reliably and efficiently?  Since this Blog is about “General Good Ideas For The Compressor Room”, I have some points below for your consideration.

  • Ideally the compressor room should be centrally located to minimize the length of the pipes and allows for easier noise control. With long piping runs leaks become more likely and frictional losses are increased.
  • The compressor room should be sized to allow for easy maintenance and future expansion.
  • For efficient operation air compressors need clean intake air. Intake air that is dusty, dirty or contains gaseous contamination will reduce the efficiency and possibly the longevity of your equipment.
  • The compressor room needs adequate ventilation since air compressors generate significant heat. If excessive heat is allowed to build up it reduces the efficiency of the air compressor raising utility costs, causes compressor lubricant to break down prematurely that could possibly result in increased maintenance and compressor failure.
  • What is the velocity of the air through the main headers? If the speed is above 1200 FPM many dryers have reduced efficiency and speeds greater than this can also carry moisture past the drainage drop legs.
  • Excess friction caused by too small of a diameter piping creates pressure loss, which reduces efficiency and if the compressor is ran above its pressure rating to overcome the frictional losses increases energy consumption, maintenance costs and down time.

Now that your compressor room is shipshape in Bristol fashion, you might think that all is well.  While that may be true, chances are there are other significant additional savings to be had.  EXAIR specializes in point of use compressed air products that are highly efficient and quiet!  If you have any blow-offs that are open tube or howl as loud as the ghost of Christmas yet to come, check out EXAIR’s Super Air Nozzles.  They are highly efficient and quiet, in fact they meet OSHA Standard 29 CFR – 1941.95 for maximum allowable noise and OSHA Standard 29 CFR 1910.242 (b) for higher than 30 PSIG blow-off pressure.  All of EXAIR’s compressed air products are engineered to minimize compressed air consumption and take advantage of the Coanda effect.  Simply stated EXAIR’s highly engineered, intelligent designs entrain (combine) ambient air with the compressed air supply which saves you money!

nozzle_anim_twit800x320
EXAIR Super Air Nozzle entrainment

EXAIR also offers the Ultra Sonic Leak Detector.  Simply point the device at a suspected leak which are typically found at unions, pipes, valves and fittings from up to 20’ away.   Plants that are not maintaining their plumbing can waste up to 30% of their compressors output through undetected leaks.

ultrasonic_2
EXAIR Ultra Sonic Leak Detector

EXAIR has a complete optimization product line that the Ultra Sonic Leak Detector is in that includes the Electronic Flow Control, Digital Flowmeter’s and a Digital Sound Level Meter.  All designed to either increase the safety or efficiency of your compressed air usage.

EXAIR has 15 other product lines all designed to increase your process efficiency and save you money by using you compressed air supply efficiently.  Why not visit the EXAIR website or call and request a free catalog?

When you are looking for expert advice on safe, quiet and efficient point of use compressed air products give us a call.   We would enjoy hearing from you!

Steve Harrison
Application Engineer
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Image taken from the Best Practices for Compressed Air Systems Handbook, 2nd Edition

Super Air Nozzles and Stay Set Hoses to Replace Open Tubes

I recently worked with an company that performs energy audits and they were working with a food company to review and propose ways to reduce the energy consumption throughout the plant. One area where we were able to help was on an onion peeling machine, shown below:

Vegetable Peeler Wide
Onion Peeler With Screw Conveyor and Blow off Tubes

The area of machine in question used a screw conveyor and friction source to help loosen the peels and fifteen (15) 1/4″ O.D. open ended tubes, which were noisy and unsafe, to blow the peels completely off and away form the onion. The auditor was able to install an air flow meter on the system and found that the machine was consuming 220 SCFM of compressed air for this operation.

Vegetable Peeler Detail
(15) Total, 1/4″ Tubes Used to Blow Air and Help Remove the Peels

We proposed to replace the tubes with a 6″ Stay Set Hose and the model 1103 Mini Super Air Nozzle.  Each model 1103 Mini Super Air Nozzle will consume just 10 SCFM of 80 PSIG compressed air. Attached to the 6″ Stay Set Hose, the nozzle can be placed exactly where needed and aimed appropriately. A strong blast of air rated at 0.56 lbs (9 ozs.), and ultra quiet at 71 dBA, the Mini Super Air Nozzle delivers the results needed.

1103-e1543953915424.jpg
Model 1103 – Mini Super Air Nozzle

1103 Performance

1103 Pattern

9256
Model 9256 6″ Stay Set Hose

The Stay Set Hose has “memory” and will not creep or bend, simply install the 1/4 NPT fitting into the compressed air supply side, an thread the 1/8 NPT Mini Super Air Nozzle into the other end and position as needed!

