Eliminating False Image Readings Using The Gen4 Stay Set Ion Air Jet

I was recently contacted by a medical device manufacturer who was interested in implementing a Static Eliminator in their production process. They have a manually operated vision station where a plastic substrate, about the same size as a credit card, is placed into a nest then a small amount of liquid is deposited onto the surface. An operator takes a picture of the liquid and substrate and the image is analyzed. The part is stationary in the nest until the image is taken.  When the station is done, the plastic part is manually removed from the nest.

After some internal testing, they determined that static build up on the plastic part was causing the liquid to move, or “bounce” as they placed it, which was leading to a significant drop in their manufacturing yield due to faulty readings. The cycle time from taking the initial  image and the analysis results is roughly 2 seconds so they were needing something that would quickly remove the charge on the plastic part.

The customer was able to email some photos and after further review, EXAIR recommended they use our Gen4 Stay Set Ion Air Jet in the process. The Gen4 Ion Air Jet is a compact ionizer delivering a quiet, focused ionized air stream to quickly eliminate the static charge on the surface of a material or object. Operating at 20 PSIG, the Gen4 Ion Air Jet is capable of dissipating a 5kV charge in 0.45 seconds while maintaining a low sound level of only 67 dBA. The Ion Air Jet entrains ambient air at a rate of 5:1 and the airflow can be adjusted from a “blast” to a “breeze” simply by increasing or decreasing the inlet pressure. The Gen4 Stay Set Ion Air Jet includes our 12” Stay Set Hose which holds position until it is physically repositioned and a magnetic base for easy installation.

If you have an application that requires a concentrated, ionized airflow or for help with selecting the best product to fit your need, give me call at 800-903-9247 for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

The Case Is Mounting For Stay Set Hoses

So, you’ve selected a quiet, efficient, and safe EXAIR Super Air Nozzle for your blow off application – good call! – and now you’re thinking about how to install it.  Sometimes, it’s as simple as replacing whatever you’re using right now:

EXAIR Intelligent Compressed Air Products have common NPT (or BSP) connections, making for easy replacement of most any existing threaded device.

Or maybe you’re using an open end blow off…in which case, you’re just an adapter away:

EXAIR Super Air Nozzles are quick and easy to install on existing copper tube, via a simple compression fitting.

Perhaps, though, it’s a new installation, or the existing supply lines aren’t suitable for one reason or another.  In those cases, we’ve still got you covered…consider the EXAIR Stay Set Hose:

Precise aiming and location is a breeze with EXAIR Stay Set Hoses.

Available in a variety of lengths from 6″ to 36″, they’re positionable, and re-positionable with a simple bending action.  They won’t kink or easily fatigue like copper tubing.  The supply end is 1/4  MNPT, and you have your choice of 1/4 MNPT or 1/8 FNPT on the other end, depending on which Super Air Nozzle, Air Jet you need to use it with.

We also offer Blow Off Systems, which are a combination of a specific Air Nozzle (or Air Jet,) fitted to a Stay Set Hose:

Model 1126-9262, for example, is a Model 1126 1″ Flat Super Air Nozzle with a 9262 Stay Set Hose.

For added convenience and ease of installation, these products can also come with a Magnetic Base:

Mag Bases come with one or two outlets. Stay Set Hoses come in lengths from 6″ to 36″.

Stay Set Hoses are also available with a variety of our Soft Grip Safety Air Guns, and they make the GEN4 Stay Set Ion Air Jet one of our most popular Static Eliminator products.  They’ve even been successfully applied with small Air Amplifiers and Air Knives…with certain limitations (spoiler alert: trying this with a 108″ Super Air Knife is going to be a definite “no.”)

Model 110003 3″ Aluminum Super Air Knife with 6″ Stay Set Hose & Magnetic Base.

From the beginning in 1983, EXAIR’s focus has been on being easy to do business with, and that goes from our friendly customer service to our expert technical support to our 99.9% on-time shipments (22 years and running) to designing our engineered products and value-added accessories with efficiency, safety, and ease of installation in mind.  If you want to find out more, give me a call.

