EXAIR Webinar 11/7/18 2pm EDT: Understanding Static Electricity

Halloween has passed, temperatures are dropping, and you’ve had enough of constantly raking up leaves. It’s clear to everyone that summer is over (much to my dismay). As temperatures decline, so too does the amount of moisture in the air. As this happens, issues related to static electricity begin to increase. If you’ve ever walked across a carpeted surface, only to be shocked as soon as you touch a doorknob, you’re familiar with the effects of static electricity. In addition to painful shocks, static can contribute to a variety of problems within industrial processes.

We’ve talked here on the EXAIR blog about several of these different applications. Some examples include: removing static on plastic packaging, stopping dust from clinging to product, or aiding in part removal in an injection molding application. These types of applications can certainly occur year-round, but the absence of humid conditions dramatically increases the potential for them to occur.

summer static
In this photo, a static charge present causes the plastic particles to cling to the end of a suction wand.

They key to combating static electricity is first understanding how it it’s generated and how to test for it. To help you gain some more knowledge about static electricity and the problems it can cause, EXAIR is hosting a FREE webinar this week. Within this webinar you’ll learn how to identify a static charge, the series of events that are causing the charge, as well as various ways to eliminate this nuisance.

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Brian Farno, EXAIR’s Application Engineering Manager, will be conducting the webinar at 2:00 ET on 11/7/18. Immediately following the presentation will also be a brief Q&A. If you can’t attend, don’t let that stop you from registering! A link to view a recorded version of the webinar will go out to all registered participants whether you’re able to attend live or not.

Click here to register and view details on this upcoming webinar. Make sure you’re educated on the issues associated with static electricity before it’s too late!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter : @EXAIR_TD

What is a Super Ion Air Wipe?

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Rendering Of The GEN4 Super Ion Air Wipe In Action

 

EXAIR’s GEN4 Super Ion Air Wipe provides a uniform 360° ionized airstream that is simple to clamp around a part for reducing static electricity and cleaning contaminants. It is great for use on pipe, cable, extruded shapes, hose, wire and much more. We offer the GEN4 Super Ion Air Wipe in either 2” or 4” inner diameter, it is powered by compressed air and an external power supply. The GEN4 Super Ion Air Wipe generates both positive and negative ions that are transmitted the emitter points located on the i.d. of the wipe. Since static charges can be either negative or positive it is easy to eliminate both states of charge due to the mixed polarity of ions being generated. The power supplies are available with either 2 or 4 outlets (can power up to 2 or 4 GEN4 Static Eliminators simultaneously) and are UL recognized, CE and RoHS compliant. The power supplies also have a selectable input voltage for either 115 or 230VAC.

Another great feature of the GEN4 Super Ion Air Wipe is the split collar design that utilizes a clamp and hinge making it easy to clamp around the surface of the material moving through it eliminating the need for time consuming “threading”.

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How does the Super Ion Air Wipe work? The Super Ion Air Wipe envelopes the part passing through it with a stream of compressed air to strip contaminants and bathes it with ions to diminish any static charge. The airflow follows the surface of the material passing through it and can be effective up to 15′ (4.6m) away from where the Super Ion Air Wipe is located. The optional pressure regulator allows for fine adjustments of the air volume and velocity and the optional shim set allows for large air volume and velocity adjustments.

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How The GEN4 Super Ion Wipe Works

 

If you would like to discuss reducing static and/or cleaning of continuous runs of  materials, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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Atomizing Spray Nozzles from EXAIR

Do you ever need to spray a liquid?  If so lets look at two of EXAIR’s Atomizing Spray Nozzles or ASN for short.  The first model we will discuss is the AD1010SS Internal Mix Deflected Flat Fan Pattern.

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AD1010SS Internal Mix Deflected Flat Fan Pattern

To begin with all EXAIR ASN’s are made from SS for durability and liquid compatibility.  As its name implies it creates a flat fan pattern that exit’s the nozzle perpendicular to the air & liquid inlets as shown above.  This unique design lends itself nicely to applications with space constraints.  The AD1010SS is the ideal choice for coating the inside of enclosures or ductwork.  It is compatible with liquids up to 300 centipoise and the air and liquid are mixed in the air cap.  The AD1010SS is designed for pressure fed applications not requiring independent air and liquid control.  What is meant by that statement is that if you vary either the air or liquid pressures you change the spray pattern and volume.  See the chart below for clarification on pressures, volumes and spray patterns.

AD1010SS Pressures
AD1010SS Chart

Next we will look at EXAIR model AT1010SS internal mix 360° hollow circular pattern ASN.

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AT1010SS 360° Circular Spray Pattern Nozzle Can Be Used To Coat Inside Diameters Or Cover A Broad Area Of Over 4′

The AT1010SS internal mix 360° nozzle is designed for applications where the spray pattern must be oriented away from the nozzle in all directions.  360° nozzles are ideal where a smooth, even coating is needed on the ID of a pipe or similar ductwork.  It is compatible with liquids up to 300 centipoise and the air and liquid are mixed in the air cap.  The AT1010SS is designed for pressure fed applications not requiring independent air and liquid control.  As above if you vary either the air or liquid pressures you change the spray pattern and volume.  See the chart below for clarification on pressures, volumes and spray patterns. They also work great for operations where a mist over a broad area is needed, such as dust suppression, humidification and cooling.  See the chart below for clarification on pressures, volumes and spray patterns.

AT1010SS Chart
AT1010SS Chart

If you would like to discuss EXAIR’s Atomizing Spray Nozzles or any EXAIR compressed air product, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer

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Basics of Static Electricity

Here in the Northern Hemisphere, we are in the middle of winter and that means extremely dry air, and frequent shocks when reaching for a door knob after walking across a carpeted surface.  While a shock is mildly uncomfortable and can be annoying to us, the presence of static electricity in an industrial manufacturing process can be much more problematic.

Problems that static cause range from operator discomfort to increased downtime to quality issues.  Dust can cling to product, product can cling to itself, rollers, frames, or conveyors. Materials may tear, jam, curl and sheet fed items can stick and mis-feed. Hazardous sparks and shocks can occur, possibly damaging sensitive electronics.

EXAIR has put together a useful tool, the Basics of Static Electricity white paper with Interactive Regions to help a person learn more about static.

Basics of Static Electricity

 

Topics covered include Electron Theory, Causes of Static Electricity, Triboelectric Series chart, and Types of Static Generation.  Also, the white paper covers the areas of How to Control Static Charge Buildup, Determining the Source of the Static Buildup, Eliminating or Minimizing the Source Causing the Buildup, and Treating Static Buildup.

The Treating Static Buildup is a comprehensive review of the EXAIR Static Elimination products and how each technology is best applied to different processes and applications.

To receive your copy of the Basics of Static Electricity white paper, click the photo above or the link here.

If you would like to talk about static electricity or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Calibration – Keep Your Meters True

EXAIR offers meters to measure the level of physical parameters such as sound and static. Each meter has sensitive electrical circuitry and a periodic calibration is recommended to ensure the meter readings are tried and true.

The model 9104 Digital Sound Level Meter is an easy to use instrument that measures and monitors the sound level pressure in a wide variety of industrial environments. The source of loud noises can be quickly identified so that corrective measures can be taken to keep sound levels at or below OSHA maximum allowable exposure limits.

The sound meter comes from the factory with an NIST (National Institute of Standards and Technology) certificate of accuracy and calibration.  As a good practice, EXAIR recommends a yearly calibration of the instrument, and we offer a service that calibrates the unit to the same NIST standards and provide a written report of the calibration.

The model 7905 Static Meter allows easy one-hand static measurements.  It is useful in both locating sources of high static charge and checking the reduction of static after treatment with an EXAIR Static Elimination product.  The unit is sensitive and responsive, and indicates the the surface polarity of objects up to +/- 20 kV when measured from 1″ away.

