The Wonders of The Gen4 Super Ion Air Knife

The Gen4 Super Ion Air Knife is a powerful static eliminator that prevents jamming, tearing, shocks and dust build up by neutralizing static and blowing away the debris.

The Gen4 Super Ion Air Knife combines the quiet and efficient Super Air Knife with the compact design of the rugged Gen4 Ionizing Bar resulting in a total solution to remove static electricity from plastics, webs, sheet stock and other product surfaces. Removing the static helps reduce or eliminate the process issues that the static electric causes, allowing for greater production speeds, improved product quality and a cleaner product.

The Gen4 Super Ion Air Knife floods an area or surface with static eliminating ions. With a uniform airflow across its length, misalignment to critical surfaces like webs is avoided.  The force can be adjusted from a light breeze, to a full out blast of air. The Gen4 Super Ion Air Knife is electrically powered, is shockless and has no moving parts.

How It Works

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How The Gen4 Super Ion Air Knife Works

In the diagram above, compressed air flows through an inlet (1) into the plenum chamber of the Gen4 Super Ion Air Knife. The flow is directed to a precise, slotted orifice. As the primary airflow exits, it creates a uniform sheet of air across the entire length, pulling in in surrounding air (2). An electrically powered Gen4 Ionizing Bar (3) fills the curtain of air with positive and negative charges. The air stream delivers the static eliminating ions to the product surface (4) where it instantly neutralizes static and cleans off dust and other particulates.

The Gen4 Super Ion Air Knives are powerful tools, and very quickly dissipates 5kV of static even at low compressed air supply pressures. At 5 PSIG, only 3.7 SCFM (0.3 BAR, only 105 SLPM) of compressed air per foot of length is required!!  Sound levels are also very low, resulting in quiet operation.

super ion air knife performance

Added Features –

  • Compressed Air Inlets are provided on each end and the bottom of the Super Air Knife
  • Thicker shims can be installed easily if a harder air flow is needed
  • Emitter points are sharp, durable stainless steel
  • The high voltage cable is armored to resist cuts and abrasion, and has integral grounding.  Threaded bayonet connector is fully assembled and ready to use
  • Electromagnetically shield cable protects sensitive electronics
  • Gen4 Ionizing Bars and Power Supplies are UL Component Recognized to U.S and Canadian safety standards and are CE and RoHS compliant
  • Power Supplies are 115/230 VAC selectable and come with 2 or 4 outlets
  • Standard lengths from 3″ to 108″ (76mm to 2743mm) are offered, and custom lengths are available to meet your process needs

Successful applications include web cleaning, pre-paint dust removal, shrink wrapper machinery, printing equipment, package cleaning,and bag opening/filling operations.

If you have questions about Gen4 Super Ion Air Knives, other types of Static Elimination products,  or 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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Twitter: @EXAIR_BB

Video Blog: Gen4 Super Ion Air Knife Conversion

The video below provides details on the simple conversion to the new Gen4 style Super Ion Air Knife from the previous style or the addition of a Gen4 Ionizing Bar to an existing Super Air Knife to add static elimination to an existing blow off.

If you have questions about the Gen4 Super Ion Air Knife or 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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Find us on the Web 
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Twitter: @EXAIR_BB

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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Super Ion Air Knife Removes Debris In Vinyl Window And Door Manufacturing

I recently worked with a vinyl window and door manufacturer on a static issue they were experiencing during the manufacturing process. After the aluminum frames are cut to length they are placed into a holding fixture where the vinyl seals are placed in a channel inside the frame and clamped together. A machining tool then travels around the parts to trim and machine the excess material, creating dust and some small chips. They tried to vacuum the debris away but were still seeing some residual material cling to the surface due to static, which resulted in manual rework of the parts, slowing down the production cycle.

Vinyl window – similar to the window being produced by the customer

The customer was able to send a drawing of the holding fixture for reference and after reviewing the information, I recommended they use our 18″ Super Ion Air Knife Kit in this application. The Super Ion Air Knife provides a high velocity, laminar sheet of ionized air across the length of the knife. As the positive and negative ions neutralize the surface charge, the airflow is able to clean the part of the unwanted material so it can be more easily vacuumed away. Using the regulator included in the kit, they can reduce the supply pressure to control the outlet flow and velocity to an acceptable level that doesn’t disrupt the current process.

Super Ion Air Knives are available in standard lengths from 3″ up to 108″ and ship from stock.

If you have an application you would like to discuss or are considering an EXAIR product for your process, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Vinyl Slider Window with Grid image courtesy of Steve Anderson via Creative Commons License

 

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.

Ion Bar
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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Find us on the Web
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Twitter: @EXAIR_BB

Static Can Become A Big Issue With Winter Approaching

Many automotive parts are made of plastic, and with nonconductive materials, static electricity can become a big problem, especially in cooler climates.

