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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Video Blog: EXAIR Swivel Fittings

A brief video showcasing the full EXAIR Swivel fittings offering. Each of the 9 Swivel Fitting models offers a 25° from center line adjustment for a total of 50° full range of adjustment. The Swivel fittings are an ideal accessory for a variety of EXAIR products.  For more product details see our product page.  For any questions or fitment suggestions contact an Application Engineer.

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

Offshore Pipe Welding Cooled with Series of EXAIR Super Air Nozzles

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EXAIR model 1122 Flat Super Air Nozzles used to provide cooling blow off.

One of the services we provide to our customers, is assistance in selection of the most suitable product solution for their application.  For most applications we have solutions readily available from stock, though that wasn’t the case in the solution shown above.

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This unique blow off solution cools welds on 450mm (18″) pipes.

This configuration of model 1122 Flat Super Air Nozzles is used to cool pipe welds in an application located off the coast of France.  Pipes with an OD of 450mm (~18”) are welded together, and in order for the welds to be of the highest quality, they must be cooled.  To cool the welds, this customer needed to blow ambient temperature air over the pipes.

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Closeup of nozzles used in this application

Initially, we explored a Super Air Wipe solution.  A Super Air Wipe can provide a full 360° blow off for this pipe, but there was an aspect of the application which led to a better solution through nozzles; an irregularity in position of the pipe.

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Another view of the 1122 Flat Super Air Nozzles

The diameter of the pipes in this application is relatively constant, but there is some fluctuation in position as the pipe is moved.  If using a Super Air Wipe, this could mean contact with a precision machined surface, resulting in a change to the performance of the unit.  But, what if we could find a way to allow the blow off solution to have some “flex”.

swivels

Flat Super Air Nozzles with swivels provide the unique solution needed for this application.

“Flex” in this solution is provided through the use of EXAIR model 9053 swivel fittings, shown above with red circles, each used to mount an 1122 Flat Super Air Nozzle (16 of each).  These allow for proper placement of the nozzles, and also for movement if anything should ever contact the blow off solution.

An additional benefit of the EXAIR 1122 nozzles used in this application, is the ability to exchange shims inside the nozzle to increase or decrease the amount of force delivered from the nozzle.

Understanding the critical requirements of the customer led to this semi-custom solution using EXAIR Super Air Nozzles.  If you‘d like to explore an EXAIR blow off solution for your application, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

EXAIR Atomizing Spray Nozzles Make It Nice & Foggy In Greenhouses

Fog. Nobody likes driving in it. It’s downright perilous to sailing vessels on the open water, but especially those near the shore, or other watercraft. Flights get delayed or cancelled, stranding travelers in airport terminals far from home, and keeping many from pressing matters that necessitated the speed of an airline flight in the first place.  Oh, and it’s ALWAYS where the bad guy is hiding in the movies.  You can tell by the ominous low-string music that starts playing right before things get real nefarious.

You know who LIKES fog, though?  Greenhouse operators.  Their plants get plenty of water to sustain their growth from the well-irrigated soil, but the leaves & petals can wither and get discolored if the humidity isn’t kept at a high level.

The same is true for the parts of a greenhouse that folks don’t see when they’re selecting the annuals to plant on the next nice spring weekend (which we should be coming up on quite soon here!) – like the seed germination chambers.  I had the pleasure of helping a greenhouse operator recently, who needed to replace some old, and malfunctioning, nozzles in one of their germination chambers.  They were interested in the extremely fine mist that our Atomizing Spray Nozzles produce.  After some experimentation with a couple of different flow rates & patterns, they determined that the Model AW1020SS (Wide Angle Round Pattern, Internal Mix) Atomizing Spray Nozzles provided optimal results.

The fine, atomized mist (left) produced by the EXAIR AW1020SS (right) optimizes the seed germination in this chamber.

The fine, atomized mist (left) produced by the EXAIR AW1020SS (right) optimizes the seed germination in this chamber.

As the fogging systems in their other chambers start to fail, they’ve been replacing them with the AW1020SS’.  We shipped them two earlier this week.

With (90) distinct models to choose from, we’ve got the solution to your liquid spraying application.

EXAIR Atomizing Spray Nozzles offer an incredibly wide range of flow rates, patterns, and adjustability to suit most any application that requires a fine liquid mist.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
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Taming The Dust Cloud With EXAIR Atomizing Spray Nozzles

Have you ever dropped one of your nice dinner plates on a tiled kitchen floor? And noticed how they seem to go in slow motion as they hurtle to their doom? I never cease to be impressed at how far some of the smaller pieces can go. I recently had to replace our oven, and I found broken dishware shards (and an impressive amount of trash scraps, pet toys, and ‘dust bunnies’) all the way against the back wall.

Curiously, as small as the pieces can be when a dinner plate meets its end, it started its life in even smaller pieces…as a fine ceramic powder, pressed into a mold and heated to a temperature that is WAY hotter than when the server at your favorite restaurant warns you that plate “might be hot.”

I’m writing about this because recently, I had the pleasure of assisting a maker of ceramic dishware with a messy little problem…this fine ceramic powder is moved from where it’s produced, to the various mold stations (dinner plates, salad plates, saucers, etc.) on a vibratory belt conveyor. The vibration keeps the powder loose and homogenous, both of which are extremely important to the molding & firing process. It also causes a cloud of dust to rise along the entire length of travel, and they wanted to minimize this. Their chemists had told the engineer who called me that they could live with a small amount of moisture, as long as it wasn’t enough to make the powder clump up – this would evaporate out at a point closer to the molds anyway.