It is also recommended that the Static Meter be calibrated on a yearly basis.  EXAIR offers (3) levels of calibration service.  The first two provide calibration in accordance with MIL Standards using accepted procedures and standards traceable to NIST.  The third calibration service conforms to the same Mil Standard, as well as ISO/IEC standards.

Annual calibration service of your EXAIR Digital Sound and Static Meter, along with proper care and storage, will keep your meter performing tried and true for many years, providing accurate and useful measurements.

To initiate a calibration service, give us a call and an Application Engineer will issue an Returned Good number, and provide instructions on how to ship the meter to EXAIR.

If you have questions regarding calibration services for your meters or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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New Gen4 Super Ion Air Knives Stop Painful Shocks on Printing Operation

Kirk Rudy inkjet
Customer’s Inkjet Machine

I recently received an inquiry from a customer that was having an issue with static on their Kirk Rudy inkjet machine. They print on a variety of different materials for a range of applications, but had some concerns with static that was being generated. Once printed, the material is transported along a conveyor. Operators then remove the pieces by hand. While doing this, they’re receiving shocks as a result of the static, some of which are quite painful! After a little discussion, we determined that a Model 112012 Gen4 Super Ion Air Knife would be the most suitable solution. I recommended the knife to be positioned so that the ionized air stream would pass over the material as it’s coming down the conveyor. The ionized airflow from the Super Ion Air Knife eliminated any residual static, allowing the operators to remove the material without experiencing any painful shocks. This drastically improved workers attitude about performing this operation and eliminated the repeated written complaints that management was getting as a result. Their issue of finding a willing participant to be repeatedly shocked was rectified and the worker quality of life was improved.

EXAIR has just released the new Gen4 Super Ion Air Knives and Ion Bars. The new bar provides a 34% improved performance from previous models, allowing you to achieve the same or better results with less compressed air. These bars and knives are also now CE approved. Some improved features of the Gen4 Super Ion Air Knives are:

-Up to 34% improved performance

-Rugged metal armored and electromagnetically shielded cable

-Integrated ground eliminates additional ground connection

-Durable stainless steel connections to Power Supply

-UL component recognized/CE Compliant

-Modular Power Supply cable eases connections and routing

If you’d like to talk about the benefits of upgrading to the new Gen4 Static Eliminators or have a new application in need of a static eliminating solution, give us a call.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

Stretch Wrap Static Solution

Recently a customer called in to EXAIR to discuss a static issue in a stretch wrap process in the plant. Stretch wrap is a highly stretchable plastic film.  The elastic recovery keeps the wrapped load tightly bound. The most common stretch wrap material is a linear low-density polyethylene or LLDPE.  The combination of the stretching of the plastic film and the sliding of the film on the cardboard boxes as it is being wrapped causes a build up of static. This static can cause serious havoc and issues in the process including personnel shocks, zapping counters and other sensors causing failures, and preventing marking systems from delivering good information on to the stratch wrap.

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Stretch Wrap Operation

The discussion started with minimum and maximum load sizes and how to design a system that would work with all configurations and be as flexible as possible.  We spoke of dimensions and where we could we could mount on 3 sides, and so forth.

Then came the question that we invariably get to and that is ‘what issue does the static cause and how does it affect the rest of the process?’  The answer here simple, ‘an operator has to write a code number on the side and affix a label, and in doing so, receives a shock.’ When it was determined that only a small section of one side of the load needed to be treated, the solution was simple.  We proposed an 18″ Ionizing Bar and Power Supply. Because the machine had a fixed datum, all loads would pass within 1-2″ of a vertically installed Ionizing Bar, so no adjustment is needed for different load sizes.

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Ionizing Bars Treating Top and Bottom Surfaces

The Ionizing Bar quickly dissipates a strong static charge as shown in the chart below.

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EXAIR offers many systems for total static control. When static is a problem on moving webs, sheet stock, three dimensional parts, extrusions or packaging, EXAIR has a solution.

To discuss your application and how an EXAIR Static Eliminator would help out, feel free to contact EXAIR and one our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Twitter: @EXAIR_BB