Not All Compressed Air Guns Are The Same

If you work in an industrial plant or manufacturing environment, chances are you use some type of compressed air gun for cleaning parts, work areas, etc. Many air guns purchased through large industrial suppliers are a common choice due to the cost of the gun but as the saying goes – “you get what you pay for”. These types of guns may be cheap to purchase but they are also made cheap and have parts that can break easily, like the trigger or nozzle. In many cases, the nozzles on these guns are also in violation of OSHA requirements, producing dangerous discharge pressures and loud noise levels, which can lead to costly fines or potentially deadly injuries.

EXAIR offers 5 different styles of Safety Air Guns that not only eliminate these concerns, but also provide a more efficient operation, which can reduce energy costs. All of our Safety Air Guns are fitted with our engineered Air Nozzles  which meet OSHA Standard 1910.242(b) for 30 PSI dead end pressure, as they provide a relief or safe path for the air to exit if the nozzle were to be blocked or pressed against an operator’s body so the exiting air pressure will never reach 30 PSIG. They are also engineered to entrain surrounding air across the profile of the nozzle, which produces a smoother airflow, ultimately reducing wind shear, resulting in much lower sound levels, meeting OSHA Standard 29 CFR 1910.95(a).

 

 

The Precision Safety Air Gun body is made of a durable high impact, glass reinforced nylon, providing for a lightweight, ergonomic operation. These guns feature a curved extension, ideal for delivering a powerful stream of air in hard to reach areas, like clearing debris from drilled holes. All of the nozzles used with these units are either 316ss construction for durable, corrosion resistance or PEEK plastic for non-marring applications. The air inlet is 1/4 FNPT and there is a convenient hanger available for safe storage.

 

 

 

Our NEW VariBlast Compact Safety Air Guns are ideal for light to medium duty processes, featuring a variable flow trigger to achieve different force levels ranging from 2.0 ounces up to 1 pound, depending on the nozzle. The body is cast aluminum and there are (2) 1/4 FNPT air inlets available, 1 on the bottom and 1 on the back of the gun, as well as a storage hanger, for easy installation. Nozzles are available in zinc aluminum alloy, 303ss, 316ss and PEEK plastic. These guns are available with aluminum extensions from 6″ up to 72″.

 

 

The Soft Grip Safety Air Guns are commonly used in long-term use applications as they feature a comfortable grip and long trigger which helps to reduce hand and finger fatigue. The cast aluminum construction is well suited for more rugged environments and again, features a hanger hook. These guns can be fitted with aluminum, stainless steel or PEEK plastic to meet the demands of a variety of applications and are available with 6″ – 72″ aluminum extensions for extra reach or Flexible Stay Set Hoses , allowing the user to aim the airflow to a specific target area. The air inlets for these guns are going to be 1/4 FNPT.

 

 

 

EXAIR’s Heavy Duty Safety Air Guns deliver higher force and flows than other air guns, as these units feature a 3/8 FNPT air inlet, which maximizes the compressed air flow to the engineered Super Air Nozzle. Like the Soft Grip, the durable cast aluminum body is designed for use in tough industrial processes, and the ergonomic and comfortable trigger are ideal for hours of use. Aluminum extension are available, again in lengths from 6″ up to 72″, but feature a larger diameter for optimal flow and superior durability.

 

The Precision, VariBlast, Soft Grip and Heavy Duty Safety Air Guns are ALL available with an optional, polycarbonate Chip Shield to protect personnel from flying chips and debris, further meeting OSHA Standard 1910.242(b) for the safe use of compressed air.

 

Lastly we offer our Super Blast Safety Air Guns. The Super Blast Safety Air Guns are ideal for wide area blowoff, cooling or drying a part, as well as long distances. They feature a comfortable foam grip and spring loaded valve that will shut off the airflow if the gun is dropped. These units use our larger Super Air Nozzles and Super Air Nozzle Clusters, providing forces levels from 3.2 lbs. up to 23 lbs. Depending on which nozzle is fitted on the assembly, air inlets will range from 3/8 FNPT up to 1-1/4 FNPT. Aluminum extensions are available in 36″ or 72″ lengths.

 

 

For help selecting the best product to fit your particular application, please contact one of our application engineers for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

EXAIR Accessories – We’ve Got you Covered

When you work with us here at EXAIR, we strive to have all the ancillary items that you might need to make your installation a success, without having to find components at the last minute or perhaps using the wrong sized components. Each specific product line such as Super Air Knives or Line Vac air operated conveyors have specific accessories such as mounting brackets or plumbing kits which EXAIR has made to simplify the installation of those particular products. We also carry generalized accessories which work across all of the product lines so you do not have to use multiple vendors or purchase orders.

Silencing Mufflers – Per OSHA Standard 1910.95(a), a worker must not be exposed to sounds levels above 90 dBA for any eight hour shift of a 40 hour work week.  EXAIR offers several types of mufflers including – Reclassifying, Sintered Bronze, Straight-Through and Heavy Duty.  For reducing the noise associated with an EXAIR E-Vac Generator, Vortex Tube, Cabinet Cooler System, or the exhaust air from cylinders, valves and other air powered equipment, we’ve got a muffler that will help to keep the noise level at an acceptable level.

Mufflers

Solenoid and Manual Valves – The easiest way to reduce compressed air usage and save on operating expense is to turn off the compressed air to a device when it isn’t needed. EXAIR carries a wide assortment of solenoid valves, with offerings in the NEMA 4/4X classification, and supply voltages of 24VDC, 120VAC, and 240VAC.  We also have manual ball valves from 1/4 NPT to 1-1/4 NPT and a foot operated valve, with 1/4 NPT connections.

Valves

Swivel Fittings, Stay Set Hoses and Magnetic Bases – To provide a great degree of flexibility for positioning an EXAIR Super Air Nozzle, Air Jets or Air Amplifiers, EXAIR offers several items.  The Swivel Fittings have 25 degree of movement from the center axis, providing a total of 50 degree of adjustability.  The position is locked in place and holds until adjustment is needed. For applications where frequent re-positioning of the air device is required, the Stay Set Hoses are ideal.  Simply mount the hose close to the application, bend it to the shape preferred, and because the hose has “memory”, it will not creep or bend.  Lastly, the Magnetic Bases are another option for flexible, movable installations.  The base has a on/off valve, and a powerful magnet to hold in any vertical or horizontal mounting arrangement.

Swivels, StaySets,MagBases2

 

Hoses – EXAIR can provide hoses for your application.  For the Line Vac air operated conveyor applications, we offer conveyance hose – a durable, clear reinforced PVC hose, in diameters of 3/8″ to 3″ ID, and lengths up to 50′. On the compressed air side, we can provide 12′ Coiled Hoses with 1/8, 1/4, and 3/8 NPT connections, and also 3/8″ and 1/2″ ID hose in lengths to 50′.

Hoses

Filter Separators, Oil Removal Filters and Pressure Regulators – Perhaps the most important accessories for use on a compressed air device are filters and regulators. Filtering the compressed air of dirt, debris, moisture and oil will help to prevent build up inside the EXAIR products, leading to longer service life, and less time spent cleaning, while providing optimum performance. Regulating the air pressure allows for tuning of the performance, using the proper amount of compressed air to obtain satisfactory results.

Filter and Regualtors

If you have questions regarding accessories for use with 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

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

Finding The Right Solution Through Dedicated Engineering Support

crate
Plastic crate in need of blow off after washing

An OEM of crate washing equipment in Lebanon recently contacted me about an application on one of their conveyors.  The conveyor carries a plastic crate out of a washer and excess water on the crate was presenting a problem in the application.  In order for the crate to move on to the next step in the machine, a blow off solution was needed, but the exit rate from the washer was inconsistent.  In a given minute there could be 5 crates exit the washer, or there could be 20.  So, the ideal solution needed to have intermittent control options with instantaneous on/off functionality.

We immediately began discussing Super Air Knives, not only because we show plastic crate blow off in one of our many videos, but also because these units are instant on/off with full compatibility with a flow control device.  Utilizing a flow controller, such as the EXAIR Electronic Flow Controller or PLC device, will allow for precise control of the blow off solution, limiting compressed air use to a minimum.

2016-12-07_164322
The first blow off system design
2016-12-07_164342
This layout utilizes Air Knives on each side of the blow off as well as the top

After discussing application details we came to the design shown above, using one 24” Air Knife on the top of the crate and two 9” Air Knives on the sides.  However, this OEM had purchased numerous 2” Flat Stainless Steel Super Air Nozzles in the past (model 1122SS) and had a number available on site.  Modifying the system to utilize the nozzles already on-site, we came to this design:

system-layout
The finalized layout for this blow off system. Click for a larger view.

This layout utilizes (1) 24” Stainless Steel Super Air Knife on the top of the crate and (2) sets of (3) 2” Flat Stainless Steel Super Air Nozzles on the sides, held in place with EXAIR Stay Set HosesNotice the independent pressure regulators for the nozzles and the knife.  This is to allow the customer to balance the air flows, because the 2” flat nozzles will create a higher force than the Air Knife when operating at the same pressure.

In this application we were able to help a returning OEM solve their problem with the right mix of needed products.  Exploring the problem and discussing numerous viable solutions led to the best fit for the application and customer.  That’s precisely why EXAIR Application Engineers are available for any application call or question.  If you’d like to explore an EXAIR solution we’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

 

“(Stay) Set It And Forget It”

The Stay Set Hose is a popular, and practical, accessory for use with many of our blow-off products. Thread one end onto a compressed air supply connection, thread a Super Air Nozzle (or maybe even a small Air Amplifier or short Air Knife) onto the other end, and you’ve got an easily repositionable blow off…which will reliably hold its position.

That last part was of considerable importance to a caller I had the pleasure of assisting recently. Some of the CNC machines in their shop were fitted with flexible plastic tubing (commonly used for coolant & cutting fluid,) supplied with compressed air to blow off chips & debris from the tooling as the parts were being machined. They use our Super Air Knives in other blow off processes (where they used to use costly & loud open blow off devices,) and wanted to see if engineered products might reduce their compressed air consumption & noise levels in the machine shop too. (spoiler alert: Yes, they can.)

Thing is, they really needed the flexibility of the modular hose, but it’s not rated for the pressure supply required for a Super Air Nozzle. This is what makes our engineered products so efficient; they use the Coanda effect to amplify the compressed airflow..and they use the supply pressure to do that. So they can’t install a Super Air Nozzle on what they have now.

Enter the Stay Set Hoses: They’ll bend to direct the nozzles’ air flow right where you need it, and they’ll keep it there until you bend it again. Which (back to what’s most important to this caller) is exactly what they needed. With our efficient & quiet Super Air Nozzles, they’re saving compressed air and improving the conditions of their work environment. With the Stay Set Hoses, they’re able to quickly & easily rig the air flow before running a job, knowing they won’t have to worry about it until the job’s done.

EXAIR Stay Set Hoses hold their position as long as you need them to. All day, every day.
EXAIR Stay Set Hoses hold their position as long as you need them to. All day, every day.

“Set it and forget about it” is a benefit you can realize from many EXAIR Intelligent Compressed Air Products. If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

High Power Super Air Nozzles Provide Forceful Air Flow

When considering the application of a compressed air product, we have an awful lot of discussions with callers about the amount of force generated.  Now, if that’s all you want, you’re not going to get more force from compressed air flow from anything but an open ended blow off.  There are problems inherent with this: it’s unsafe, it’s loud, and it’s a horribly inefficient way to use compressed air.  By the time they’ve called EXAIR, they probably know this, but the main concern is still the same: solving their application.

Good news is, you don’t need a lot of FORCE for most blow off situations.  Think about it…how much do sawdust, machining chips, coolant droplets, etc., weigh, anyway?  All you really need to do is optimize the air flow, which is EXACTLY what EXAIR Intelligent Compressed Air Products are engineered & designed for.  So, we talk a LOT about how often a high amount of force isn’t needed in compressed air blowing applications.

Then…I got a call from a user who needed force.  They had an air knife installed to blow parts out of a mold, as the halves separated.  There’s a rectangular array of parts in a multi-cavity mold, and the air knife just wasn’t getting them all out, all the time.

The air knife, was, of course, originally chosen for its efficiency, but it just wasn’t delivering the needed “punch.” They even tried other shim thicknesses (which increases the outlet air gap) to increase the flow & force delivered, and that helped a little, but wasn’t 100% effective.

The solution came in the form of an array of HP1125-9212 2″ High Power Flat Super Air Nozzles, supplied with 12″ Stay Set Hoses.  They’re able to mount these closer to the mold than the air knife, and the ability for each nozzle to operate independently meant they were able to be aimed precisely where they can do the most good.  They are now able to evacuate the molds the first time, every time.

Sometimes, you DO need the high force of the HP1125 2″ High Power Flat Super Air Nozzle

If you have questions about how to get the most out of your compressed air use, give me a call.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook