Tag: problem solving

Next Level Customer Service

Published on by Brian FarnoLeave a comment

I recently spoke with a customer who is a casting / machining manufacturer.  They had an automated cell that was finish machining a feature on a cast aluminum part then placing it on a conveyor belt for an operator to pick up and continue processing.

The parts were placed 3 pieces wide per row and the conveyor would index with every three parts.   The operator would pick three pieces up and transfer them to another station during the machining time.  These parts were carrying residual machining coolant and debris onto the outbound conveyor.

The operator would blow them off with a handheld blow gun and all the coolant and chips would generally end up on the floor in the area causing a slip hazard.  The focus of the project is to eliminate the safety hazards and leave the parts as clean as possible for the inspection and further process.

The metal parts were positioned similar to the parts I placed in the mock up picture below.  The conveyor the customer has is an open mesh conveyor so the process will work better than if it was a solid belt like in the mock up.

The bulk of the concern from the customer was the outside of the part and they stated that anything to blow out the internal is a bonus.  The objective is to get as much coolant off as possible.   For that we recommended they span the conveyor with a Super Air Knife Kit to blow all the parts off at once.  This is mounted closely in the mock up because the customer had space restrictions.

The Super Air Knife Kit with Universal Air Knife Mounting System will firmly mount the knife over the parts and leave adjustment if needed.
The model 1103 Mini Super Air Nozzles with Stay Set Hoses of various lengths easily bend into place and hold their positioning for the side hole on each part.

Then, because the parts are always placed in the same location with the same orientation we can locate the ID hole with a Mini Super Air Nozzle on a Stay Set Hose of varying length to reach each set of parts as they come through.  Once I had the idea and the products in place I delivered the customer  a quote and dimensional CAD file for each part.

Another recommendation was to use a regulator and filter to control just the knife then operate the three nozzles off their own regulator and filter so that the forces between the two can be varied and the performance of the other is not effected.  Accompanying the models were installation sheets for each item as well.   Followed by the pictures of this mock up for their application.

Needless to say the customer was amazed that we would go to such lengths just to give them more assurance than our 30 day guarantee.  They were extremely thankful and are pleased we shipped from stock and met their installation window.

If you are looking for a creative solution, next level customer service, same day product availability, or just a nice human to talk to about compressed air, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Two Birds With One Stone (and A Shim)

Published on by Russ BowmanLeave a comment

Blowing off bottles is such a popular application for the EXAIR Super Air Knife, it’s been featured on the cover of our Catalog…several times…and is the “banner” pictures on the Super Air Knives page on our website:

This always makes me thirsty for orange soda.

I had the pleasure of helping a caller from a bottling plant recently with just such an application.  Thing is, they run a couple of different size bottles, and it’s not a very big facility…they didn’t want to, or have room to, install different lengths of Air Knives, and also didn’t want to waste air flow when they were running the shorter bottles.

9″ Air Knives were required for the taller bottles, but their shorter bottles were a little under 6″ tall.  They had considered buying both 6″ and 9″ Air Knives, but called me to see if there was a less expensive, and possibly, easier way.  (There is!)

EXAIR makes, and stocks, every product in our 208 page catalog right here in this building in Cincinnati, Ohio.  We also make custom parts when the need arises…and custom Air Knife shims were the solution to this customer’s application.

By installing two Model 110009 9″ Aluminum Super Air Knives, one on either side of the conveyor (just like the photo above,) they’re able to blow off the taller bottles.  When they run the shorter bottles, they change out the shims for ones that limit the flow to a 6″ curtain.

So…for a little under $50.00 (2017 cost for those custom shims,) they’re going to save almost $550.00 per year in compressed air costs – AND make sure that their compressed air system is optimized & available for other loads throughout the plant.

EXAIR offers the Super Air Knife in lengths from 3″ to 108″, with a 0.002″ shim installed.  They’re ideal for most industrial and commercial blow off applications, right out of the package.  If your application calls for something a little “outside the box,” you may only be a shim away from success.  If you have such an application, give me a call.