Fifteen (15) of the Mini Super Air Nozzles will pass 150 SCFM of compressed air compared to the current usage of 220 SCFM, resulting in a 70 SCFM drop, or a 31.8 % reduction.  At a typical cost of $0.25 per 1000 Cubic Feet of Compressed Air, the nozzles would save $1.05 per hour of operation. Rate of Return yields a full pay-off in just 43 days of operation (24 hours per day operation)!

If you are looking for ways to save on compressed air usage in your facility that is safe to operate and quiet to use, we will have a solution for you.

If you have questions about any of the 16 different EXAIR 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.

Brian Bergmann
Application Engineer
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Henri Coanda: June 7, 1886 – November 25, 1972

Henri Coanda was a Romanian aeronautical engineer best known for his work on the fluid dynamic principle with his namesake, the Coanda effect. Before this, Henri patented what he labeled as a jet engine.

Jet Engine 1
Jet Engine

Henri’s patent (French patent No. 416,54, dated October 22, 1910) gives more information into how he envisioned the motor working. When air entered the front, it passed through different cavities that caused the air stream to first contract and then expand. In Henri’s opinion this contraction and expansion converted the air’s kinetic energy into potential energy.  The air ultimately was channeled to a diffuser where it was discharged.

Henri stated that the efficiency of this engine could be improved by heating the air in the cavities, Henri’s logic was that this would increase the pressure of the air passing through.

What is obviously lacking in the patent (including identical ones taken out in England and the United States) is any mention of injecting fuel, which in a true jet engine would combust with the incoming air. Judging only by Henri’s patent, it was little more than a large ducted fan and it could not have flown.  Throughout Henri’s career he changed his story many times on whether this plane actually flew or not.

Not to cast too much shade on Henri’s accomplishments he did discover the Coanda effect.  The Coanda effect states that a fluid will adhere to the surface of a curved shape that it is flowing over.  One might think that a stream of fluid would continue in a straight line as it flows over a surface, however the opposite is true.  A moving stream of fluid will follow the curvature of the surface it is flowing over and not continue in a straight line. This effect is what causes an airplane wing to produce lift, and enhance lift when the ailerons are extended while at lower air speeds such as occurs during takeoff and landing.

plane-1043635_1920
Ailerons positioned for cruising speed

EXAIR uses the Coanda effect to offer you highly engineered, intelligent and very efficient compressed air products.  Our designs take a small amount of compressed air and actually entrain the surrounding ambient air with the high velocity exiting compressed air stream to amplify the volume of air hitting a surface.

nozzle_anim_twit800x320
Surrounding Air Captured (Entrained) In Exiting Compressed Air Stream

How Air Knife Works
1). Compressed Air Inlet, 2). Compressed Air Exiting EXAIR Super Air Knife 3). Surrounding Air Being Entrained With Exiting Compressed Air Stream

Super Air Amplifier
EXAIR Super Air Amplifier Entraiment

When you are looking for expert advice on safe, quiet and efficient point of use compressed air products give us a call.   We would enjoy hearing from you.

Steve Harrison
Application Engineer
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Back Blow Nozzles Clean Inside Metal Tubes

A manufacturing plant EXAIR worked with made cast aluminum tubes for the automotive industry.  After the parts were cast, a machining operation would clean the ends.  This left coolant and metal shavings inside the tube.  Before going to assembly, they had to clean the part.  They created a two-tube fixture (reference picture above) to fit the 25mm tubes in place.

Two home-made nozzles were used to fit inside the tubes to blow compressed air.  The nozzles were attached to the ends of two 17mm pipes which supplied the compressed air.  A cylinder was used to push the nozzles from the top of the aluminum tube to the bottom then back up again.  The liquid emulsion and debris would be pushed downward into a collection drum.  When they started operating their system, the inside of the tubes still had contamination inside.  They wanted to improve their process, so they looked for an expert in nozzle designs, EXAIR.

Back Blow Air Nozzle Family

EXAIR designed and manufactures a nozzle for just this type of operation, the Back Blow Air Nozzles.  We offer three different sizes to fit inside a wide variety of diameters from ¼” (6.3mm) to 16” (406mm).  They are designed to clean tubing, pipes, hoses, and channels.  The 360o rear airflow pattern can “wipe” the entire internal surface from coolant, chips, and debris.  For the application above, I recommended the model 1006SS Back Blow Air Nozzle.  This 316SS robust design would fit inside the tubes above.  The range for this Back Blow Air Nozzle is from 7/8” (22mm) to 4” (102mm) diameters.  The customer did have to modify the function of the equipment by placing the cylinder and the rods under the aluminum tubes.  The reverse airflow would still push the contamination into the collection drum that was placed underneath the tubes.