This was an ideal application for the EXAIR Atomizing Spray Nozzles…they produce a fine mist of liquid that is precisely controllable…one Model AW1010SS Internal Mix, Wide Angle Round Pattern Nozzle was installed near the beginning of the line, and once they find out how long it takes the dust-suppression supplied by the misted water to evaporate away, they will install more nozzles accordingly.

EXAIR Atomizing Spray Nozzles are a perfect solution for dust suppression.

EXAIR Atomizing Spray Nozzles are a perfect solution for dust suppression.

EXAIR Atomizing Spray Nozzles are ideal for situations where you need a fine liquid mist and fine adjustment of the flow & pattern. With ninety models to choose from, we’ve got the one you’re looking for. Call me if you want to find out more.

Russ Bowman
Application Engineer
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Bench Testing with Blowoff Kits

Last week, a customer connected with us online via the chat option.  He explained that he was working on a project to remove dust from parts on a table conveyor, situated in a 3 x 5 array. He had purchased the EXAIR Blowoff Kits model 1909SS and model 1910 and had been able to bench test and develop a blowoff system that was successful.  He was ready to scale the up design and procure a set of nozzles and swivels that would work in the automated process.

1909SS Blowoff Kit

Model 1909SS – Stainless Steel Blowoff Kit

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Model 1910 – Instant Blowoff Station

 

The Blowoff Kits such as the Model 1909SS offer an easy way to explore the various nozzle types that EXAIR offers and to test the performance of each for Force, Flow and Sound Levels in your process or test environment.  Each nozzle will have particular traits, and identifying the one that most perfectly matches all your criteria can be done.

The Model 1909SS Blowoff Kit contains (7) different nozzles, all with stainless steel construction.  Included are (4) sizes of the Super Air Nozzle (10, 14, 35 and 60 SCFM capacities), the Micro Air Nozzle, the Adjustable Air Nozzle, and lastly, the 2″ Flat Super Air Nozzle.  A similar Blowoff Kit, model 1909, is available with materials of construction of zinc aluminum alloy, aluminum, and brass.

We have put together a detailed review of blowoff applications, available in the Third Edition of the Air Nozzles Blowoff Guide.  Inside, you can find the technical specifications of all of the Nozzles, Blowoff Kits, Flexible Stay Set Hoses, and Safety Air Guns, that might be of interest to you and your application.

blowoff guide

To Request a copy of the EXAIR Blowoff Guide click here

To discuss your application and how the EXAIR Nozzle and Jets can benefit your process, 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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Twitter: @EXAIR_BB

 

Can Counting Carbs Help in Your Compressed Air System?

Breakfast Cereal

Breakfast Cereal

Have you ever counted the amount of carbs that you eat?  People typically do this to lose weight, to become healthier, or for medical reasons like diabetes.  Personally, I like to eat cereal in the morning.  I will pull a box of cereal down from the cupboard and look at the Total Carbs field.  One morning, I looked at a box of gluten-free rice flakes and compared it to a peanut butter nugget cereal.  I noticed that the carbs were very similar.  The rice cereal had 23 grams of total carbs while the peanut butter nuggets had only 22 grams of total carbs.  Then I looked at the serving size.  The rice cereal had a serving size of 1 cup while the nuggets only had a serving size of ¾ cups.  So, in comparison, for one cup of nugget cereal, the total amount of carbs was 27.5 grams.  Initially, I thought that they were similar, but the peanut butter nugget was actually 20% higher in carbs.  This same “misdirection” occurs in your compressed air system.

Here is what I mean. Some manufacturers like to use a lower pressure to rate their products.  This lower pressure makes it seem like their products will use less compressed air in your system.  But, like with the serving sizes, it can be deceiving.  It is not a lie that they are telling, but it is a bit of misconception.  To do an actual comparisons, we have to compare the flow rates at the same pressure (like comparing the carbohydrates at the same serving size).  For example, MfgA likes to rate their nozzles at a pressure of 72.5 PSIG.  EXAIR rates their nozzles at 80 PSIG as this is the most common pressure for point-of-use equipment.  You can see where I am going with this.

To compare nozzles of the same size, MfgA nozzle has a flow rate of 34 SCFM at 72.5 PSIG, and EXAIR model 1104 Super Air Nozzle has a rating of 35 SCFM at 80 psig. From an initial observation, it looks like MfgA has a lower flow rating.  To do the correct comparison, we have to adjust the flow rate to the same pressure.  This is done by multiplying the flow of MfgA nozzle by the ratio of absolute pressures.  (Absolute pressure is gage pressure plus 14.7 PSI).  The ratio of absolute pressures is:  (80PSIG + 14.7) / (72.5PSIG + 14.7) = 1.09.  Therefore; the flow rate at 80 PSIG for MfgA nozzle is now 34 SCFM * 1.09 = 37 SCFM.  Now we can compare the flow rates for each compressed air nozzle.  Like adjusting the serving size to 1 cup of cereal, the MfgA will use 9% more compressed air in your system than the EXAIR model 1104 Super Air Nozzle.  This may not seem like much, but over time it will add up.  And, there is no need to waste additional compressed air.

Family of Nozzles

Family of Nozzles

The EXAIR Super Air Nozzles are designed to entrain more ambient air than compressed air needed. This will save you on your pneumatic system, which in turn will save you money.  The other design features gives the EXAIR Super Air Nozzle more force, less noise, and still meet the OSHA compliance.

If you want to run a healthier compressed air system, it is important to evaluate the amount of compressed air that you are using. To do this correctly, you always want to compare the information at the same pressure.  By using the EXAIR Super Air Nozzles in your compressed air system, you will only have to worry about your own weight, not your pneumatic system.

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

 

Picture: Breakfast Cereal by Mike Mozart Creative Commons Attribution 2.0 Generic License

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