Russ Bowman
Application Engineer
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More Power May Not Be The Solution

Published on by Russ BowmanLeave a comment

I can’t tell you how much it pains me to write this after last week’s blog. But, if we’re being honest here, every Tim “The Tool Man” Taylor (“More Power!”) does indeed need an Al Borland (“I don’t think so, Tim.”) As evidence of this, I had an opportunity to provide reasoned advice to a caller on the tech support line this week:

They had just purchased a Model 110224 24″ Aluminum Super Air Knife Kit. The flow it produced wasn’t powerful enough for their needs, so they installed extra shims from the Shim Set (which comes with the Kit) – increasing the shim gap to 0.009″ (which can produce a great deal more air flow and force)…more power, right?

Super Air Knife Kits include a Shim Set, Filter Separator, and Pressure Regulator.
Super Air Knife Kits include a Shim Set, Filter Separator, and Pressure Regulator.

Unfortunately, not. The Super Air Knife makes a hard hitting curtain of air when supplied properly…but it’s going to need a 1/2″ pipe (ID of ~5/8″) to carry enough compressed air flow to make that happen. Turns out, they were using 1/4″ tubing, which wasn’t even getting enough compressed air flow to the unit with just the 0.002″ shim installed. Putting in the extra shims actually made that worse. Once they ran a 3/4″ hose to the Air Knife (and took out those extra shims,) they were actually able to regulate the air supply back to about 60psig, which provided a strong enough air flow to solve the application.

This table comes directly from the Installation & Operation Instructions for the Super Air Knife.
This table comes directly from the Installation & Operation Instructions for the Super Air Knife.

Sometimes, though, compressed air product applications DO come down to a need for more power.  Next week, I’ll tell you about a caller who said he needed “the biggest and most powerful” Safety Air Gun we had – and unlike the last time I wrote a blog about that – he was RIGHT.

Russ Bowman
Application Engineer
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EXAIR Knowledge Base Makes Problem Solving Easy

Published on by exaircorpLeave a comment

EXAIR makes every effort to solve your manufacturing problems, increase your efficiency and raise the bar on your safety practices. We try to do that immediately, today, right now and we’d like you to be on your way to an improved facility by tomorrow – that is why we stock all of our cataloged products and ship same day on domestic orders received by 3 pm. In order to do that it seems you would prefer to be working with a company that’s easy to do business with, and EXAIR is easy. One way we try and achieve this is by providing as much general information as we can under the Knowledge Base section of our website.  By taking advantage of the free registration, you gain access to a variety of helpful information that can help simplify your selection process and provide the final details to complete a particular project.

Knowledge Base
The Knowledge Base can be found in the black menu bar at the top of our webpage.

Take, for example, our full CAD Library providing 3D models and 2D dimensional drawings in several different formats which can be used by MANY different programs. Whether you are looking for a .stp file for a 72″ Super Air Knife or the .dwg file for a medium sized Vortex Tube, the information is readily available for download without needing to place a call to our office.

Another useful tool is our Case Study library which features a database showcasing the  benefits of using an EXAIR product in place of existing inefficient or unsafe blowoffs. Just a few benefits to list would be compressed air savings, safety improvements, achieving OSHA compliance, an increase in production, lowering the decibel level in a work area or overall money savings. We are continually looking to add useful information to the library and can offer some EXAIR swag or an incentive in exchange for quantifiable data. (give me a call for details!)

Case Study (505x640)
Example of a Case Study Report.

Maybe your looking for a specific EXAIR solution to a common industrial process? I invite you to take a look at our Application Database. From conveying plastic pellets to a hopper or needing to remove noxious fumes from a coating application, the desired information might just be a simple click away.

These are just a small sample of the useful tools available for easy use. If you can’t find the information you’re looking for or have a specific application you would like to discuss, give us a call so we can help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN