Last week I worked with a gutter manufacturer who was looking for a way to spray a light coating of vanishing oil on the rollers of a forming machine. Roll forming is commonly used when needing to maintain a constant and consistent shape or feature across the length of the part. In this particular case, a sheet of aluminum, used as a cover for the gutter, is fed into the machine where it passes over a series of dyes that bends “ribs” and punches small holes into the part to keep leaves or debris from settling on top, while allowing the rainwater to pass through the holes and into the gutter.
They were needing to apply the oil to the rollers because they were starting to see some irregularities in hole size as well as some deformities to the shape of the ribs due to heat being generated during the forming process. The customer was interested in using some type of atomizing spray nozzle in the hopes that providing an atomized mist of liquid may provide for a faster evaporation of the oil so there wasn’t much residue left on the part before packaging.
After further discussing the details, they advised that they were going to have the oil in a container about 12″ below the machine but didn’t have a way to pressurize or pump the liquid to the nozzle. Once again, EXAIR has the perfect solution with our 1/4 NPT Siphon Fed Atomizing Nozzles. These nozzles are the ideal solution where pressurized liquid isn’t available as they use the compressed air to the draw the liquid into the nozzle, up to 36″ of suction height, and mix it internally to produce a mist of atomized liquid spray. For this particular application, the Model # SR1010SS was a good solution as it provides a low flow rate of only 0.8 GPH and a tight spray pattern to focus right at the rollers to avoid any waste or overspray.
EXAIR offers an extensive range of Atomizing Nozzles that can be used for light coating applications, like above, or for wider coverage areas or higher flow rates. For help selecting the best option to fit your needs, contact one of our application engineers for assistance.
A stamping facility had a high speed perforating operation. The idea was to punch holes into a matrix at a fast feed rate. In their operation, they started to see issues with the punched holes, and they also noticed that the punch points were prematurely failing. With a tight punch-to-matrix clearance, heat was building up from the friction. This effect was galling the material and affecting the hole appearance and dimensions. They also noticed heat damage to the punch points. They either had to slow their process down, or find a way to cool the punch points. They contacted EXAIR to see if we could help.
To remove heat, you need to have a fluid moving across the material to carry the heat away. For this customer, the fluid would be air. Just like a hot cup of coffee, you can cool it by blowing across the top of it. In this instance, EXAIR can blow a lot of air with using very little amount of compressed air. Because of the gap opening of the tool die was narrow, I suggested the Super Air Knife. It has a compact design and can blow nicely between the upper and lower die. With slight modifications, they were able to mount the Super Air Knives right into the base set. Because the tool die was a “bowl” type design, I suggested that they should use two pieces of the model 110206 Super Air Knife. They could mount one to each side to make sure to hit all the punch points. (Reference the picture below).
EXAIR Super Air Knives are the most efficient compressed air knives in the market. It is designed to have a 40:1 amplification ratio. That means for every one part of compressed air, it will entrain 40 parts of the free ambient air. As with the coffee reference above, the more air that you can blow, the better the cooling effect. With the Super Air Knife, we can reach a velocity of 11,800 feet per minute at 80 PSI. After the customer installed the Super Air Knives, they were able to increase production by 10%. Also, they found that the punch points were lasting twice as long. They were so impressed with the effectiveness of the Super Air Knives, they mounted them to all their punch press machines.
If you find that heat is affecting your process, EXAIR could have a product to help you. We have a variety of efficient air movers to cool your parts. As for this customer above, we were able to increase production and extend the life of their tools.
The five C’s of EXAIR products are Cooling, Cleaning, Conserving, Conveying, and Coating. All EXAIR products are suitable for applications in these areas, with varying degree of possibility. When it comes to cooling, one of the most suitable EXAIR products is the Super Air Amplifier.
An Air Amplifier can increase the volume of ambient air directed over an specific area, effectively decreasing the cooling time needed in an application. Air Amplifiers cool effectively due to the fundamental principles of convective heat transfer. In convective heat transfer, cooling capacity can be increased by increasing the temperature differential between the cooling medium and the object to be cooled, or by increasing the flow of the cooling medium.
An Air Amplifier is the best cooling choice when the material to be cooled is at an extremely high temperature. For example, in the application above, 903°C (1650°F) cylinders need to be cooled to ambient temperature as quickly as possible. Vortex Tubes are another product our customers consider for cooling applications. Vortex Tubes are the best choice when the area to be cooled is small and the temperature differential is not as large. A Vortex Tube based solution will provide very cold air, but at a lower air flow over a small area and they were not the best choice for the application in the image above.
In the same application, a Super Air Amplifier can provide large volumes of ambient air over a large area, effectively cooling the cylinders much more efficiently. The cooling can be achieved in less time, and with maximum efficiency of compressed air implementation. Air Amplifiers also offer great benefits over electric fans in this rough environment: they can withstand higher temperatures and there are no moving parts to wear or break.
If you have an application in need of efficient cooling, contact an EXAIR Application Engineer to find out if an Air Amplifier will work for you.
This week I had the opportunity to work with a customer that manufactures automotive glass. Part of the process of manufacturing the glass is to apply a thin plastic film of polyvinyl butyral (PVB) in between glass sheets.
This creates the laminated safety glass that protects passengers from flying glass shards in the event of an accident.
The customer was having a quality problem. Glass was being rejected on their low volume compound curved glass production line for debris being trapped between the layers during the laminating process. We worked on identifying how the dust could be introduced into his laminating process. First, each of the glass panels are cleaned by hand with a cleaner and a soft cloth to remove any dirt, grease or oil that can be left behind from production, shipping, or handling. The soft cloth can leave behind some lint.
On the high production line, a cleaning roller would remove any lint left behind on the flat glass. On the curved glass of the low production line, the curvature of the glass prevented the roller from applying even pressure across the glass and was leaving lint of the cleaning cloth is left behind. This lint will become a defect in the glass after the glass is cured in an oven.
I recommended the customer use an Ion Air Gun immediately after the hand cleaning cloth step since the Ion Air Gun is also a manual, hand held product. The PVB is pulled from a stack of thin film which generates a static charge from dragging one sheet over another and increasing the chance that lint will stick. The Ion Air Gun will remove the static charge and blow off the lint just prior to lamination. If this was a high volume product, I would have recommend one of our long one piece Super Ion Air Knivesto cover the whole piece of glass in a single blow off. Because this was already a manual process due to a low volume specialty glass, the Ion Air Gun is the best product for the job.