After installing the model 1006SS onto the rods, the cleaning operation became more efficient.  Not only was the entire internal diameter getting clean, they were able to turn off the compressed air until they reached the top of the tube.  With the model 1006SS, they only needed one pass to clean.  This cut the air consumption in half, saving them much money by using less compressed air.  In addition, they were able to speed up their operation by 20%.  Cleaner tubes, less time, cost savings; they were happy that they contacted EXAIR for our expertise.

Reverse Air Flow

If you need to clean the inside of tubes, hoses, pipes, etc., EXAIR has the perfect nozzle for you, the Back Blow Air Nozzles.  EXAIR can also offer these nozzles on our VariBlast, Soft Grip and Heavy Duty Air Guns for manual operations.  They come with Chip Shields and extensions that can reach as far as 72” (1829mm).  Or like the customer above, automate the system to get a great non-contact cleaning.

If you require any more details, you can contact an Application Engineer at EXAIR.  We will be happy to help.

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

What’s In My Air, And Why Is It Important?

Everyone knows there’s oxygen in our air – if there wasn’t oxygen in the air you’re breathing right now, reading this blog would be the least of your concerns. Most people know that oxygen, in fact, makes up about 20% of the earth’s atmosphere at sea level, and that almost all the rest is nitrogen. There’s an impressive list of other gases in the air we breathe, but what’s more impressive (to me, anyway) is the technology behind the instrumentation needed to measure some of these values:

Reference: CRC Handbook of Chemistry and Physics, edited by David R. Lide, 1997.

We can consider, for practical purposes, that air is made up of five gases: nitrogen, oxygen, argon, carbon dioxide, and water vapor (more on that in a minute.)  The other gases are so low in concentration that there is over 10 times as much carbon dioxide as all the others below it, combined.

About the water vapor: because it’s a variable, this table omits it, water vapor generally makes up 1-3% of atmospheric air, by volume, and can be as high as 5%.  Which means that, even on a ‘dry’ day, it pushes argon out of the #3 slot.

There are numerous reasons why the volumetric concentrations of these gases are important.  If oxygen level drops in the air we’re breathing, human activity is impaired.  Exhaustion without physical exertion will occur at 12-15%.  Your lips turn blue at 10%.  Exposure to oxygen levels of 8% or below are fatal within minutes.

Likewise, too much of other gases can be bad.  Carbon monoxide, for example, is a lethal poison.  It’ll kill you at concentrations as low as 0.04%…about the normal amount of carbon dioxide in the atmosphere.

For the purposes of this blog, and how the makeup of our air is important to the function of EXAIR Intelligent Compressed Air Products, we’re going to stick with the top three: nitrogen, oxygen, and water vapor.

Any of our products are capable of discharging a fluid, but they’re specifically designed for use with compressed air – in basic grade school science terms, they convert the potential energy of air under compression into kinetic energy in such a way as to entrain a large amount of air from the surrounding environment.  This is important to consider for a couple of reasons:

  • Anything that’s in your compressed air supply is going to get on the part you’re blowing off with that Super Air Nozzle, the material you’re conveying with that Line Vac, or the electronics you’re cooling with that Cabinet Cooler System.  That includes water…which can condense from the water vapor at several points along the way from your compressor’s intake, through its filtration and drying systems, to the discharge from the product itself.
  • Sometimes, a user is interested in blowing a purge gas (commonly nitrogen or argon) –  but unless it’s in a isolated environment (like a closed chamber) purged with the same gas, most of the developed flow will simply be room air.

Another consideration of air make up involves EXAIR Gen4 Static Eliminators.  They work on the Corona discharge principle: a high voltage is applied to a sharp point, and any gas in the vicinity of that point is subject to ionization – loss or gain of electrons in their molecules’ outer valences, resulting in a charged particle.  The charge is positive if they lose an electron, and negative if they gain one.  Of the two gases that make up almost all of our air, oxygen has the lowest ionization energy in its outer valence, making it the easier of the two to ionize.  You can certainly supply a Gen4 Static Eliminator with pure nitrogen if you wish, but the static dissipation rate may be hampered to a finite (although probably very small) degree.

At EXAIR Corporation, we want to be the ones you think of when you think of compressed air.  If you’ve got questions about it, give us a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Air photo courtesy of Bruno Creative Commons License