A customer with whom I spoke recently assembles instrumentation clusters for vehicles.  The assembly process started by using a regular compressed air gun to blow the surfaces clean before assembly.  The operator would place a polycarbonate applique onto a lighting fixture.  Then a clear polycarbonate cover would go over both parts.  To complete the cluster assembly, an ultrasonic welder would weld the plastic studs around the outside edge and seal the parts together.  This completed the assembly process.  However, during inspection, they started to notice more visual defects after the welding process.  The cause was debris that became lodged between the applique and the clear cover. The debris was still present even after blowing.  If the debris wasn’t cleared prior to welding, the entire assembly would have to be scrapped due to the visual defect. The customer knew about EXAIR from previous projects and so decided to get help from us again to solve this expensive reject situation.

Initially, blowing the plastic components with regular compressed air before assembling and welding  worked well, but then they started seeing an increase in the reject rate.  I came to find out that they were located in Michigan. So I asked the customer about the weather there recently. They indicated that was getting cooler as we begin to head into Fall and Winter. As cooler weather is among us, static can be generated much easier because cool air cannot hold as much moisture. And with less moisture, which aids to eliminate a static charge, the likelihood that static will generate goes up.  Once static is generated on plastic components, dust and debris likes to stick to the surface.  Static charges are very strong, and even with blowing compressed air, the debris can still cling to edges or even “jump” to another location.  This was a manual operation and they needed to remove the static from the surface in order to eliminate the debris from the assembly.

8493-ion-air-gun

I recommended the model 8493 Ion Air Gun Kit. It combines static removal capability with a blowing force that one would normally associate with a compressed air blowgun.  The kit includes the Ion Air Gun, power supply, filter and regulator.  The Ion Air Gun is designed with a 5:1 amplification ratio; minimizing compressed air usage and maximizing ionized airflow.  With the regulator, you can control the force from a “blast” to a “breeze”.  The ionized airflow eliminates the static from the plastic surfaces, allowing the airstream to remove any dirt and debris.  They replaced their current air gun with the EXAIR Ion Air Gun, and the rejection rate decreased to the acceptable levels that they were seeing in the summer months.

Being that the winter months are approaching, you may want to re-evaluate your processes.  If you are working with non-conductive materials like plastic, wood, glass, or textiles, EXAIR has a variety of Static Eliminators that can save you from getting headaches, losing money, and saving time.  With our customer above, they weren’t able to get ahead of the static issue, and it created many problems until they investigated using EXAIR Static Eliminators. Get rid of your static headaches by using an EXAIR Static Eliminator today.

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

Static Electricity – What is it?

Now that the air is cooling and the humidity is dropping, you may often experience the phenomena of static electricity, and the resultant shock when touching something metal. As a child, you may have learned about static electricity by rubbing a balloon on your head and then seeing it stick to the wall. What is the science behind static electricity?

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All materials are made up of atoms, which have a positively charged core called the nucleus surrounded by a cloud of negatively charged electrons.  Each material is different, and in some types of materials the positive nucleus has a very strong pull on the electrons while in other materials the pull is very weak.  If we were to put a strong  pull material in contact with a weaker pull material, atoms from the weak pull material will migrate, and when the materials are separated, additional electrons will remain with the strong pull material.  Due to the overall increase in electron quantity, the material becomes negatively charged and the other material becomes positively charged. If the materials are rubbed together, the opportunities for the electron migration increases, and thus more electrons are exchanged.

Electrons build up more easily in dry conditions. When the air has humidity, static build up is less common because a very thin layer of water molecules coat most surfaces, which allows the electrons to move more freely and make most materials conductive and static free.

In some cases, static electricity can be a good thing – laser printers and photocopiers use static electricity to transfer ink from the drum to the paper.  Also, some power plants and chemical factories use static electricity  to remove pollutants in a process that takes place within the smokestack.

But generally when EXAIR gets involved, it is because the static electricity is causing an unwanted build up of static charge that affects a manufacturing process. The results of a static charge imbalance can result in a shock to an operator, materials sticking together, poor print quality, sensor or counter malfunctions, bad surface finish, or any number of other problems.

EXAIR offers systems for total static control, such as the Super Ion Air Knife and Ionizing Bars for wide applications such as paper, film and plastic webs, the Super Ion Air Wipe for narrow, continuously moving materials such as wire, tube, or extrusions.  Also offered are the handheld Ion Air Gun for use on three dimensional parts prior to assembly, packaging painting or finishing. Other options include the Ion Air Cannon for limited space or remote mounting applications, Ion Air Jet for tight spaces and concentrated airflow, and the Ionizing Point to provide close distance and accurate static removal.

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Super Ion Air Wipe

To discuss your static elimination concerns , feel free to contact EXAIR and one our  Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web
Like us on Facebook
Twitter: @EXAIR_BB

Spark Photo Credit – Eric Skiff – via Creative Commons License